GOALI: Micro/Meso Scale Characterization of Interface Phenomena in Environmentally Clean Machining

这一建议的赠款机会学术联络与工业（GOALI）研究的目的是表征界面现象和摩擦边界条件沿着前所未有的分辨率的工具-芯片接口。研究目标包括确定变形区的应变和应变率分布，测量沿着前刀面的刀-屑接触区的流体膜厚度，以及估计前刀面区域和二次变形区的温度。通过在适当的拓扑结构中组装这些测量值，将开发一个模型来描述摩擦边界条件。该方法包括增强的粒子图像测速技术，估计应变和应变率的测量技术的发展，使用发光分子传感器，估计流体膜厚度和温度分布沿着刀具前刀面;和耦合测量的应变和温度数据与加工模拟，推导出摩擦边界条件。研究结果将提高预测能力的软件工具的加工，并使分析设计的近干式加工过程中，通过合作的努力，包括普渡大学，第三波系统，公司和通用汽车公司的研发Center.There是广泛的兴趣，在开发完整的预测能力的工业加工过程。拟议的研究将提供一个重要的桥梁之间的基本理解的摩擦和变形在加工界面和摩擦边界条件的定量模型，在先进的加工软件工具的开发的重要一步。该研究还将生成验证加工模型所需的详细微观/介观尺度数据，并回答有关接触条件和加工界面润滑的长期问题。结合开发的摩擦模型的软件工具将使工业加工过程的分析设计和优化成为可能，包括具有明显环境和经济效益的近干加工能力。最后，有待开发的高分辨率成像技术提供了一种具有成本效益的系统解决方案，可在工业环境中有效实施。补充研究是一个教育和培训计划，包括短期的学生/研究人员访问工业合作伙伴;联合行业-大学短期课程的从业者;和夏季本科生研究实习，重点是学生从代表性不足的部门。

The objective of this proposed Grant Opportunity for Academic Liaison with Industry (GOALI)research is to characterize interface phenomena and friction boundary conditions along the tool-chip interface at unprecedented resolution. The research objectives include a determination of the strain and strain rate distribution in the deformation zones, measurement of fluid film thickness in the tool-chip contact zone along the rake face, and estimation of temperature in the rake face region and secondary deformation zone. By assembling these measurements in the appropriate topology, a model will be developed to describe the friction boundary condition. The approach includes enhancement of a Particle Image Velocimetry technique to estimate the strain and strain rate; development of measurement techniques using luminescent molecule sensors to estimate the fluid film thickness and temperature distribution along the tool rake face; and coupling the measured strain and temperature data with machining simulations to derive the friction boundary condition. The results will enhance predictive capability of software tools for machining and enable analytical design of near-dry machining processes through a collaborative effort involving Purdue University, Third Wave Systems, Inc and General Motors R&D Center.There is widespread interest in developing complete predictive capabilities for industrial machining processes. The proposed research will provide a vital bridge between fundamental understanding of friction and deformation at machining interfaces and a quantitative model of the friction boundary condition, a major step in development of advanced machining software tools. The research will also generate the detailed micro/meso scale data needed for validation of machining models and answer long-standing questions about contact conditions and lubrication of machining interfaces. Software tools incorporating the developed friction models will enable analytical design and optimization of industrial machining processes, including near-dry machining capabilities with obvious environmental and economic benefits. Lastly, the high-resolution imaging techniques to be developed offer a cost-effective system solution that can be implemented effectively in industrial settings. Complementing the research is an education and training program that includes short-term student/researcher visits to the industrial partners; joint industry-university short-courses for practitioners; and summer undergraduate research internships with focus on students from under-represented sectors.