SBIR Phase I: Analytical Modeling and Performance Prediction of Remanufactured Gearbox Components

这个小企业创新研究第一阶段项目将开发分析疲劳模型，应用于NSF SBIR第一阶段招标11-577(主题NM？纳米技术，先进材料和制造，子主题m3建模和仿真)。开发该技术的第一步涉及通过模拟磨损齿轮来展示基本模型能力，使用各向同性超精加工（ISF）工艺进行再制造，如本提案所述。该模型将基于ISF工艺对磨损齿轮的适用性、ISF对齿轮特性（材料微观结构、微观几何、残余应力、表面粗糙度）的影响以及随后对抗损伤性的影响的基础研究。该模型将用于预测再制造部件的疲劳寿命，从而量化这种加工的效益，并证明这种工具的可行性。研究结果将为扩展Sentient？S仿真技术，将各种其他再制造过程纳入更全面的设计和分析框架，能够优化剩余操作，延长高附加值部件的使用寿命。这项提议的发展对依赖高度工程化（因而昂贵）齿轮箱的可靠功能的行业产生了直接影响。航空航天、能源和交通运输。组件必须在极端环境中运行，这通常会导致过早拆卸或大修。尽管磨损或损坏，这些组件仍然有能力发挥作用，只要部署适当的再制造过程。这样做可以减少生产替换部件所需的大量资源（材料、能源、人力）。此外，有人认为某些再制造工艺的应用实际上可以提高某些部件的耐用性。不幸的是，目前的设计和分析方法需要大量的测试和评估，以验证已在现场使用的组件的有效性和安全性，然后在原始OEM规范之外进行加工。要测试所有可能的组件组合，以及通过各种加工方法修复的不同程度的潜在损坏，将是一项不可能的昂贵和耗时的壮举，因此禁止在整个行业广泛部署再制造过程。然而，正如本文所建议的那样，这样的评估和验证可以通过建模和仿真来实现。由此产生的技术进步将为安全回收齿轮箱部件的使用寿命提供直接价值。

This Small Business Innovation Research Phase I project shall develop analytical fatigue models as applied to the performance analysis of remanufactured gearbox coponents under NSF SBIR Phase I Solicitation 11-577 (Topic NM?Nanotechnology, Advanced Materials, and Manufacturing, Subtopic M3-Modeling and Simulation). The first step in developing this technology involves demonstrating basic model capability through the simulation of a worn gear, remanufactured using an isotropic superfinish (ISF) process, as described in this proposal. This model will be based on the fundamental research of the applicability of the ISF process to worn gears, the effects of ISF on gear characteristics (material mictrostructure, microgeometry, residual stress, surface roughness), and the subsequent effect on damage resistance. The model will be used to predict the fatigue life of the remanufactured component, thus quantifying the benefits of such processing and demonstrating the feasibility of such a tool. The results will lay the groundwork for expanding Sentient?s simulation technology to include various other remanufacturing processes in a more comprehensive design and analysis framework capable of optimizing reman operations to extend the useful life of high value added components.The proposed development has immediate impact on industries that rely on the reliable function of highly engineered (and thus expensive) gearboxes ? aerospace, energy, and transportation. Components must operate in extreme environments, often leading to premature removal or overhaul. Though worn or damaged, these components still have the ability to function given the appropriate remanufacturing processes are deployed. Doing so reduces a significant amount of resources (materials, energy, manpower) otherwise required to produce a replacement part. Furthermore, it is thought that the application of certain remanufacturing processes can actually enhance durability of certain components. Unfortunately, current design and analysis approaches require extensive testing and evaluation to validate the effectiveness and safety of a component that has been used in the field then processed outside of original OEM specification. To test all possible combination of component coupled with various levels of potential damage repaired through various options of processing would be an impossibly expensive and time consuming feat, thus prohibiting a broad deployment of remanufacturing processes across industry. However, as postulated in this proposed effort, such evaluation and validation can occur through modeling and simulation. The resulting advancement in technology will provide immediate value in safely reclaiming useful life of gearbox components.