Digital Platform for modelling of surface integrity when machining aerospace materials (AeroCUT)

Purpose and goal

Surface integrity (SI) is the link between manufacturing, its influence on surface properties, and in-service performance. Evaluation of SI relies on destructive testing, through metallographic evaluations. The interaction between work material, cutting tool, and other factors makes SI difficult to predict. The project aims to use physics informed AI, existing and new sensors, with the goal to non-destructively evaluate SI. The result is a prediction tool that can guide CAM engineers.

Expected effects and result

A prediction tool that reduces the need for destructive evaluation of surface integrity. This leads to reduced need for physical testing when, for example, introducing new cutting tools, processes and root cause analysis in case of quality problems. The expected effect of this is reduced quality losses, faster introduction of new tools and introduction of new products. The developed technologies also have potential to monitor SI in ongoing production, in order to detect deviations more quickly.

Planned approach and implementation

The plan is to develop and extend Chalmer´s current 2D hybrid FE-based approach to 3D, where also SI parameters are predicted. Microstructure-sensitive constitutive models will also be developed to handle the complex variations of Titanium alloys. Finally an integrated physics-based and sensor-based digital twin will be developed, where data from sensors will be used where physics based prediction models fall short today, e.g. chip side-flow and buil-up edge formation.