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，材料在与刀具的交互作用中会经历非常复杂的变形条件，如图1所示。为了满足质量标准和实现高效的生产率，通常需要进行大量耗时且昂贵的试验来优化切割参数并显示零件的一致性，特别是对于安全关键的航空零部件。虽然已经有一些关于切割操作对加工表面质量和亚表面变形的影响的知识，但还没有可靠的无损技术来检测它们的存在，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要，但这些策略要么非常耗时，要么不够全面，无法将工艺参数和仿真与部件的使用寿命相关的质量联系起来。该项目旨在开发一个数字平台，用于模拟高温合金的加工过程、所生产的表面完整性和功能性能，以创建关于所应用的切割参数和刀具条件的过程控制和优化的智能框架。建立基于物理的多尺度有限元模型，模拟切屑形成过程，预测加工过程中工件材料的变形和应力状态。这些结果被用来模拟加工表面的微观组织形态和表面完整性，并将其输入到各种使用载荷下的功能性能分析中。

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.