GOALI: Process Modeling and Analysis for "Smart Tool" Redevelopment in Flexible Line Boring

这个赠款机会学术联络与工业（GOALI）项目的目的是扩大基础研究的结果在工业环境中，以协助开发一个更可重构的线钻孔过程。 线镗广泛用于加工同心线的孔，例如用于发动机凸轮轴或曲轴的孔。 工业合作伙伴Lamb Technicon Machining Systems最近完成了一台原型柔性线镗机床，但其“智能刀具”需要进一步开发，即通过内部激光反馈和压电驱动来补偿刀具振动。 一个新的过程稳定性解决方案，解决了真实的，角圆角的牙齿几何形状在钻孔操作中看到的将被扩展到占工具的导垫，致动器和控制器的动态效果。 一个新的切削齿的概念，然后将建模和分析，以减少50%的径向加工力。 将对基于模型的齿设计进行测试，以比较使用传统圆角刀具测量的力、切削功率和刀具磨损。如果成功，扩展稳定性解决方案将有助于避免可能损坏昂贵智能刀具的不稳定性。 由于系统的复杂性增加，拥有这样一个基于科学的工具在这里尤为重要。 如果可以通过新的切割齿概念来减小径向力，那么对致动器尺寸和功率的要求将降低，或者将实现增加的致动器运动。 这将有助于更小的镗杆和更少的要求，对致动器的电力感应系统，必须在整个旋转界面操作。 也许这次合作最重要的成果将是对Lamb Technicon和研究者的研究计划的双边影响。 调查员将带来具体的专业知识，以智能工具的问题，同时了解更多有关该行业的真正需求和他们的日常挑战

This Grant Opportunity for Academic Liaison with Industry (GOALI) project aims to extend the results of basic research in an industrial setting to assist in the development of a more reconfigurable line boring process. Line boring is widely used to machine a concentric line of bores, such as those for an engine camshaft or crankshaft. The industrial partner, Lamb Technicon Machining Systems, recently completed a prototype flexible line-boring machine, but further development is needed for its "smart tool", which is to provide compensation for tool vibration through internal laser feedback and piezoelectric actuation. A new process stability solution that addresses the real, corner-radiused tooth geometry seen in boring operations will be extended to account for the dynamic effects of the tool's guide-pads, the actuator and the controller. A new cutting tooth concept will then be modeled and analyzed toward reducing the radial machining force by 50%. Model-based tooth designs will be tested to compare forces, cutting power and tool wear to those measured using conventional corner-radiused tools.If successful, the extended stability solution will help avoid instability that can damage the expensive smart tool. Having a science-based tool like this is particularly important here due to the added complexity of the system. If the radial force can then be reduced through the new cutting tooth concept, either the requirements on actuator size and power will be reduced or increased actuator motion will be achieved. This will facilitate smaller boring bars and less demand on the actuator power-induction system that must operate across a rotating interface. Perhaps the most important outcome of this collaboration will be the bilateral impact on the research programs of both Lamb Technicon and the investigator. The investigator will bring specific expertise to the smart tool problem while learning more about the industry's true needs and their day-to-day challenges