GOALI: Mechanics and Dynamics of Machining with Applied Chip Tension

该学术联络与工业（GOALI）奖的资助机会支持在加工过程中使用控制摩擦的方法来增强材料剪切机制的基础研究。金属切削中的切屑作为副产品处理，通常作为废料处理。然而，这种新方法试图通过施加张力来使用切屑，从而减少和消除加工中的摩擦力。通过减弱摩擦力，这种新的车削工艺在拉屑的辅助下可以以更低的切削力和能量实现材料去除;提供更大的稳定性裕度，更长的刀具寿命，并促进高产量节能精密制造。一个潜在的机制，抑制切屑堵塞与定制的切削刀具的几何形状也可能与新的方法。与美国航空航天工业的合作伙伴合作将有助于确保技术转让。研究的重点是探讨切削过程中切屑上施加的张力对切削力学和动力学的影响。切屑的有效利用需要对其流动进行稳健的控制。微织构刀具将被设计用于控制和导航切屑流以实现张力的施加。将开发分析模型，以了解微槽刀具几何形状之间的联系，以切屑流动力学和切屑流动的可控性。将研究施加张力对切屑的影响。施加在切屑上的张力消除了前刀面上的摩擦力，减少了切削力，同时改善了切削力学。将进行分析模型和实验表征，以了解拉切屑对合成切削力，切削能量，它们之间的动态关系，和限制的影响。基于这种理解，切屑张力将被引入作为一个创新的过程控制参数，以改善静态和动态特性的加工过程。通过切屑张力和力控制使总切削力最小化，可实现加工精度高的零件，并降低形状误差。通过调节切屑张力和工艺参数，可以获得更大的颤振稳定裕度，从而缩短加工周期并提高材料去除率。

This Grant Opportunity for Academic Liaison with Industry (GOALI) award supports fundamental research on enhancement of material shearing mechanisms in machining processes, using an approach that also controls friction. The chip in metal cutting is treated as a by-product, typically as waste. However, this new approach attempts to use the chip by applying tension and thereby reduce and cancel friction forces in machining. By attenuating friction forces, this new turning process assisted by chip-pulling can enable material removal with much lower cutting effort and energy; provide greater stability margins, longer tool-life, and facilitate high-throughput energy efficient precision manufacturing. A potential mechanism of suppressing the chip-jam with tailored cutting tool geometries is also likely with the new approach. Collaboration with a partner from US aerospace industry will help ensure the technology transfer. The research focus is to investigate how tension applied on the cut chip during machining processes affects cutting mechanics and dynamics. Effective use of the cut chip requires robust control of its flow. Micro-textured tools will be designed to control and navigate the chip flow to realize application of tension. Analytical models will be developed to understand the link between micro-grooved tool geometry to the chip flow mechanics and chip flow controllability. The effect of applying tension on the cut chip will be investigated. Tension applied to the chip cancels the friction force on the rake face and reduces the cutting effort while improving cutting mechanics. Analytical models and experimental characterization will be performed to understand the effect of pulling the chip on resultant cutting forces, cutting energy, the dynamic relation amongst them, and the limitations. Based on this understanding, chip tension will be introduced as an innovative process control parameter to improve static and dynamic characteristics of the machining process. Machining of precision parts can be realized with lower form errors by minimizing overall cutting forces through chip tension and force control. Reduced machining cycle times and increased material removal rates can be achieved through greater chatter stability margins that can be attained by modulating the chip tension jointly with process parameters.