CAREER: Hybrid Processes for Machining Brittle Materials

这个CAREER项目的总体目标是提高陶瓷磨削的基础知识，提高本科生和研究生解决问题的能力。陶瓷优异的性能使其成为许多应用领域的理想材料。然而，陶瓷元件的制造成本往往是令人望而却步的。其中一个问题发生在陶瓷磨削中，砂轮的快速降解阻碍了表面质量和生产率。该项目的研究目标是通过使用高频振动作为砂轮在加工过程中的清洁手段来提高砂轮的效率；并且，使用研磨水射流作为过程中的清洁和修整技术。分析和实验将用于评估高频振动对单个颗粒和砂轮性能的影响。此外，高压水射流（带和不带磨料）与砂轮之间的相互作用将被研究。这个项目的教育部分将在课堂上引入基于问题的学习理念。解决开放式实际问题的技巧将在本科课程中引入，而实验练习将在研究生解决问题的专题课程中发展。该项目的潜在影响包括改进陶瓷的无断口磨削方法，关于高频振动对磨削过程的影响以及高压水射流与砂轮之间相互作用的新科学知识，以及对本科生和研究生解决实际问题的教育。

The overall goals of this CAREER project are to advance fundamental knowledge leading to higher productivity of ceramics grinding and to improve the problem solving abilities of undergraduate and graduate students. The superior properties of ceramics make them a desirable material for many applications. However, the fabrication cost of ceramic components is often prohibitive. One of the problems occurs in the grinding of ceramics, where the rapid degradation of the grinding wheel hinders surface quality and production rate. The research objectives of this project are to improve grinding wheel effectiveness through the use of high-frequency vibrations as a means of in-process cleaning of the wheel; and, the use of an abrasive waterjet as an in-process cleaning and dressing technique. Both analysis and experimentation will be used to evaluate the effect of high-frequency vibrations on the performance of individual grains as well as the grinding wheel. In addition, the interaction between a high-pressure waterjet (with and without entrained abrasive) and a grinding wheel will be investigated. The education part of this project will introduce problem-based learning concepts in the classroom. Techniques for solving open-ended practical problems will be introduced in an undergraduate class, and experimental exercises will be developed in a problem-solving project course for graduate students. The potential impact of the project includes improved methods for fracture-free grinding of ceramics, new scientific knowledge on the effect of high-frequency vibrations on the grinding process as well as on the interaction between a high-pressure waterjet and a grinding wheel, and the education of undergraduate and graduate students in practical problem solving.