Intelligent machining simulation: Process Modelling and Functional Performance Prediction of Superalloys

机械加工是一种基本的制造操作，其中材料在与切削刀具相互作用期间经历非常复杂的变形条件，如图1所示。为了达到质量标准并实现高效的生产效率，通常使用大量耗时且昂贵的实验试验来优化切割参数并显示零件一致性，特别是对于安全关键的航空航天部件。虽然已经有一些关于切割操作对生产表面质量和地下变形的影响的知识，但没有可靠的非破坏性技术可以检测它们的存在，也不知道这些特征对零件性能的影响程度。此外，已经开发了许多建模策略来减少对实验观察的需求，然而，这些建模策略要么非常耗时，要么不够全面，无法将工艺参数和模拟与零件质量及其使用寿命联系起来。该项目旨在开发一个数字平台，用于模拟加工过程、生产表面完整性和高温合金的功能性能，以便创建一个智能框架，用于在应用切削参数和刀具条件方面进行过程控制和优化。建立基于多尺度物理的切削过程有限元模型，模拟切屑形成过程，预测加工引起的工件材料变形和应力状态。结果用于模拟加工表面的微观结构形态和表面完整性，这些数据将用于各种服务载荷下的功能性能分析。

Machining is one of the fundamental manufacturing operations wherein the material experiences a very complex deformation condition during the interaction with a cutting tool, Figure 1. To meet quality standards and achieve efficient productivity, a number of time-consuming and costly experimental trials are typically used to optimise cutting parameters and show partconformity, particularly for safety critical aerospace components. Although there already exists some knowledge about the effect of cutting operation on the produced surface qualities and subsurface deformation, there is not a reliable non-destructive technique available to detect their presence nor the extent of which these features affect the parts performance is known. Additionally, many modelling strategies have already been developed to reduce the need for experimental observations, however these are either very time consuming or not comprehensive enough to link the process parameters and simulations to the parts quality with respect to their service life.The project aims to develop a digital platform for simulation of machining process, produced surface integrity and functional performance of the superalloys in order to create an intelligent framework for process control and optimisation with respect to the applied cutting parameters and cutting tool conditions. A multi-scale physics based Finite Element model of the cutting process will be realised to simulate the chip formation and predict the machining induced deformation and stress state on the workpiece materials. The results are used to model microstructural morphology and surface integrity at the machined surface that will be fed into a functional performance analysis under various service loads.