Manufacturing Processes for Advanced Materials

先进材料的制造工艺

• 批准号: RGPIN-2016-06268
• 负责人: Elbestawi, Mohamed
• 金额: $ 1.89万
• 依托单位: McMaster University
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2020
• 资助国家: 加拿大
• 起止时间: 2020-01-01 至 2021-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=710242
• 关键词: Manufacturing; Processes; Advanced; Materials

Summary of Proposal The proposed research deals with high performance cutting of light-weight materials that are of major interest to the automotive and aerospace industries. An integrated research program is proposed that deals with two types of light-weight materials as follows; 1) High performance machining for advanced composite materials such as Carbon- Fiber Reinforced Polymers will be investigated. Preliminary experimental results have shown that carbon fiber pull-out, particle fracture, delamination and debonding at the fiber or particle matrix interface have significant influence on tool failure. There is a significant need to develop robust modeling approaches which can be used to optimize the cutting process. Finite element models will be developed to simulate the machining processes considering material characteristics, tool geometry, and cutting conditions. A comprehensive experimental program will validate these models and evaluate the performance of various advanced tool materials and geometries. Experimental work will be performed to study high performance cooling strategies including minimum quantity lubrication (MQL). Machinability maps will be developed to investigate the effect of cutting speeds and feeds. 2) Machinability of Compacted Graphite Iron (CGI) focusing on the development of a fundamental scientific understanding of the effect of the microstructure on process variables for applications in the automotive industry. The finite element model previously developed by the applicant and his team, will be generalized to include various cutting tool materials and geometries, tool material degeneration due to wear as well as the effect of minor inclusions in the material on cutting performance. In particular, approaches to deal with the relatively poor machinability of CGI will be developed and investigated. The differences in the machinability of CGI compared to gray cast iron will also be considered in order to investigate the influence of material mechanical and physical properties, dictated by the shape, size, and growth mechanism of graphite in their microstructures. A wide-ranging experimental program will be performed to validate the generalized model developed above. These experiments will be designed to study chip formation, cutting forces and tool wear under various cutting conditions. These two materials (CFRP and CGI) were selected as examples of light-weight materials which are gaining prominence and cover a wide range of applications in both the automotive and aerospace industries. The methodologies developed as a result of this research can be used for process optimization, preserving part integrity and reducing sub-surface damage. The research proposed here is essential for dealing with some of the most important requirements for increasing productivity, improving fuel efficiency and environmental impact in these industries.

提案摘要 拟议的研究涉及汽车和航空航天工业主要感兴趣的轻质材料的高性能切割。 提出了一项综合研究计划，涉及以下两种类型的轻质材料： 1）将研究碳纤维增强聚合物等先进复合材料的高性能加工。初步实验结果表明，碳纤维拔出、颗粒断裂、纤维或颗粒基体界面处的分层和脱粘对刀具失效有显着影响。非常需要开发可用于优化切割过程的稳健建模方法。将开发有限元模型来模拟加工过程，考虑材料特性、刀具几何形状和切削条件。 综合实验计划将验证这些模型并评估各种先进刀具材料和几何形状的性能。将进行实验工作来研究高性能冷却策略，包括微量润滑（MQL）。将开发可加工性图来研究切削速度和进给量的影响。 2) 蠕墨铸铁 (CGI) 的机械加工性，重点是对汽车行业应用中的微观结构对工艺变量的影响建立基本的科学理解。申请人及其团队先前开发的有限元模型将被概括为包括各种切削刀具材料和几何形状、由于磨损而导致的刀具材料退化以及材料中的微小夹杂物对切削性能的影响。特别是，将开发和研究解决 CGI 相对较差的机械加工性的方法。为了研究由微观结构中石墨的形状、尺寸和生长机制决定的材料机械和物理性能的影响，还将考虑 CGI 与灰口铸铁的可加工性差异。 将进行广泛的实验计划来验证上面开发的广义模型。这些实验旨在研究各种切削条件下的切屑形成、切削力和刀具磨损。 这两种材料（CFRP 和 CGI​​）被选为轻质材料的示例，它们在汽车和航空航天工业中日益受到重视并广泛应用。本研究开发的方法可用于工艺优化、保持零件完整性并减少表面下损伤。 这里提出的研究对于解决这些行业提高生产率、提高燃油效率和环境影响的一些最重要的要求至关重要。