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

机加工是基本的制造操作之一，其中材料在与切削工具相互作用期间经历非常复杂的变形条件，图1。为了满足质量标准并实现高效生产率，通常会使用大量耗时且成本高昂的试验来优化切削参数并显示零件符合性，特别是对于安全关键的航空航天部件。虽然已经存在一些知识的影响，切削操作上生产的表面质量和表面下的变形，有没有一个可靠的非破坏性的技术来检测它们的存在，也不知道这些功能的程度影响零件的性能。此外，许多建模策略已经被开发出来，以减少对实验观察的需求，但是这些策略要么非常耗时，要么不够全面，无法将工艺参数和模拟与零件质量（相对于其使用寿命）联系起来。该项目旨在开发一个数字化加工过程模拟平台，生产的表面完整性和功能性能的超级合金，以创建一个智能框架的过程控制和优化方面的应用切削参数和切削刀具条件。将实现基于多尺度物理的切削过程有限元模型，以模拟切屑形成并预测工件材料上的加工引起的变形和应力状态。结果被用来模拟加工表面的微观结构形态和表面完整性，将被送入各种服务负载下的功能性能分析。

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.