GOALI/Collaborative Research: Deformation Machining - A New Hybrid Process

该学术与工业联络合作项目（GOALI）的研究目标是(1)对新提出的变形加工过程提供基本的理论和实验理解，(2)建立有效的数值建模和仿真方法，以及(3)将基本理解和建模与工艺规划，零件可重复性，零件精度，加工和加工过程中的策略相结合。以及设计指南。模拟的方法将是一种自适应有限元方法，这将大大减少计算时间，从而允许研究各种工艺组合和序列。特别强调将通过实验和模拟确定残余应力和疲劳寿命。数值和实验分析将用于研究材料变形行为，预测疲劳寿命，并设计可行的操作顺序，以实现工艺的重复性和准确性。如果成功，这项研究的好处和更广泛的影响将来自更高的可靠性和改进的设计自由度。这种新的制造工艺将允许使用当前制造工艺无法实现的新结构、几何形状和产品。理论认识、实验技术和新的模拟方法将提供新的见解。因此，在可制造性和产品特性方面，增强的产品能力以及新的灵活性和功能将成为可能。最后，在学术和教育环境中，一个新的混合过程的提议为传统上不互动的研究团体之间的合作打开了大门。该教育计划将鼓励不同背景的学生进行合作，并将为他们提供新的机会和团队成员的指导。每所大学的学生和教师、政府实验室人员和行业人员之间的密切互动将产生丰富的跨学科教育经验。

The research objectives of this Grant Opportunity for Academic Liaison with Industry (GOALI) collaborative project are (1) to provide fundamental theoretical and experimental understanding of the newly proposed deformation machining process, (2) to establish efficient numerical modeling and simulation methodologies, and (3) to integrate the fundamental understanding and modeling with pre-process and in-process strategies for process planning, part repeatability, part accuracy, and design guidelines. The approach for the simulation will be an adaptive finite element method that will significantly reduce computation time, thereby allowing the study of various process combinations and sequences. Particular emphasis will be placed determining residual stresses and fatigue life through experiments and simulation. Numerical and experimental analysis will be used to study material deformation behavior, to predict fatigue life, and to design workable operational sequencing to achieve process repeatability and accuracy.If successful, the benefits and broader impacts of this research will come from the greater reliability and improved design freedom. This new manufacturing process will permit new structures, geometries, and products that are not feasible using current manufacturing processes. The theoretical understanding, experimental techniques, and new simulation methods will provide new insights. As a result, enhanced product capability as well as new flexibility and functionality in terms of manufacturability and product features will be possible. Finally, in the academic and educational environment, the proposal of a new hybrid process opens the door for collaboration between research communities that traditionally do not interact. The education plan will encourage students with diverse backgrounds to collaborate, and it will provide them with new opportunities and mentoring from the team members. The close interaction among students and faculty from each university, government laboratory personnel, and industry personnel, will result in rich, cross-disciplinary educational experience.