Collaborative Research: Fundamental Research on Titanium Drilling with Rotary Ultrasonic Machining

该合作研究奖支持对钛及其合金的旋转超声加工的基础研究，以便为国家航空航天工业开发创新且具有成本效益的钛钻孔工艺。具体而言，本研究将建立基于物理的钛合金旋转超声加工切削力预测模型，并进行实验验证，验证钛合金旋转超声加工中冷却液流向是表面粗糙度决定因素的假设，评估钛合金旋转超声加工中使用冷空气作为冷却液替代切削液的可行性，建立主导工具磨损机制和加工条件之间的关系，测量切削温度，并量化旋转超声加工和扭转钻孔对加工钛零件造成的损伤。研究结果将提供知识和理解，以满足国家航空航天工业开发更具成本效益的钛钻孔工艺的关键需求。一个具有全球竞争力的航空航天工业将有助于国家的经济，更好的质量和更低的制造成本的飞机将有利于消费者和社会。 研究成果也将使钛广泛应用的其他行业受益。通过用冷空气代替切削液作为冷却剂，这项研究将对环境产生积极的影响。这个合作研究项目的特点是堪萨斯州立大学，马萨诸塞州洛厄尔大学，阿贡国家实验室和工业界之间的独特合作。这种合作为项目资源提供了良好的协同作用，确保了研究与工业的相关性，并加快了技术商业化。它还将对两所大学的工程教育产生积极影响，促进工业从业者的终身学习，并扩大代表性不足的群体对研究的参与。

This collaborative research award supports fundamental research on rotary ultrasonic machining of titanium and its alloys in order to develop an innovative and cost-effective titanium drilling process for the nation's aerospace industry. Specifically, the research will develop a physics-based predictive model for cutting forces in drilling titanium with rotary ultrasonic machining and conduct experiments to verify the model, test the hypothesis that coolant-flow direction is the determining factor for surface roughness in titanium rotary ultrasonic machining, evaluate the feasibility of using cold air as a coolant to replace cutting fluids in titanium rotary ultrasonic machining, establish the relationship between the dominating tool-wear mechanism and machining conditions, measure the cutting temperatures, and quantify the damage to machined titanium parts caused by rotary ultrasonic machining and twist drilling. Research results will provide knowledge and understanding to meet the critical need to develop more cost-effective titanium drilling processes for the nation's aerospace industry. A globally competitive aerospace industry will contribute to the nation's economy, and airplanes with better quality and lower manufacturing cost will benefit consumers and the society. Research results will also benefit other industries where titanium is widely used. By replacing cutting fluids with cold air as a coolant, the research will have a positive impact on the environment. This collaborative research project features a unique collaboration among Kansas State University, University of Massachusetts Lowell, Argonne National Laboratory, and industry. This collaboration provides excellent synergy for project resources, ensures the relevance of the research to industry, and expedites technology commercialization. It will also positively impact engineering education at two universities, promote lifelong learning for industrial practitioners, and broaden participation of underrepresented groups in research.