CAREER: A Hybrid High Strain Rate Forming Process -- Laser Dynamic Forming for Micro- and Meso- Scale 3D Shapes

该学院早期职业发展（Career）补助金为开发独特的成形工艺激光动态成形提供资金，以形成中观和微观尺度的3D结构。该工艺结合了金属成形和激光冲击强化的优点，可以在各种材料，特别是脆性和难成型材料中产生三维成形。本课题将探索激光动态成形的基本工艺机理，并对其进行精确控制。实验将用于研究成形过程中的尺寸效应、成形性、温度效应、起皱和回弹。将采用多尺度模拟方法来模拟成形过程。将建立分析模型来预测成形后的疲劳寿命和断裂韧性，并通过实验进行验证。一个逆多目标优化将发展设计成形工艺所需的几何变化，和力学性能。该项目的教育目标是将研究活动与教育工作相结合，例如建立激光加工教育实验室；非传统制造教育与制造课程的结合通过新的教学模块和暑期研究项目，为高中生和弱势群体开展拓展活动。这项工作的顺利完成，将对微、中三维结构工艺产生革命性的改进，并对制造业产生重大影响。这项工作将从根本上推进激光加工的知识状态，通过一种新的混合成形工艺，改善产品的机械性能。该项目将通过建立强大的研究综合教育活动，增加非传统制造技术在教育中的存在。美国原住民高中生将受到启发，追求科学和工程事业。鼓励少数民族、妇女、残疾人参与，激发他们对理工科的兴趣。

This Faculty Early Career Development (CAREER) grant provides funding to develop a unique forming process laser dynamic forming, to form meso- and micro-scale 3D structures. This process combines the advantages of metal forming and laser shock peening to generate 3D shaping in various materials, especially brittle and hard to form materials. The project will discover the fundamental process mechanism of laser dynamic forming, and control the process accurately. Experiments will be designed to study size effects, formability, temperature effects, wrinkling and springback of the forming process. A multiscale simulation approach will be used to simulate the forming process. Analytical models will be built to predict fatigue life and fracture toughness after forming, and validated via experiments. An inverse multiobjective optimization will be developed to design the forming process desired geometry change, and mechanical properties. The education goal of the project is to integrate research activities with educational efforts, such as development of a Laser Processing Education Lab; incorporation of nontraditional manufacturing education into manufacturing courses; and outreach activities for high school students and under-represented minorities through new teaching modules and summer programs with research projects. The successful completion of this work will make a revolutionary improvement to the process of micro- and meso- three-dimensional structures, and have a major impact on manufacturing industry. This work will fundamentally advance the state of knowledge of laser processing through a novel hybrid forming process with improved mechanical properties of product. This project will increase the presence of non-traditional manufacturing techniques in education by establishing a strong research integrated education activities. Native American high school students will be inspired to pursue science and engineering careers. Ethnic minorities, women, and person of disability will be encouraged to participate in this project to pique their interests in science and engineering.