Prediction of Dynamics at the Micro-Tool Tip for Micromachining when using Ultra-High-Speed Spindles

该奖项通过为精确预测刀尖三维动态响应提供新的框架来支持机械微加工的研究。研究目标是通过结合实验确定的主轴动力学，旋转微刀具动力学的精确模型，以及主轴和刀具附件误差引起的非理想运动，对刀具尖端动力学有基本的了解。 具体的研究方法包括（1）使用专门的动态测试方法对主轴动态进行实验建模，（2）使用三维线性弹性技术对旋转微工具的动态进行建模，以及（3）使用激光干涉测量法测量超高速主轴的误差运动。随后，主轴和刀具动力学和误差运动的模型进行整合，以获得刀具尖端动力学。该研究还将涉及对不同微型工具和不同操作条件下的组合工具尖端动力学预测的实验验证。教育目标包括加强现有的制造课程，并通过大学预科外展活动吸引学生进入制造业。该研究将提供一个全面的建模能力，用于预测使用超高速主轴时刀具尖端的动态行为，从而促进以可预测和有效的方式从金属，聚合物和复合材料制造具有精确微尺度特征的零件。这些零件在许多行业都有很高的需求，例如医疗和能源转换设备。虽然微机械加工技术在过去几年中取得了很大的进步，但尚未实现广泛的工业应用。主要原因之一是对过程特性缺乏深入的理解，特别是过程力学和动力学。该项目将提供一个有效的方法表征和可预测的利用微加工过程。该项目的工业相关性将通过我们与两家领先的主轴公司的合作来确保，这将使研究成果迅速转移到工业中，从而对美国的先进制造业产生积极影响。

This award supports research on mechanical micromachining by providing a new framework for accurate prediction of three-dimensional dynamic response at the tool tip. The research objective is to gain fundamental understanding on tool-tip dynamics by combining experimentally-determined spindle dynamics, accurate models of rotating micro-tool dynamics, and the non-ideal motions arising from the spindle and tool-attachment errors. The specific research approach involves (1) the use of specialized dynamic testing methods for experimental modeling of spindle dynamics, (2) the use of three-dimensional linear elasticity techniques to model dynamics of rotating micro-tools, and (3) the use of laser interferometry to measure error motions of ultra-high-speed spindles. Subsequently, the models for spindle and tool dynamics and error motions are integrated to obtain tool-tip dynamics. The research will also involve experimental validation of the combined tool-tip dynamics predictions for different micro-tools and under different operating conditions. The educational objectives include enhancing the existing manufacturing curricula, and attracting students to manufacturing through pre-college outreach activities.The research will offer a comprehensive modeling capability for predicting dynamic behavior at the tool tip when using ultra-high-speed spindles, and will thereby facilitate fabrication of parts with precise micro-scale features in a predictable and efficient fashion from metals, polymers, and composites. Such parts are in high demand from many industries, such as medical and energy-conversion devices. Although micromachining technology has come a long way in the last few years, a wide-range industrial adoption has not yet been realized. One of the main reasons is the lack of thorough understanding on process characteristics, specifically process mechanics and dynamics. This project will provide an effective approach for characterization and predictable utilization of micromachining processes. The industrial relevance of the project will be ensured through our collaboration with two leading spindle companies, which will enable rapid transfer of research findings to industry, and thus, will positively impact advanced manufacturing efforts in the United States.