3D Laser Forming of Doubly Curved Shapes: Process Prediction and Synthesis

许多工程结构的表面设计为双曲线形状，以满足流体力学、美学或结构等功能要求。实验表明，激光成形双曲面等三维形状是可行的，但成形精度问题需要通过增强工艺预测能力来更好地理解。同样，为简单形状的激光成形(LF)开发的工艺综合方案也需要进一步改进，以用于3D LF工艺。该项目的目的是显著提高知识水平的LF技术，从理想化到更实用的形状，从分析到综合。建模和综合工作将伴随着一项实验计划，包括成形前和成形后的微观结构和机械性能表征。其他高温变形工艺将能够利用该项目将开发的改进的理解和合成能力。实际上，该项目的成功将为制造高性能但传统上难以成形的材料打开新的机会，导致创新应用，从而打开新的设计选择。可靠的工艺综合方案的开发将使该工艺能够进入工业应用，成为大批量生产的快速原型工具和低产量金属板材加工的灵活制造工具。这一结果将对经济和行业竞争力产生重大影响，因为板材加工如此普遍。这个项目的结果将被整合到研究生水平的课程中。将努力吸纳本科生，并从传统上代表人数较少的背景中寻找和招收合格的学生。

Surfaces of many engineering structures are designed as doubly curved shapes to fulfill functional requirements such as hydrodynamic, aesthetic, or structural. Experiments have shown that it is feasible to laser form 3D shapes such as doubly curved shapes, but forming accuracy issues need to be better understood via enhanced process prediction capability. Similarly, the process synthesis schemes developed for laser forming (LF) of simple shapes need further advancement for 3D LF process. This project is aimed at significantly advancing the state of knowledge LF technology, from idealized to more practical shapes, and from analysis to synthesis. The modeling and synthesis efforts will be accompanied by an experimental program including pre- and post-forming microstructure and mechanical property characterizations. Other high temperature deformation processes will be able to leverage upon the improved understanding and synthesis capabilities to be developed in the project. Practically, the success of the project will open-up new opportunities for manufacturing of high performance but conventionally hard-to-form materials, leading to innovative applications, thus opening new design options. The development of reliable process synthesis schemes will enable the process make its way to industrial applications, as a rapid prototyping tool for high production volume and a flexible manufacturing tool for low production volume sheet metal working. The results will have a significant impact on the economy and industry competitiveness since sheet metal working is so pervasive. Results from this project will be integrated into a graduate level course. Efforts will be made to involve undergraduate students, and to identify and recruit qualified students from traditionally underrepresented backgrounds.