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

该合作研究奖支持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一种创新且具有成本效益的钛钻孔工艺。具体而言，研究将建立基于物理的旋转超声钻钛切削力预测模型并进行实验验证，验证冷却剂流动方向是钛旋转超声加工中表面粗糙度决定因素的假设，评估用冷空气作为冷却剂替代钛旋转超声加工中切削液的可行性。建立主要刀具磨损机理与加工条件之间的关系，测量切削温度，量化旋转超声加工和麻花钻削对已加工钛零件的损伤。研究结果将提供知识和理解，以满足为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。具有全球竞争力的航空航天业将为国家经济做出贡献，质量更好、制造成本更低的飞机将使消费者和社会受益。研究结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，该研究将对环境产生积极影响。这个合作研究项目是堪萨斯州立大学、马萨诸塞大学洛厄尔分校、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，并扩大未被充分代表的群体在研究中的参与。

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.