H2 Manufacturing: Hybrid-Hybrid machining of next generation aerospace materials

在金属基复合材料等难加工航空航天材料的加工中，激光辅助加工/加工在降低刀具磨损方面显示出良好的应用前景。另一方面，超声辅助加工已被成功地用于证明在改善已加工表面质量的同时，切削力显著降低。该项目是一个基础研究方案，旨在综合研究这两种技术，并明确实施路线。通过向混合-混合制造工艺的过渡，英国工业将能够通过高效和可持续地利用未来航空航天材料的制造资源来满足当前和未来部门/客户日益增长的需求。研究将重点放在热场-超声波振动-机械变形对MMC材料的影响上，同时考虑到材料的初始基础微结构。由于外加热场和变形速率(由于机械加工)的影响，金属基材料的动态再结晶和晶粒长大将受到特别的关注。同时，将在现有的数控机床上设计、开发和安装激光-超声辅助加工系统，目的是在没有冷却剂的情况下进行切割，使用更少的力和加工造成的损坏。加工研究将在与工业相关的加工条件下进行。将与目前的做法进行比较，以获得最佳的加工结果。预计新的混合-混合制造将导致更小的加工力，减少刀具磨损和加工后(拉伸)残余应力。最后，将进行几个案例研究，目的是开发下一代工具，以实现最优制造。

The application of laser assisted machining/processing has shown promise in reducing tool wear in the machining of difficult-to-machine aerospace materials, such as, metal matrix composites (MMCs). On the other hand, ultrasonically assisted machining has been successfully used to demonstrate essential reductions in cutting forces with an improvement of machined surface quality. This project is a fundamental research programme that aims to comprehensively study the two techniques in combination with a clear route to implementation. Through the transition to hybrid-hybrid manufacturing processes such as the one proposed, UK industries will be able to meet the growing needs of present and future sectors/customers by efficient and sustainable resource usage in the manufacture of future aerospace materials.The research will focus on the influence of the thermal field-ultrasonic vibrations-mechanical deformation on the MMC material taking into consideration the initial underlying micro-structure of the material. Special attention will be paid to dynamic recrystallization and grain growth of the metallic matrix material due to the influence of the imposed thermal field and deformation-rates (due to machining). In parallel, a laser-ultrasonically assisted machining system will be designed, developed and installed on an existing CNC machine, with the aim of cutting without coolants, using less force and machining-induced damage. Machining studies will be conducted at industrially relevant machining conditions. Comparisons will be drawn with current practice forbest machining outcomes. It is expected that the new hybrid-hybrid manufacture will lead to less machining forces with reduced tool wear and post machining (tensile) residual stresses.Finally, several case studies will be conducted with the aim of developing next generation tools for optimal manufacture.