Tool Temperature Measurement during Diamond Turning of Steel

该奖项的研究目标是在切削深度小于10微米的精密加工过程中测量刀具/工件界面的温度，精度为5摄氏度。为了进行这种测量，将在已经具有三维力传感器的精密车床上添加许多重要的传感器。将增加视觉和红外显微镜系统，以便在小切割深度处观察芯片中的物质流动。这些将提供与芯片/工具接口相关的温度分布的整体视图。此外，还将制作一种独特的椭圆形导光金刚石工具，将刀尖的红外辐射聚焦到光谱仪中，提高峰值刀具温度测量的灵敏度。将采用一种独特的磨损测量技术来比较刀具磨损随材料、切削深度、温度和切削距离的变化。保持刀具刃口锋利和避免随时间退化是加工钢铁等材料的关键因素，因为温度是化学磨损的主要原因。加工过程的模型可用于计算刀具温度，但需要测量来证实这些结果。如果成功，这项研究的好处和影响将提高精密制造工艺的知识和科学家和工程师的教育。提出的温度测量需要1)证实加工过程的模型，2)预测加工重要结构材料（如钢）时的刀具磨损。光学和精密机械系统在美国现代生活中发挥着无处不在的作用，需要纳米级制造工艺才能产生所需的性能。迫切需要改进这些制造工艺，使新工艺可视化，并教育下一代学生创造这些工艺。技术成果将发表在工程杂志上，并纳入大学课程。研究生和本科生将在机器设计、控制、材料响应、动态系统和精密制造等关键领域发展专业知识。

The research objective of this award is to measure the temperature at the tool/workpiece interface during precision machining for depths of cut less than 10 micrometers to an accuracy of 5 degrees Celsius. To make this measurement, a number of important sensors will be added to a precision lathe that already has 3-dimensional force sensors. Visual and infrared microscope systems will be added to view the material flow in the chip at small depths of cut. These will provide an overall view of the temperature distribution in relation to the chip/tool interface. In addition, a unique elliptically shaped, light-guiding diamond tool will be fabricated to focus the infrared radiation from the tool tip into a spectrometer and improve the sensitivity of the peak tool temperature measurement. A unique wear measurement technique will be used to compare the tool wear with changes in material, depth of cut, temperature and cutting distance. Keeping the tool edge sharp and avoiding degradation with time are key factors in machining materials like steel where chemical wear due to temperature dominates. Models of the machining process are available to calculate tool temperature, but measurements are needed to corroborate these results. If successful, the benefits and impact of this research will be improved knowledge of precision manufacturing processes and education of scientists and engineers. The proposed temperature measurement is needed to 1) corroborate models of the machining process and 2) predict tool wear when machining important structural materials like steel. Optical and precision mechanical systems play a pervasive role in modern life in the US and require nanometer-scale fabrication processes to yield the required performance. There is a critical need to improve these manufacturing processes, to visualize new processes and to educate the next generation of students needed to create them. The technical results will be published in engineering journals and integrated into university courses. The graduate and undergraduate students involved will develop expertise in key areas like machine design, control, materials response, dynamic systems and precision manufacturing.