SBIR Phase I: Analytical Modeling and Performance Prediction of Remanufactured Gearbox Components

该小型企业创新研究第一阶段项目将开发分析疲劳模型，应用于NSF SBIR第一阶段征集11-577(主题NM？纳米技术、先进材料和制造，分主题M3-建模和仿真)下的再制造变速箱部件的性能分析。开发这项技术的第一步包括通过模拟磨损的齿轮来展示基本的模型能力，该齿轮使用各向同性超精(ISF)工艺重新制造，如本提案所述。该模型将基于ISF工艺对磨损齿轮的适用性、ISF对齿轮特性(材料微观组织、微观几何形状、残余应力、表面粗糙度)的影响以及随后对抗损伤性能的影响的基础研究。该模型将被用来预测再制造部件的疲劳寿命，从而量化这种加工的好处，并证明这种工具的可行性。研究结果将为扩展森特？S仿真技术，将各种其他再制造工艺纳入更全面的设计和分析框架，从而优化再制造操作，延长高附加值部件的使用寿命奠定基础。拟议的开发将对依赖高工程(因此昂贵)变速箱可靠功能的行业产生直接影响。航空航天、能源和交通。组件必须在极端环境中运行，通常会导致过早拆卸或大修。尽管这些部件磨损或损坏，但如果部署了适当的再制造工艺，它们仍有能力发挥作用。这样做可以减少生产更换部件所需的大量资源(材料、能源、人力)。此外，人们认为，某些再制造工艺的应用实际上可以提高某些部件的耐用性。不幸的是，目前的设计和分析方法需要广泛的测试和评估，以验证已在现场使用并在原始OEM规范之外加工的部件的有效性和安全性。测试所有可能的组件组合以及通过各种加工选项修复的各种级别的潜在损坏将是一项昂贵而耗时的壮举，因此阻碍了再制造工艺在整个行业的广泛部署。然而，正如在这项拟议的努力中假设的那样，这种评估和验证可以通过建模和模拟来进行。由此产生的技术进步将在安全回收变速箱部件的使用寿命方面提供直接价值。

This Small Business Innovation Research Phase I project shall develop analytical fatigue models as applied to the performance analysis of remanufactured gearbox coponents under NSF SBIR Phase I Solicitation 11-577 (Topic NM?Nanotechnology, Advanced Materials, and Manufacturing, Subtopic M3-Modeling and Simulation). The first step in developing this technology involves demonstrating basic model capability through the simulation of a worn gear, remanufactured using an isotropic superfinish (ISF) process, as described in this proposal. This model will be based on the fundamental research of the applicability of the ISF process to worn gears, the effects of ISF on gear characteristics (material mictrostructure, microgeometry, residual stress, surface roughness), and the subsequent effect on damage resistance. The model will be used to predict the fatigue life of the remanufactured component, thus quantifying the benefits of such processing and demonstrating the feasibility of such a tool. The results will lay the groundwork for expanding Sentient?s simulation technology to include various other remanufacturing processes in a more comprehensive design and analysis framework capable of optimizing reman operations to extend the useful life of high value added components.The proposed development has immediate impact on industries that rely on the reliable function of highly engineered (and thus expensive) gearboxes ? aerospace, energy, and transportation. Components must operate in extreme environments, often leading to premature removal or overhaul. Though worn or damaged, these components still have the ability to function given the appropriate remanufacturing processes are deployed. Doing so reduces a significant amount of resources (materials, energy, manpower) otherwise required to produce a replacement part. Furthermore, it is thought that the application of certain remanufacturing processes can actually enhance durability of certain components. Unfortunately, current design and analysis approaches require extensive testing and evaluation to validate the effectiveness and safety of a component that has been used in the field then processed outside of original OEM specification. To test all possible combination of component coupled with various levels of potential damage repaired through various options of processing would be an impossibly expensive and time consuming feat, thus prohibiting a broad deployment of remanufacturing processes across industry. However, as postulated in this proposed effort, such evaluation and validation can occur through modeling and simulation. The resulting advancement in technology will provide immediate value in safely reclaiming useful life of gearbox components.