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

GOALI：基于 6-Sigma 的稳健工艺设计，在刀具磨损情况下实现硬车削中精密加工部件的千兆疲劳寿命

基本信息

批准号：
0825780
负责人：
Yuebin Guo
金额：
$ 33.78万
依托单位：
University of Alabama Tuscaloosa
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：
2008-08-15 至 2012-12-31
项目状态：
已结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=0825780&HistoricalAwards=false
关键词：
GOALI Six Sigma Based Robust

项目摘要

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.

该奖项的首要研究目标是揭示硬车削中疲劳寿命与刀具磨损进展的基本演变，以创建基于六西格玛的稳健工艺设计。为了实现研究目标，将进行协同实验和理论研究。研究方法是：（1）综合表征表面完整性随切削时间和刀具磨损的演化，（2）将滚动接触疲劳寿命的分布和方差映射到切削时间和相应的刀具磨损进程上;以及（iii）为硬车削行业创建基于六西格玛的稳健工艺设计工具，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允许机械加工工业制造可靠的部件，同时最大化生产中的工具寿命。所创造的新知识将大大推进对工艺参数、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，所开发的稳健工艺设计方法也可用于广泛的制造工艺。这项研究将有利于机械加工经济取代昂贵的磨削便宜和环保的车削和降低相关的工具成本。协同的大学-工业合作伙伴关系将通过在工业环境中进行研究和实践经验，为教师和学生提供独特的机会。强大的工业参与将通过合作、共同为学生提供建议、工业研讨会和快速技术转让来建立长期的研究基础设施。