Purdue Research Foundation

M4 Sciences LLC

James Bradley Mann

Srinivasan Chandrasekar

Walter Dale Compton

Wilfredo Moscoso

Kevin Paul Trumble

Seong Eyl Lee

Christopher Javellana Saldana

Yang Guo

M Ravi Shankar

Koushik Viswanathan

Dinakar Sagapuram

Mert Efe

W Dale Compton

Tatsuya Sugihara

Anirudh Udupa

Xiaolong Bai

Processes for producing sheet metal products by machining a solid metal body with a cutting tool in a single step to continuously produce a continuous bulk form from material obtained from the solid metal body, and without performing a hot rolling operation thereon, cold rolling the continuous bulk form to produce a sheet metal product. The machining step is a large-strain machining process capable of being directly performed on an as-cast ingot or other solid body to produce a continuous intermediate product that can be directly cold rolled without any intervening hot rolling operation, and optionally without homogenization or annealing.

Methods of sheet metal production and sheet metal products produced thereby

Methods of inducing segmented flow in a material in which a ductile flow mode would otherwise occur during machining. A monolayer molecular film is formed on a surface of a body of a material in a state such that the material exhibits ductile flow when subjected to shear. The monolayer molecular film has molecules each having a head group adsorbed to the surface, a terminal group, and a hydrocarbon chain therebetween having a chain length of greater than 6. A surface portion of the body is removed by engaging the body with a tool in a contact region below the surface of the body and moving the tool relative to the body to remove the surface portion and the monolayer molecular film thereon. The monolayer molecular film induces segmented flow in the material during the removing of the surface portion.

Methods of modifying material flow mode during machining and products formed thereby

A tool holder is provided for holding one of a tool and workpiece. The tool holder is configured for mounting to a driving member of a machining device. The tool holder includes a tool holder first end including a coupler for coupling the tool holder to the driving member of the machining device. A tool holder second end includes a clamp for releasably holding one of the tool and workpiece. A force sensor is disposed between the clamp and the coupler for sensing force exerted on the one of the tool and workpiece held by the clamp. A linear actuator is disposed between the clamp and the force sensor for linearly moving the one of the tool and workpiece.

Tool holder assembly for machining system

A modulating tool holder includes a tool holder first end and a tool holder second end, and a central axis extending between the tool holder first end and the tool holder second end. The tool holder first end has a coupler for coupling the tool holder to a drive member of a machining device and the second end includes a clamp for releasably holding either a tool or a workpiece. A rotatable spindle member extends axially in the tool holder and imparts a rotational movement to the clamp. A central fluid passageway extends between first and second ends of the rotatable spindle member for conveying a fluid. A linear actuator is configured to impart an oscillating movement to the clamp. The linear actuator is functionally decoupled from the torsional load of the rotatable spindle member.

Machining system spindle for modulation-assisted machining

Assemblies, apparatus, and methods are described for designing modulation tool holder assemblies and installations for modulation-assisted machining, and, in particular, for rotating machining applications that benefit from the sinusoidal modulation motion while cutting fluids are simultaneously applied through the tool. In addition, the design of rotating modulation tool holder assemblies and systems is described. In a tool holder assembly for modulation in a rotating spindle, the electric power and/or control signals are transferred from an external source to the modulation tool holder assembly installed in the rotating machine spindle. Similarly, the high-pressure cutting fluid is transferred from a stationary source to the rotating tool holder assembly for modulation.

Rotating tool holder assembly for modulation assisted machining

Processes by which bulk forms can be produced in a single continuous operation, as opposed to multi-stage deformation processes that involve a series of separate and discrete deformation operations or stages. Such processes generally entail deforming a solid body using a large-strain extrusion machining technique and deformation conditions that obtain a predetermined crystallographic texture in the continuous bulk form that differs from the crystallographic texture of the solid body.

Large strain extrusion machining processes and bulk forms produced therefrom

Methods suitable for producing textured surfaces in surfaces of objects, by which the methods are able to achieve a desired three-dimensional surface topography and optionally a desired subsurface microstructure through the use of a controlled modulation machining technique. The methods include selecting a predetermined surface texture for a surface of a body, and then imposing a superimposed sinusoidal feed-modulation on a cutting tool so as to move the cutting tool in a feed direction relative to the body while machining the body with the cutting tool and generating a machined surface of the body. The surface texture of the machined surface is intentionally controlled by at least the modulation amplitude and the modulation frequency of the superimposed sinusoidal feed-modulation.

Method of producing textured surfaces

A method is provided for controlling a machining operation wherein a tool performs a machining operation on a workpiece. The method includes providing a tool holder for holding a tool, a workpiece holder for holding a work piece, and a linear slide for linearly moving a linearly moving part that is either the tool or the workpiece. The step of selecting appropriate machining parameters includes the step of selecting an appropriate feed rate for the linear slide move the linear moving part and appropriate rotational speed is selected for the rotator to rotate the rotating part. The set of appropriate machining parameters are incorporated into the digital controller. The digital controller is then used to control the operation of a linear slide, rotator and modulator to execute the machining of the workpiece by the tool in accordance with a selected appropriate set of parameters.

Control systems and methods for machining operations

A products having at least a portion thereof with a nanocrystalline microstructure, and methods of producing such products. The method generally entails machining a body to produce a polycrystalline chip having a nanocrystalline microstructure. The chips produced by the machining operation may be in the form of particulates, ribbons, wires, filaments and/or platelets. The chips may be consolidated (with or without comminution) to form a product, such that the product is essentially a nanocrystalline monolithic material consisting essentially or entirely of nano-crystals, or of grains grown from nano-crystals. Alternatively, the chips may be dispersed in a matrix material, such that the product is a composite material in which the chips are dispersed as a reinforcement material. According to a particular aspect, a monolithic article can be formed entirely from a single chip by deforming the chip and/or removing material from the chip.

Method of producing nanocrystalline monolithic articles

A method of controllably producing chips with a desired shape and size. The method generally entails machining a body with a cutting tool while superimposing modulation on the cutting tool so as to move the cutting tool relative to the body being machined and cause instantaneous and periodic separation between the cutting tool and the body at a point of contact between the cutting tool and the body, wherein each separation between the cutting tool and the body yields a chip. In this manner, the shapes and sizes of the chips are determined at least in part by the modulation cycle, and particularly the length of time the cutting tool is engaged with the body being machined.

Machining method to controllably produce chips with determinable shapes and sizes

A process by which nanostructured monolithic bodies can be produced in a single continuous operation, as opposed to multi-stage deformation processing. The process generally entails continuously producing a chip having a nanostructured microstructure by engaging a solid body with a cutting edge of a tool while the solid body and the cutting edge move relative to each other, and simultaneously extruding the chip in the immediate vicinity of the cutting edge, such as with a constraining member, as the chip is separated from the solid body by the cutting edge to continuously plastically deform the chip and produce a nanostructured monolithic body immediately downstream of the cutting edge. The shape and size of the chip can be simultaneously controlled by the extrusion process so that the nanostructured monolithic body has a predetermined geometry. The nanostructured monolithic body can be in the form of a product suitable for immediate use, or undergo further processing to yield a product.

Process of producing nanocrystalline bodies

A tool holder assembly and method for intentionally inducing modulation in a machining process. The tool holder assembly is configured for mounting in a tool block on a machining apparatus and includes a tool holder body configured to be secured to the tool block of the machining apparatus, a tool holder mounted on the tool holder body and configured for securing a cutting tool thereto, and a device for imposing a superimposed modulation on the tool holder so as to move the cutting tool relative to the tool holder body and thereby relative to the tool. The tool holder assembly is useful in a process for producing chips having a desired shape and size, and particularly to a method of controllably producing nanocrystalline chips.

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West Lafayette, IN, United States of America

James Bradley Mann