Development of Virtual CNC Machine Tools and Web-Based Machining Process Simulation and Learning

该奖项的研究目标是研究虚拟制造和基于网络的加工过程仿真以及研究和教育学习的一些技术：1)计算机数控铣床、车床和立式加工中心的虚拟建模；2)航空航天制造中钛合金等难加工金属薄壁零件高速端铣切削力和表面粗糙度的机理建模；3)基于网络的加工过程仿真与学习。研究方法将基于三维仿真环境、机械模型、有限元分析、传感器数据、实验设计和实验验证的集成，以建模和模拟切削力和表面粗糙度，并模拟加工过程。将研究切削参数（主轴转速、每齿进给量、轴向和径向切削深度以及拐角半径）和刀具的影响。切削力模型将考虑立铣刀角半径和槽数。如果成功，该研究的好处和更广泛的影响将是：模拟和预测钛合金高速端铣切削力和表面光洁度的机械模型；可靠的虚拟制造工具，即计算机模拟加工过程；提高了对切削力和切削参数影响的认识；提高生产效率、质量和生产率；缩短了商用和军用飞机零件的交货时间和成本；减少了计算机数控程序员和操作员的培训时间；创新运用科技，教授学生对三维环境的兴趣；减少物理机器上的教学时间，节约相关成本；便携式网络学习环境，允许在校外向世界各地的工业研究人员和工程师教授计算机数控课程；以及少数族裔学生的参与。研究成果将通过期刊和会议出版物向工程界传播。

The research objective of this award is to investigate a number of technologies for virtual manufacturing and web-based machining process simulation and learning for research and education: 1) virtual modeling of computer numerical control mill, lathe and vertical machining center, 2) mechanistic modeling of cutting forces and surface roughness in high speed end-milling of thin-walled components of difficult-to-machine metals, such as titanium alloys used in aerospace manufacturing, 3) web-based machining process simulation and learning. The research approach will be based on integration of three-dimension simulation environment, mechanistic models, finite element analysis, sensor data, design of experiment, and experimental verification for modeling and simulating cutting forces and surface roughness, and simulation of machining processes. The effects of cutting parameters (spindle speed, feed per tooth, axial and radial depth of cut, and corner radius) and cutting tools will be investigated. Cutting force models will consider end-mill corner radius and number of flutes.If successful, the benefits and broader impacts of the research will be: mechanistic models for simulating and predicting cutting forces and surface finish in high speed end-milling of titanium alloys; reliable tool for virtual manufacturing , that is, computer simulation of machining processes; improved knowledge of cutting forces and the effect of cutting parameters; increased manufacturing efficiency, quality and productivity; reduced lead-time and cost of making both commercial and military aircraft parts; reduced training time for computer numerical control programmers and operators; innovative use of technology to teach students with interest in 3-dimensional environment; reduced teaching time on physical machines with associated cost savings; portable web-based learning environment that allows teaching computer numerical control course off campus to researchers and engineers in industry worldwide; and involvement of underrepresented minority students. The research results will be disseminated to the engineering community through journal and conference publications.