Manufacturing Processes for Advanced Materials

提案摘要 拟议的研究涉及汽车和航空航天工业感兴趣的轻质材料的高性能切割。 提出了一个综合研究计划，涉及两种类型的轻质材料如下; 1)研究先进复合材料如碳纤维增强复合材料的高性能加工.初步的实验结果表明，碳纤维拔出，颗粒断裂，分层和脱粘在纤维或颗粒基体界面有显着的影响，刀具失效。有一个显着的需要，以开发强大的建模方法，可用于优化切割过程。考虑材料特性、刀具几何形状和切削条件，将开发有限元模型来模拟加工过程。 一个全面的实验计划将验证这些模型，并评估各种先进的刀具材料和几何形状的性能。实验工作将进行研究高性能的冷却策略，包括最小量润滑（MQL）。将开发可加工性图，以调查切削速度和进给量的影响。 2)压实石墨铁（CGI）的可加工性，重点是发展微观结构对汽车工业应用过程变量的影响的基本科学理解。由申请人及其团队先前开发的有限元模型将被推广以包括各种切削刀具材料和几何形状、由于磨损引起的刀具材料退化以及材料中的微小夹杂物对切削性能的影响。特别是，将开发和研究处理CGI相对较差的可加工性的方法。CGI的可加工性相比，灰铸铁的差异也将被考虑，以调查材料的机械和物理性能的影响，由石墨的形状，尺寸和生长机制在其微观结构。 一个广泛的实验方案将进行验证上述开发的通用模型。这些实验将被设计来研究在各种切削条件下的切屑形成、切削力和刀具磨损。 这两种材料（CFRP和CGI）被选为轻型材料的例子，这些材料在汽车和航空航天工业中的应用越来越广泛。作为本研究的结果开发的方法可用于工艺优化，保持零件的完整性和减少亚表面损伤。 这里提出的研究对于处理这些行业中提高生产率，提高燃料效率和环境影响的一些最重要的要求至关重要。

Summary of Proposal The proposed research deals with high performance cutting of light-weight materials that are of major interest to the automotive and aerospace industries. An integrated research program is proposed that deals with two types of light-weight materials as follows; 1) High performance machining for advanced composite materials such as Carbon- Fiber Reinforced Polymers will be investigated. Preliminary experimental results have shown that carbon fiber pull-out, particle fracture, delamination and debonding at the fiber or particle matrix interface have significant influence on tool failure. There is a significant need to develop robust modeling approaches which can be used to optimize the cutting process. Finite element models will be developed to simulate the machining processes considering material characteristics, tool geometry, and cutting conditions. A comprehensive experimental program will validate these models and evaluate the performance of various advanced tool materials and geometries. Experimental work will be performed to study high performance cooling strategies including minimum quantity lubrication (MQL). Machinability maps will be developed to investigate the effect of cutting speeds and feeds. 2) Machinability of Compacted Graphite Iron (CGI) focusing on the development of a fundamental scientific understanding of the effect of the microstructure on process variables for applications in the automotive industry. The finite element model previously developed by the applicant and his team, will be generalized to include various cutting tool materials and geometries, tool material degeneration due to wear as well as the effect of minor inclusions in the material on cutting performance. In particular, approaches to deal with the relatively poor machinability of CGI will be developed and investigated. The differences in the machinability of CGI compared to gray cast iron will also be considered in order to investigate the influence of material mechanical and physical properties, dictated by the shape, size, and growth mechanism of graphite in their microstructures. A wide-ranging experimental program will be performed to validate the generalized model developed above. These experiments will be designed to study chip formation, cutting forces and tool wear under various cutting conditions. These two materials (CFRP and CGI) were selected as examples of light-weight materials which are gaining prominence and cover a wide range of applications in both the automotive and aerospace industries. The methodologies developed as a result of this research can be used for process optimization, preserving part integrity and reducing sub-surface damage. The research proposed here is essential for dealing with some of the most important requirements for increasing productivity, improving fuel efficiency and environmental impact in these industries.