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和学习的一些技术，用于研究和教育：1）计算机数控铣床、车床和立式加工中心的虚拟建模; 2）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;如用于航空航天制造的钛合金; 3）基于网络的加工过程仿真和学习。该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，对切削力和表面粗糙度进行建模和仿真，并对加工过程进行仿真。切削参数（主轴转速，每齿进给量，轴向和径向切削深度，和拐角半径）和切削刀具的影响将进行研究。 切削力模型将考虑立铣刀圆角半径和槽数，如果研究成功，其好处和更广泛的影响将是：模拟和预测钛合金高速立铣刀切削力和表面光洁度的机理模型;虚拟制造的可靠工具，即加工过程的计算机模拟;提高了制造效率、质量和生产力;减少了制造商用和军用飞机部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;创新地使用技术来教授对三维环境感兴趣的学生;减少了物理机器的教学时间，节省了相关的成本;便携式基于网络的学习环境，使计算机数控课程校外教学的研究人员和工程师在世界各地的行业;和参与人数不足的少数民族学生。研究成果将通过期刊和会议出版物传播给工程界。

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.