CAREER: A Fundamental Study on Hard Turning - Prediction and Synthesis of Surface Integrity and Component Life

这项教师早期职业发展(Career)计划奖支持关于难加工的基础研究。该职业奖的研究目标是通过硬车削来预测和综合表面完整性和部件寿命。具体的研究方法是：(A)建立和验证硬态车削的细观/微观有限元分析模型，通过对动态力学行为的精确建模，结合加载历史效应、材料损伤和被加工材料的微观组织效应，预测表面完整性；(B)利用新颖的实验和模拟方法，识别滚动接触中残余应力分布和白层对疲劳寿命的单独和复合影响。教育目标是将研究成果整合到制造工程的学术学科和职业道路上的教育活动中。具体的方法包括课程开发和协作学习；一个艰难的学院；接触当地历史上的黑人学院和大学、高中生和专业协会；与工业从业者、领先的学术团体和国家实验室合作；以及各种评估工具和广泛的传播。如果成功，这一职业计划将使机械加工行业能够以高效率、灵活性和低成本制造高质量的轴承、齿轮、凸轮、轴、小齿轮、模具、工具和其他零件，同时减少对环境的影响。这将使用于滚动接触的机械加工部件具有更低的价格和更好的疲劳性能，从而造福于经济和社会。所建立的硬车削范例可以作为其他制造工艺的范例。这些研究成果将大大提高阿拉巴马大学Hard Turning财团的研究和制造能力，通过高影响力的研究和创造训练有素的制造业劳动力来刺激阿拉巴马州的经济增长。教育举措还将促进学生的学习过程和持续教育；扩大代表不足的学生对研究的参与；并将新的研究成果传递给更广泛的受众。

This Faculty Early Career Development (CAREER) Program award supports fundamental research on hard turning. The research objective of this CAREER award is to predict and synthesize surface integrity and component life by hard turning. The specific research approaches are: (a) create and verify meso/micro-scale finite element analysis models of hard turning to predict surface integrity through accurate modeling of dynamic mechanical behavior with loading history effects, materials damage, and microstructure effects of work materials and (b) identify the individual and compound effects of residual stress profile and white layer on fatigue life in rolling contact using novel experimental and simulation approaches. The education objective is to integrate the research results into education activities across academic disciplines and career paths in manufacturing engineering. The specific approach includes curriculum development and collaborative learning; a hard turning academy; outreach to local historically black colleges and universities, high schoolers, and professional societies; collaborations with industrial practitioners, leading academic groups, and national labs; and various assessment tools and broad dissemination.If successful, this CAREER plan will enable machining industry to make high quality bearings, gears, cams, shafts, pinions, dies, molds, tools, and other parts at high efficiency, flexibility and low cost, while lessening the environmental impact. This will result in cheaper and superior fatigue performance of machined components used in rolling contact, thereby benefiting the economy and society. The established hard turning paradigm can be an example for other manufacturing processes. The research accomplishments will significantly advance research and manufacturing capabilities of the hard turning consortium at The University of Alabama to stimulate economic growth in Alabama through high-impact research and creating well-trained manufacturing workforce. The educational initiatives will also facilitate students' learning processes and continuing education; broaden participation of underrepresented students in research; and transfer new research findings to a broad audience.