Grant: Research Networks

The goal of the Network is the development of the worlds most advanced Virtual Machining Technology (VMT) for both macro and micro machining operations. This VMT will comprise a complete set of modeling and analysis tools for the planning of optimal machining operations in a virtual environment. It will enable the economical manufacture of innovative products without first resorting to costly physical trials. A key element to validating the effectiveness of this technology will be its application on a new state-of-the-art 5-axis meso-scale milling machine, to be developed within the mandate of the proposed Network. The Network will include the premier and most active Canadian researchers in the manufacturing field, with proven track records in their respective disciplines 20 Professors from 7 Universities in Alberta, British Columbia, New Brunswick, Ontario, and Quebec. The team is well balanced it includes 11 full Professors, 4 Associate Professors, and 5 Assistant Professors. This group of experienced senior and very energetic and talented young scientists is certainly capable of creating the necessary tools for achieving the worlds first comprehensive VMT, and the new 5-axis robotic meso-scale milling machine. An effective Virtual Machining Technology requires the formulation and seamless integration of a large number of rigorous mathematical models describing all the individual steps in a production chain, thus, the main Themes of our Network. Steps to be modeled include material behaviour at the microstructure level, tribology of the tool and workpiece, cutting-process dynamics, positioning errors and imperfections in the calibration of the machine-tool, and processing of part-geometry data. When these steps are modeled accurately and simulated with precision, profitable machining strategies can be achieved and new products and machines developed rapidly, innovatively, and in an environmentally-friendly manner. Significantly, meso-machines, due to their smaller scale, require fewer resources to produce, have a significantly smaller footprint, and require less energy to operate compared to todays standard macro-scale counterparts. They are also environmentally friendlier for the manufacture of smaller-sized parts, and provide a new paradigm for the advanced manufacturing of precision complex-geometry parts with micro-scale features. The Networks primary deliverables will be the proposed (i) VMT that will include numerous easy-to-use software tools readily integrable into commercial CAD/CAM systems, and (ii) new 5-axis meso-milling machine. We expect that all our developed technologies will be commercialized by Canadian companies (see support letters). About 100 additional new engineers will also be graduating from our labs over the next five years ( funded through this Network), who will facilitate the transfer of the results of our work to the Canadian aerospace, automotive, power generation, die & mold, and automation-systems-manufacturing industries in an efficient manner.