GOALI/Collaborative Research: Electrically-Enhanced Precision MicroRolling

GOALI学术合作机会奖的研究目标是通过仪表式台式轧钢机将高密度电流与机械变形相结合，显著提高薄板金属的成形性和微米级成形特征的尺寸精度。为了实现这些目标，将解决两个基本问题：(1)电流如何影响变形金属的塑性和残余应力；(2)如何实现有效的微轧制过程控制的过程中测量。计划的研究任务是：(1)机械和电气加载下材料行为的实验表征和本构模型；(2)微轧制过程和磨机结构中机械应力、热场和电磁场的多物理建模；(3)用于过程表征的过程传感和数据映射；以及(4)系统集成。如果成功，新的混合工艺将降低工艺设计的复杂性，减少能源消耗，并减少化学废物，以获得所需的表面光洁度的薄金属箔。新的传感方法和仪器设计将在尺寸、精度、成本和能源效率方面突破目前轧制过程的极限。金属箔的众多用途之一是用于下一代生物植入物的微电极和触点，例如用于治疗心脏疾病的起搏器，用于潜在治疗帕金森？S病、抑郁症、肌张力障碍或慢性疼痛的脑深部模拟电极，以及用于监测和开发调节1型糖尿病的新疗法的人工胰腺。通过微缩技术实现的设备微型化将使患者受益，提高他们的生活质量。学术机构和产业界之间的合作将激发美国制造业公司保持竞争力所需的创新和人才。该项目将通过研究机会、课堂项目、短期课程和实习为研究生、本科生和实践者提供培训。

The research objective of this Grant Opportunity for Academic Liaison with Industry (GOALI) award is to significantly enhance the formability of thin sheet metals and the dimensional accuracy of formed features at the micrometer scale by integrating high-density electrical current with mechanical deformation through an instrumented desktop rolling mill. Two fundamental questions will be addressed in achieving the objectives: (1) how electrical current affects the plasticity and residual stress of metals subjected to deformation; and (2) how to realize in-process measurement for effective microrolling process control. The planned research tasks are: (1) Experimental characterization and constitutive modeling of material behavior subjected to mechanical and electrical loading; (2) Multi-physics modeling of mechanical stress, thermal and electro-magnetic fields in the microrolling process and mill structure; (3) In process sensing and data mapping for process characterization; and (4) System integration. If successful, the new hybrid process will reduce process design complexity, reduce energy consumption, and reduce chemical wastes in achieving thin metal foils with desired surface finish. The new sensing methods and instrument design will push the current limits of the rolling process in terms of size, precision, cost, and energy efficiency. One of the many uses of the metal foil is micro-electrodes and contacts for the next generation of bio-implants, such as pacemakers for treating heart disorders, deep brain simulation electrodes for potentially treating Parkinson?s disease, depression, dystonia or chronic pain, and artificial pancreas for monitoring and developing new therapeutics that regulate Type 1 Diabetes. Device miniaturization enabled by microrolling will benefit patients by improving their quality of life. The collaboration between academic institutions and industry will inspire the innovations and talents needed for U.S. manufacturing companies to remain competitive. The project will provide training to graduate and undergraduate students and practitioners through research opportunities, class projects, short courses, and internships.