GOALI: Six-Sigma Based Robust Process Design Under Tool Deterioration for Giga Fatigue Life of Precision Machined Components in Hard Turning

该奖项的主要研究目标是揭示在硬车削过程中疲劳寿命随刀具磨损进程的基本演变，以创建基于六西格玛的稳健工艺设计。为实现研究目标，将进行协同实验和理论研究。研究方法是：(I)综合表征表面完整性随切削时间和刀具磨损的演变；(Ii)将滚动接触疲劳寿命的分布和变化映射到切削时间和相应的刀具磨损进程；(Iii)创建基于六西格玛的硬车削行业稳健工艺设计工具，用于疲劳寿命管理，同时最大化刀具寿命。如果成功，基于六西格玛的设计工具将使机械加工行业在生产中制造可靠的零件，同时最大化刀具寿命。创造的新知识将极大地促进对工艺参数、表面完整性和产品性能之间联系的基本理解。当疲劳性能受到关注时，开发的稳健工艺设计方法也将适用于广泛的制造工艺。这项研究将以更便宜、更环保的车削取代昂贵的磨削，并降低相关的刀具成本，从而有利于机械加工的经济性。通过在工业环境中进行研究和实践经验，协同的大学和行业伙伴关系将为教职员工和学生提供一个独特的机会。产业界的大力参与将通过合作、共同建议学生、产业研讨会和快速技术转让建立长期的研究基础设施。

The overarching research objective of this award is to reveal the basic evolution of fatigue life with tool wear progression in hard turning for creating a six-sigma based robust process design. To realize the research objective, a synergistic experimental and theoretical study will be conducted. The research approaches are to: (i) Comprehensively characterize surface integrity evolution versus cutting time and tool wear; (ii) Map the distribution and variance of rolling contact fatigue life onto cutting time and the corresponding tool wear progression; and (iii) Create a six-sigma based robust process design tool for hard turning industry for fatigue life management while maximizing tool life.If successful, the six-sigma based design tool will allow the machining industry to manufacture reliable components while maximizing tool life in production. The new knowledge created will significantly advance the basic understanding of the linkage between process parameters, surface integrity, and product performance. The developed methodology of robust process design will also be useable in broad manufacturing processes when fatigue performance is of concern. This research will benefit machining economics by replacing expensive grinding by cheap and environmentally friendlier turning and reducing the associated tool costs. The synergetic university-industry partnership will afford a unique opportunity for faculty and students through the conduct of research and practical experience in industrial settings. The strong industrial participation will build a long-term research infrastructure through collaboration, co-advising students, industrial seminars, and rapid technology transfer.