High-Performance Micro-Forming, Joining, and Punching Processes Enabled by a Novel Design and Control of Magnetostrictive Actuators

本计画的目标是借由超音波辅助微成形，以前所未有的操作速度，来改善目前微成形制程的微制造平台。为了克服现有技术的局限性，将使用基于磁致伸缩Terfenol-D的致动器，能够进行超声振动以及高速宏观变形。 本计画的目标为：（1）设计并建构一种新颖的Terfenol-D致动器，以达到微成形应用所需的性能;（2）发展一套先进的基于模型的前馈-反馈控制技术，以克服Terfenol-D在高速精密运动控制中的非线性迟滞和动力学效应;（3）通过研究如何通过引入超声振动和高速操作来提高工具寿命和零件质量，研究微成形的基本方面。下一代微机床系统（mMTS）中的三维执行器。 这将延长刀具寿命，提高零件质量，减少占地面积，解决微制造中的几个关键挑战，包括维护成本，能耗和吞吐量限制。 双级磁致伸缩致动器的新应用沿着先进的控制技术，将使高频振动对微成形过程的基本影响的系统研究成为可能，为微成形技术走向工业应用做出了重要贡献。 教育活动将包括研究生和本科课程的课程模块开发、本科生和高中教师的暑期实习机会、开放实验室参观与实践活动以及中学询问模块。图尔斯。 这些活动的目标是使本科生、研究生和高中学生和教师接触微型制造、活性材料和先进控制领域的前沿研究。

The goal of this project is to improve the current micro-manufacturing platform for microforming processes by the ultrasonic-assisted microforming at unprecedented operation speed. To overcome the limitations of existing technology, actuators based on magnetostrictive Terfenol-D, capable of ultrasonic vibration as well as high-speed macro deformations will be used. The objectives of the project are to (1) design and construct a novel Terfenol-D actuator to achieve the required performance of microforming applications; (2) develop a suite of advanced model-based feedforward-feedback control techniques to overcome the nonlinear hysteresis and dynamics effects of Terfenol-D on high-speed, precision motion control; and (3) investigate the fundamental aspects of microforming by studying how the tool life and part quality are improved by the introduction of ultrasonic vibration and high speed operation.The proposed research represents one of the first attempts in utilizing Terfenol-D actuators in the next-generation micro-machine tool system (mMTS). This will lead to increased tool life, improved part quality, and reduced footprint addressing several critical challenges in micro-manufacturing including maintenance cost, energy consumption, and throughput limitations. The novel application of the dual stage magnetostrictive actuator along with the advanced control techniques will enable the systematic study of the fundamental effects of high frequency vibration on microforming processes making significant contributions to moving microforming techniques towards industry applications. Educational activities will include course module development for graduate and undergraduate classes, summer internship opportunities for undergraduates and high school teachers, open lab tours with hands on activities, and middle school inquire module. The goal of these activities is to expose undergraduate, graduate, and high school students and teachers to cutting edge research in the areas of micro-manufacturing, active materials, and advanced controls.