Investigation of thermoelastic and dynamic phenomena for improved design and control of manufacturing and tribological systems

研究热弹性和动态现象，以改进制造和摩擦系统的设计和控制

• 批准号: RGPIN-2015-05632
• 负责人: Attia, Mahmoud
• 金额: $ 2.11万
• 依托单位: McGill University
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2019
• 资助国家: 加拿大
• 起止时间: 2019-01-01 至 2020-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=683145
• 关键词: Investigation; thermoelastic; dynamic; phenomena; improved

This proposal deals with two major issues; high performance machining processes, and predictive capability for fretting wear under complex excitation. These two issues are interrelated, since the integrity of machined surfaces control the tribological behaviour of the component. The proposal consists of the following elements (E1 to E5): ***E1. Integrated Laser Assisted Machining, Cryogenic Cooling and Minimum Quantity Lubrication: The objective is to investigate the synergetic effect of cryogenic cooling (LiN), minimum quantity lubrication on tool wear, productivity. and surface integrity in laser-assisted machining. Process optimized will defined through experimental investigation and process simulation. ***E2. Intermittent Drilling of Composites using Conventional and Superabrasive Tools: A predictive cutting force model was developed, based on a fundamental understanding of FRP composites cutting by a single diamond grain. The model will be extended to predict and optimize the orbital drilling process using superabrasive tools. Vibration-assisted drilling at high frequency-low amplitude regime will also be investigated using conventional tools. ***E3. Detection of Tool Pre-Failure in Turning Processes: The objective is to develop a system to detect unexpected tool breakage in machining. Various signals will be evaluated and special consideration will be given to feature extraction using different signal processing techniques in the time and frequency domains. A multi-sensor fusion model will be developed for 2-way communication with the NC controller. ***E4. Prediction of Machining-Induced Residual Stresses and Micro-structural Changes: A 2D FE model was developed to predict machining-induced residual stress (RS), assuming non-segmental chip formation. To improve prediction accuracy, it is proposed to consider the effects of chip segmentation, flank tool wear, and material phase transformation. For validation, oblique cutting experiments will be conducted for conventional and laser-assisted machining. ***E5. High Temperature Fretting Wear of Superalloys under Pseudo Random Excitation: Following the experiments on the role of surface oxide in fretting wear of cobalt-based superalloys at 550oC, a FE-based model was developed to estimate friction-induced temperature rise, considering the spatial and height random distributions of contact asperities. The applicant's `generalized fretting wear theory', will be extended by considering the effect of: (a) crack initiation and propagation due to frictional heating, (b) oxidation kinetics, and (c) random excitation; an aspect that has not been investigated before. **

该建议涉及两个主要问题：高性能加工工艺和复杂激励下微动磨损的预测能力。这两个问题是相互关联的，因为加工表面的完整性控制部件的摩擦学行为。本提案包括以下内容（E1至E5）：*E1。集成激光辅助加工、低温冷却和最小量润滑：目的是研究低温冷却（LiN）、最小量润滑对刀具磨损和生产率的协同效应。以及激光辅助加工中的表面完整性。通过实验研究和工艺模拟确定工艺优化方案. *E2。使用常规和超硬磨料工具对复合材料进行间歇钻孔：基于对单个金刚石颗粒切割FRP复合材料的基本理解，开发了一种预测性切割力模型。该模型将扩展到预测和优化使用超硬磨料工具的轨道钻削过程。还将使用传统工具研究高频低振幅区域的振动辅助钻井。*E3。车削过程中刀具预失效的检测：目标是开发一个系统来检测加工中意外的刀具断裂。将对各种信号进行评估，并特别考虑在时域和频域中使用不同的信号处理技术进行特征提取。一个多传感器融合模型将被开发用于与NC控制器的双向通信。*E4。预测加工引起的残余应力和微观结构变化：一个2D有限元模型被开发来预测加工引起的残余应力（RS），假设非分段切屑形成。为了提高预测精度，建议考虑切屑分割、后刀面刀具磨损和材料相变的影响。为了验证，斜角切割实验将进行常规和激光辅助加工。*E5。伪随机激励下高温合金的高温微动磨损：在550 ° C下表面氧化物在钴基高温合金微动磨损中的作用实验之后，考虑空间和高度随机分布，开发了一个基于有限元的模型来估计摩擦引起的温升。接触粗糙度。申请人的“广义微动磨损理论”将通过考虑以下因素的影响而得到扩展：（a）由于摩擦加热而产生的裂纹萌生和扩展，（B）氧化动力学，以及（c）随机激励;这是以前从未研究过的一个方面。**