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

磁致伸缩执行器的新颖设计和控制实现了高性能微成型、连接和冲压工艺

• 批准号: 0800353
• 负责人: Gap-Yong Kim
• 金额: $ 20万
• 依托单位: Iowa State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2008
• 资助国家: 美国
• 起止时间: 2008-07-15 至 2013-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0800353&HistoricalAwards=false
• 关键词: Performance; Micro; Forming; Joining; Punching

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.

该项目的目标是通过超声波辅助微成型以前所未有的运行速度改进当前微成型工艺的微制造平台。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，该致动器能够进行超声波振动以及高速宏观变形。 该项目的目标是 (1) 设计和构建新型 Terfenol-D 执行器，以实现微成型应用所需的性能； (2) 开发一套先进的基于模型的前馈-反馈控制技术，以克服Terfenol-D对高速、精密运动控制的非线性迟滞和动态效应； (3) 通过研究如何通过引入超声波振动和高速运行来提高刀具寿命和零件质量，研究微成型的基本方面。该研究代表了在下一代微型机床系统 (mMTS) 中使用 Terfenol-D 执行器的首次尝试之一。 这将延长刀具寿命、提高零件质量并减少占地面积，解决微制造中的几个关键挑战，包括维护成本、能源消耗和产量限制。 双级磁致伸缩致动器的新颖应用以及先进的控制技术将能够系统地研究高频振动对微成形过程的基本影响，为将微成形技术推向工业应用做出重大贡献。 教育活动将包括研究生和本科生课程模块开发、本科生和高中教师暑期实习机会、开放实验室参观和实践活动以及中学探究模块。 这些活动的目标是让本科生、研究生和高中生和教师接触微制造、活性材料和先进控制领域的前沿研究。