CAREER: Measurement and Predictive Dynamics of Meso-scale Milling

摘要当前用于预测铣削过程动态行为的方法是有限的，因为它们不能提供组合的稳定性和准确性信息。因此，加工参数的选择通常基于有限的信息或经验。其结果是刀具振动产生了不必要的零件误差。这些误差是生产精密部件(例如薄壁结构和微型部件)时的限制因素。刀具振动对工业能力造成了严重限制：1)精度降低；2)表面光洁度差；3)成本增加，这与不稳定有关。尽管研究针对的是传统尺寸工具的这些局限性，但在微型水平上的动力学差异和作用实际上仍然没有被研究过。这项研究旨在开发传统到微型铣削动力学的分析和传感方法；这些开发将使智能机床能够考虑振动的影响。动态系统分析和建模工作为将控制策略集成到智能机器中提供了关键的第一步。这项研究旨在提高传统加工应用到微型加工应用的工业能力，开发监测转轴运动的新能力，并在微型零部件生产(如小型医疗设备和MEMS)方面提供进展。外展和招聘工作集中在K-12学生和本科生，特别是来自传统上代表性较低的群体的学生，通过：1)开发一个“那么你想成为一名工程师？”外展计划，有一个亲身实践的儿童学习博物馆；2)现有的两个UF外展项目。此外，这项研究开发了工具，为未来的研究加强基础设施，并寻求使微型加工动力学的工业应用成为可能。

AbstractCurrent methods for predicting the dynamic behavior of the milling process are limited because they do not provide combined stability and accuracy information. Therefore, the selection of machining parameters is commonly based upon limited information or experience. The result is unnecessary part errors that are created from tool vibrations. These errors are a limiting factor when producing precision components (e.g. thin wall structures and miniature components). Tool vibrations impose severe limitations on industrial capability: 1) reduced accuracy; 2) a poor surface finish; and 3) increased costs which are linked to instability. Although research studies target these limitations for conventional size tools, the differences and role of dynamics at miniature levels has remained virtually unstudied. This research seeks to develop analysis and sensing methods for conventional to miniature milling dynamics; these developments will enable Smart Machine Tools that account for the effects of vibration. Dynamical system analysis and modeling efforts provide the crucial first steps for integrating control strategies into smart machines.This research seeks to advance industrial capability for conventional to miniature machining applications, develop new capabilities for monitoring rotating shaft motions, and provide advances in miniature part production (e.g. small medical devices and MEMS). Outreach and recruiting efforts focus on K-12 students and undergraduate students, particularly from traditionally underrepresented groups, through: 1) developing a "So you want to be an engineer?" outreach program with a hands-on children's learning museum; 2) two existing UF outreach programs. Furthermore, this research develops tools that enhance the infrastructure for future research and seeks to enable the industrial application of miniature machining dynamics.