Manufacturing Processes for Advanced Materials

建议书摘要 这项拟议的研究涉及对汽车和航空航天行业主要感兴趣的轻质材料的高性能切割。 提出了一项综合研究计划，涉及以下两种类型的轻质材料； 1)研究碳纤维增强聚合物等先进复合材料的高性能加工。初步实验结果表明，碳纤维拔出、颗粒断裂、纤维或颗粒界面的剥离和剥离对刀具失效有重要影响。迫切需要开发健壮的建模方法，以用于优化切割过程。考虑材料特性、刀具几何形状和切削条件，建立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，并评估各种先进工具材料和几何形状的性能。将进行实验工作，以研究包括最小数量润滑(MQL)在内的高性能冷却策略。将开发可加工性地图，以调查切割速度和进给量的影响。 2)压实石墨铸铁(CGI)的可加工性，重点是对汽车工业中应用的微观组织对工艺变量的影响进行基础科学的理解。申请人和他的团队之前开发的有限元模型将被推广到包括各种刀具材料和几何形状、刀具材料因磨损而退化以及材料中的微小夹杂物对切割性能的影响。特别是，将开发和研究处理CGI相对较差的加工性的方法。还将考虑CGI与灰口铸铁在可加工性方面的差异，以研究由石墨的形状、尺寸和微观结构中的生长机制决定的材料机械和物理性能的影响。 将执行一个广泛的实验程序来验证上面开发的通用模型。这些实验旨在研究不同切割条件下的切屑形成、切削力和刀具磨损。 这两种材料(CFRP和CGI)被选为轻质材料的范例，它们在汽车和航空航天工业中得到了广泛的应用。这项研究开发的方法可用于工艺优化、保持零件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、改善燃料效率和环境影响的一些最重要的要求是必不可少的。

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.