Atomized Dielectric-Based Electric Discharge Machining for Sustainable Manufacturing
用于可持续制造的雾化电介质放电加工
基本信息
- 批准号:1563475
- 负责人:
- 金额:$ 29.93万
- 依托单位:
- 依托单位国家:美国
- 项目类别:Standard Grant
- 财政年份:2016
- 资助国家:美国
- 起止时间:2016-04-01 至 2020-03-31
- 项目状态:已结题
- 来源:
- 关键词:
项目摘要
Electro discharge machining process has been successfully employed in aerospace, automobile, and other industries to manufacture high-accuracy micro-parts with range of materials irrespective of their hardness. However, the efficiency of the process has been low due to low energy of individual discharges and accumulation of debris particles in the inter-electrode gaps, especially, when machining micro-scale features. Further, the electro discharge machines use pressure flushing techniques that result in consumption of significantly higher amount of dielectric than needed for an effective discharge process. This award supports research to study an atomized dielectric-based electro discharge machining process that can reduce the consumption of the dielectric 10-20 folds and helping to achieve an environmentally sustainable machining process. The new process will offer unique capabilities of manufacturing high-accuracy components and devices with complex geometries. In addition, the quantitative understanding of plasma discharges in flowing liquid will be useful in a number of plasma applications ranging from water purification to plasma medicine. The overall goal of this research is to improve the efficiency of the micro-electro discharge machining process and produce an environmentally-sustainable machining process by reducing the consumption of hazardous dielectric. The approach is to atomize dielectric and produce a thin moving film that fills inter-electrode gap and flushes out the debris efficiently. This research has four specific objectives: (1) to understand film formation, flow characteristics, melt-pool formation, and debris flushing; (2) to understand the formation, collapse, and discharge of plasma in liquid medium; (3) to establish the relationship between the trajectory of the debris and the dielectric velocity; and (4) to establish relationships between process parameters and machining characteristics (discharge energy, material removal, and debris flushing). To achieve these objectives, a film formation model will be developed using mass and momentum transfer from the dielectric droplets in the spray; a spatially-resolved three-dimensional plasma model will be developed using a fluid-based approach; and the debris flushing model will be developed using the force balance at the flowing debris particle in the inter-electrode gap. To validate these models, experimentally measured data will be compared to model predictions. Film thickness will be measured using high-speed camera, plasma temperature and electron density will be measured using spectroscopy, and debris particle distribution around the discharge location will be determined from the measurements of different sized debris particles using scanning electron microscope.
电火花加工工艺已成功地应用于航空航天、汽车等行业,用于制造各种材料的高精度微型零件,而无论其硬度如何。然而,由于单个放电的低能量和碎片颗粒在电极间间隙中的积累,该工艺的效率一直很低,特别是在加工微尺度特征时。此外,放电机器使用压力冲洗技术,这导致消耗比有效放电过程所需的电介质量显著更高的电介质量。该奖项支持研究雾化电介质放电加工工艺,可将电介质的消耗减少10-20倍,并有助于实现环境可持续的加工工艺。新工艺将提供制造具有复杂几何形状的高精度部件和设备的独特能力。此外,在流动液体中的等离子体放电的定量理解将是有用的,在一些等离子体应用,从水净化等离子体医学。本研究的总体目标是通过减少有害电介质的消耗来提高微电火花加工过程的效率并产生环境可持续的加工过程。该方法是将电介质研磨并产生薄的移动膜,该移动膜填充电极间间隙并有效地冲洗碎片。本研究有四个具体目标:(1)了解薄膜形成、流动特性、熔池形成和碎片冲刷;(2)了解液体介质中等离子体的形成、崩溃和放电;(3)建立碎片轨迹与介电速度之间的关系;以及(4)建立工艺参数和加工特性(放电能量、材料去除和碎屑冲洗)之间的关系。为了实现这些目标,将开发一个膜形成模型,使用质量和动量转移的电介质液滴在喷雾;空间分辨的三维等离子体模型将开发使用基于流体的方法;和碎片冲洗模型将开发使用力平衡在流动的碎片颗粒在电极间的间隙。为了验证这些模型,将实验测量数据与模型预测进行比较。将使用高速照相机测量膜厚度,将使用光谱法测量等离子体温度和电子密度,并且将使用扫描电子显微镜从不同尺寸的碎片颗粒的测量来确定放电位置周围的碎片颗粒分布。
项目成果
期刊论文数量(0)
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Shiv Kapoor其他文献
Hyponatremia Reflects Neurohormonal Activation in Patients with Pulmonary Arterial Hypertension
- DOI:
10.1016/j.cardfail.2008.06.094 - 发表时间:
2008-08-01 - 期刊:
- 影响因子:
- 作者:
Kristen Hyland;Alix Morse;Shiv Kapoor;Darren B. Taichman;Harold I. Palevsky;Paul R. Forfia - 通讯作者:
Paul R. Forfia
Shiv Kapoor的其他文献
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{{ truncateString('Shiv Kapoor', 18)}}的其他基金
Collaborative Research: An Atomization-Based Cutting Fluid and CO2 Spray System for Machining Titanium Alloys
合作研究:用于加工钛合金的雾化切削液和 CO2 喷雾系统
- 批准号:
1233944 - 财政年份:2012
- 资助金额:
$ 29.93万 - 项目类别:
Standard Grant
Magnetic Field-Assisted Material Removal in Micro Electro Discharge Machining Process
微放电加工过程中的磁场辅助材料去除
- 批准号:
1033362 - 财政年份:2010
- 资助金额:
$ 29.93万 - 项目类别:
Standard Grant
Design of CNT Composite Microstructural Characteristics for Enhanced Engineering Functionality and Manufacturability
设计碳纳米管复合材料微观结构特性以增强工程功能和可制造性
- 批准号:
1029221 - 财政年份:2010
- 资助金额:
$ 29.93万 - 项目类别:
Standard Grant
Mitigating Fouling of Membranes in the Microfiltration of Metal-Working Fluid for Sustainable Manufacturing
减轻金属加工液微滤中的膜污染,实现可持续制造
- 批准号:
0856172 - 财政年份:2009
- 资助金额:
$ 29.93万 - 项目类别:
Standard Grant
EAGER: A Thermally-Assisted Magnetic Flow-Based Process for the Manufacture of Bulk Metallic Glass Surgical Cutting Edges
EAGER:一种基于热辅助磁流的工艺,用于制造块状金属玻璃手术切割边缘
- 批准号:
0937771 - 财政年份:2009
- 资助金额:
$ 29.93万 - 项目类别:
Standard Grant
Machinability of Carbon Nanotube Composites
碳纳米管复合材料的机械加工性能
- 批准号:
0523034 - 财政年份:2005
- 资助金额:
$ 29.93万 - 项目类别:
Standard Grant
Industry/University Cooperative Research Center for Machine Tool Systems Research
机床系统研究产学合作研究中心
- 批准号:
9816302 - 财政年份:1998
- 资助金额:
$ 29.93万 - 项目类别:
Continuing Grant
Industry/University Cooperative Research Center for Machine Tool Sytems - Tribology and Fixturing of Machined Parts
机床系统产学合作研究中心-机加工零件的摩擦学和夹具
- 批准号:
9625245 - 财政年份:1996
- 资助金额:
$ 29.93万 - 项目类别:
Standard Grant
Industry/University Cooeperative Research Center for Machine-Tool Systems - Machine-Tool Research Chatter Prevention Through Speed Variation
机床系统产学合作研究中心 - 通过变速防止机床颤振研究
- 批准号:
9523353 - 财政年份:1995
- 资助金额:
$ 29.93万 - 项目类别:
Standard Grant
I/UCRC for The Machine-Tool Systems Research Center (MSRC)
I/UCRC 机床系统研究中心 (MSRC)
- 批准号:
9314639 - 财政年份:1993
- 资助金额:
$ 29.93万 - 项目类别:
Continuing Grant
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