GOALI/IUCRP: Rotary Ultrasonic Machining of Ceramic Materials

小行星9500420 结构陶瓷材料可用于发动机、电子产品、工具或其他对高温性能、强度重量比和耐磨性或耐腐蚀性很重要的应用。 今天，结构陶瓷的使用受到限制，部分原因是它们很难加工成有用的产品，而且成本很高。 该项目将提供一种称为旋转超声加工（RUM）的新工艺的基本理解，该工艺有望减少加工时间，从而降低成本，而不会造成限制结构陶瓷部件寿命和可靠性的亚表面损伤。 RUM使用垂直于表面的超声波振动，其产生的目的是在脆性硬材料中通过断裂而不是通过塑性变形来增强材料去除。 该项目研究了RUM过程中的基本材料去除机制，将用于设计第一代RUM加工系统。 在这种机器的设计中也存在基本的集成问题，例如，在加工时使用自适应控制来保持标称正常压力。 这种对RUM的基本理解和实验工作有可能提供一种具有成本效益的方法来加工结构陶瓷。 这一新知识的影响将使受到移动接触的机械部件的寿命更长，或者由结构陶瓷制成的更高密度和更低成本的电子存储设备。 ***

9500420 Ferreira Structural ceramics materials can be used in engines, electronics, tooling or other applications where high temperature performance, strength to weight ratios, and wear or corrosion resistance are important. Today the use of structural ceramics is limited, in part, because they are very difficult and costly to process into useful products. This project will provide a fundamental understanding of a new process called rotary ultrasonic machining (RUM), that promises to reduce the processing time, and hence cost, without imparting sub-surface damage that would limit the life and reliability of structural ceramic components. RUM uses ultrasonic vibration normal to a surface that is being generated to enhance material removal by fracture, rather than by plastic deformation, in brittle hard materials. This project examines the fundamental material removal mechanisms in the RUM process, that will be used to design a first generation RUM machining system. There are also fundamental integration issues in the design of such a machine, for example, the use of adaptive control to maintain nominal normal pressure while machining. This fundamental understanding and experimental work on RUM has the potential to provide a cost effective way to process structural ceramics. This impact of this new knowledge will be longer life for mechanical components subjected to moving contact, or higher density and lower cost electronic storage devices made from structural ceramic. ***