Material Effects and Tool Wear in Vibration-Assisted Machining

该奖项的研究目标是测试金刚石刀具的微米振幅振动将减少力，改善表面光洁度和减少刀具磨损的假设。 材料科学和机械工程教师和学生将测量和建模材料去除过程，并定义控制工具力，工具磨损和所选材料的表面光洁度的参数。 材料的选择提供了一系列的物理和化学性能，将测试材料流动，温度产生和磨损机制的建议的概念。 将使用测量切屑几何形状、表面光洁度、刀具边缘锋利度和碳从刀具到切屑/工件的扩散的独特技术来描述该过程的细节。 如果成功，该项目将量化在钢、玻璃或陶瓷等被认为会快速磨损金刚石工具的材料上创建高质量表面所需的振动条件。 钢是最常用的工程材料，由于其优良的性能，可用性和低成本。 汽车、医疗和光学行业对亚微米精度的超精密钢零件和系统存在着国家和全球需求。 精密玻璃和陶瓷部件的需求也很高。 此外，该研究项目为北卡罗来纳州州立大学的研究生和本科生提供了学习细节和扩展超精密加工能力的机会。 工作结果将在技术会议上介绍，并在科学期刊上发表。 提供给每个小组的研究经验将提高科学和工程教育的质量。

The research objective of this award is to test the hypothesis that micrometer-amplitude vibration of a diamond cutting tool will reduce forces, improve surface finish and decrease wear of the tool. Material science and mechanical engineering faculty and students will measure and model the material removal process and define the parameters that control tool forces, tool wear and surface finish for the selected materials. Materials have been chosen to provide a range of physical and chemical properties that will test proposed concepts of material flow, temperature generation and wear mechanisms. Unique techniques for measuring the chip geometry, surface finish, tool edge sharpness and diffusion of the carbon from the tool to the chip/workpiece will be used to describe the details of the process. If successful, this project will quantify the vibration conditions needed to create high-quality surfaces on materials such as steel, glass or ceramics that were thought to rapidly wear diamond tools. Steel is the most frequently used engineering material due to its excellent properties, availability and low cost. A national and global demand for ultra-precision steel parts and systems with sub-micrometer accuracy exists in automotive, medical and optical industries. Precision glass and ceramic components are also in high demand. In addition, this research project provides the opportunity for graduate and undergraduate students at North Carolina State University to learn the details and extend the capability of ultraprecision machining. The results of the work will be presented at technical meetings and published in scientific journals. The research experience provided to each of these groups will improve the quality of the science and engineering education.