Modeling and Control of Subsurface Damage During the Grinding of Intermetallic Compounds

Kurfess金属间化合物（IMC）因其重量轻、强度高、熔点高和抗氧化性优异而闻名。 为了实现这些先进材料的潜力，必须考虑几个问题，包括二次加工的发展，如机械加工和精确的过程控制，以保证质量以及可靠性和成本。 该研究有三个主要目标：确定各种磨削参数对金属间化合物的影响，建立损伤形成的机理模型，并通过实验方法验证损伤模型。 为了开发一个经验模型，磨削参数和材料中产生的塑性变形，将在高度仪表化的磨床上进行一组析因实验。 这些数据集将用于开发和验证模型。 模型开发将基于对应用于IMC的磨削过程物理学（包括机械和热过程特性）的理解。 一旦模型被开发和验证，将设计和实现控制器，该控制器操纵控制参数以实现期望的结果。 此外，将开发用于定义过程参数轨迹的更高级别的控制器，其还解决经济考虑（例如，加工时间）。该项目的成功完成将导致一个很好的理解磨削IMC的物理，损伤制定的机械模型，并实现所需的磨削结果的有价值的控制策略。 与几家工业公司的合作提供了良好的协同作用和机构资源共享。 该项目将特别影响航空航天、汽车和化工行业。

DMI-9812967Kurfess Intermetallic compounds (IMCs) are noted for their light weight, high strength, high melting point, and excellent oxidation resistance. To realize the potential of these advanced materials several issues must be considered, including the development of secondary processes such as machining and precise process control for quality assurance as well as reliability and cost. The research has three major objectives: determining the influence of various grinding parameters on intermetallic compounds, developing a mechanistic model for damage formulation, and verification of the damage model via experimental methods. To develop an empirical model relating grinding parameters and resulting plastic deformation in the material, a set of factorial experiments will be conducted on a highly instrumented grinder. These data sets will be used to develop and verify the model. The model development will be based on the understanding of the grinding process physics (including both the mechanical and thermal process characteristics) applied to IMCs. Once the model has been developed and validated, a controller will be designed and implemented that manipulates the control parameters to achieve the desired results. Furthermore, a higher-level controller for defining process parameter trajectories will be developed that also addresses economic considerations (e.g., machining time). Successful completion of this project will lead to a good understanding of the physics of grinding IMCs, a mechanistic model for damage formulation, and a valuable control strategy for achieving desired grinding results. The collaboration with several industrial firms provides excellent synergy and sharing of institutional resources. The project should impact especially on the aerospace, automotive and chemical sectors.