AIR: Large-Scale Manufacturing of Metal Fibers by Modulation-Assisted Machining

该AIR项目将为金属纤维的大批量生产带来一种新的基于加工的工艺，即调制辅助加工（MAM）。通过将低频调制叠加到锋利的工具上，通过在单级变形过程中切割来产生具有高度均匀尺寸和形状的单个纤维。将在拟议的工作中解决的关键研究目标是：1）生产率的可扩展性，用于创建纤维，2）在商业生产率下的纤维尺寸和形状的可重复性;和3）和生命周期分析相关的调制设备在典型的生产率。与传统的多步拉伸工艺相比，MAM平台具有独特的能力，能够以高生产率生产尺寸可控的金属纤维。将展示大规模生产纤维材料的原型方法，同时改变各业务部门的加工技术，并为先进材料的加工生产开辟新的应用领域。MAM美安萌提供了一种低成本的生产路线和工艺突破，用于生产使用现有技术难以生产的纤维。MAM美安萌独特的颗粒几何形状和结构将为纤维基产品和复合材料系统的生产带来新的商业机会。作为对这项研究的补充，还有一项教育和培训计划，涉及研究生和本科生的公司实习。合作研究将使学生接触到先进的材料加工和相关的商业化，以及最近的制造业初创公司的动态环境

This AIR project will bring to commercial prototype stage a new machining-based process, Modulation-Assisted Machining (MAM), for large-volume production of metal fibers. By super imposing low-frequency modulation onto a sharp tool, individual fibers having highly uniform size and shape are created by cutting in a single-stage deformation process. The key research objectives that will be addressed in the proposed work are: 1) scalability of the production rate for creating fibers, 2) repeatability of fiber size and shape under commercial production rates; and 3) and life-cycle analysis related to the modulation device at rates typical of production. The MAM platform offers a unique ability to produce metal fibers with controlled size at high production rates compared to traditional multi-step drawing processes. A prototype method for large-scale production of fiber materials will be demonstrated, while transforming machining technology across business sectors and opening a new applications domain for machining production of advanced materials. MAM offers a low cost production route and a process breakthrough for producing fibers that are difficult to create using current technology. The unique particle geometries and structure created by MAM will enable new commercial opportunities for production of fiber-based products, and composite material systems. Complementing the research is an education and training program involving company internships for graduate and undergraduate students. The collaborative research will expose the students to advanced materials processing and related commercialization, and the dynamic environment of a recent manufacturing start-up company