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Seminar on Industrial Problems
Modeling and Simulation of Some High-Speed Manufacturing Processes
May 1, 1998

Presented by: T.J. Burns, NIST

  • Abstract:
    The most basic manufacturing processes involve the mechanical working of a material, resulting in a permanent alteration of its shape to produce a finished component. These plastic deformation processes can be classified according to the order of magnitude of the rate of deformation, or strain rate, at which they are performed. Processes such as rolling, forming, and drawing are characterized by relatively low strain rates that do not exceed about 103s-1. On the other hand, operations such as stamping, punching, and machining can involve strain rates as high as 107s-1. Annual expenditures on high-strain-rate manufacturing operations in the United States exceed 3% of the GDP.

    Trial-and-error prototyping is the current method used by industry to select process parameters. This method is expensive, and it often leads to sub-optimal parameter choices. For these reasons, and because of increasing international competition, U.S. industries are beginning to investigate more sophisticated approaches to the design and optimization of manufacturing processes. A necessary step towards improved process control is the development of better models of these operations. While considerable progress has been made in the development of predictive models for low-strain-rate processes, there is currently a need for improved predictive capabilities for high-rate processes.

    In this talk, a survey will be given of some work in progress at NIST on the application of nonlinear dynamics to the modeling and simulation of two high-speed machining operations that are currently of considerable interest in industrial applications: high-speed turning and milling of metals. Unlike more conventional machining operations, which can be considered to be quasi-static, these more modern manufacturing processes are dynamic, and there are significant nonlinear effects which lead to complicated process dynamics.

  • Slide Presentation:
    Modeling and Simulation of Some High-Speed Manufacturing Processes (in PDF format; 13.8M)
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