Tool Temperature Measurement during Diamond Turning of Steel

该奖项的研究目标是在切割深度小于10微米、精度为5摄氏度的精密加工过程中测量刀具/工件界面的温度。为了进行这一测量，一些重要的传感器将被添加到已经有三维力传感器的精密车床上。将增加视觉和红外显微镜系统，以观察小切割深度下芯片中的材料流动。这些将提供与芯片/工具界面相关的温度分布的整体视图。此外，还将制造一种独特的椭圆形导光钻石工具，将来自工具尖端的红外辐射聚焦到光谱仪中，并提高峰值工具温度测量的灵敏度。一种独特的磨损测量技术将被用来比较刀具磨损与材料、切割深度、温度和切割距离的变化。在像钢这样的材料加工中，保持刀具刃的锋利并避免随着时间的推移而退化是关键因素，因为在这些材料中，温度导致的化学磨损占主导地位。加工过程的模型可以用来计算刀具温度，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是提高对精密制造工艺的知识以及对科学家和工程师的教育。所提出的温度测量对于1)证实加工过程的模型和2)在加工重要结构材料(如钢)时预测刀具磨损是必要的。光学和精密机械系统在美国的现代生活中扮演着普遍的角色，需要纳米级的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，并教育需要创造这些工艺的下一代学生。技术成果将发表在工程期刊上，并整合到大学课程中。参与的研究生和本科生将发展关键领域的专业知识，如机械设计、控制、材料响应、动力系统和精密制造。

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.