MSEC2010 Final Program

ASME 2010 International Manufacturing Science and Engineering Conference
MSEC 2010
Erie, Pennsylvania, USA October 12-15, 2010
Final Program
Sponsored by The ASME Manufacturing Engineering Division
SPONSORS
Our sincere appreciations to the following for their financial support
Los Alamos National Laboratory
Cummins Inc.
General Electric Company
Komatsu America Corporation Lord Corporation
National Science Foundation
Hero BX
NWIRC
Ben Franklin Technology Partners
Aerotech
The ASME OldGuard
Manufacturer & Business Association
Welcome
WELCOME BY THE HOST

On behalf of the MSEC Organizing Committee and the School of Engineering at Penn State Erie, The Behrend College, we would like to extend a warm welcome to the ASME International Manufacturing Science and Engineering Conference (MSEC). We are excited about hosting you, the participants, at the Bayfront Convention Center on the shores of Lake Erie. Come visit the College, and our School, on October 12 for pre-conference activities. Penn State Behrend was established in Erie in 1948 and is a comprehensive four-year, residential college offering thirty-four bachelor's degrees, two masters degrees, and six associate degree programs. Our campus is the second-largest in the twenty-one campus Penn State system, next to University Park, our faculty-to-student ratio of 1:16 provides students with a personalized learning experience from accomplished instructors. Penn State Behrend (http://www.behrend.psu.edu) is committed to excellence in teaching, research, and outreach, and prides itself on the balance it achieves between teaching and research. The School of Engineering has over 1,200 students in our ABET accredited programs. Research and outreach are at the heart of our mission at Penn State Behrend. Annually, the college funds nearly $250,000 in undergraduate research opportunities and operates more than two dozen outreach centers, programs, and initiatives. The School of Engineering collocated with the Sam and Irene Black School of Business in the Jack Burke Research and Economic Development Center in 2006 and is amongst the first such partnership of engineering and business schools in the country. Located on a beautiful, wooded hilltop campus, Penn State Behrend offers its 4,700 undergraduate and graduate students an inspiring and technologically-advanced environment characterized by close student/faculty interaction. The campus is alive with more than 110 clubs and organizations, 21 NCAA Division III mens and womens varsity athletic teams, and several intercollegiate and intramural sports. Erie, a metropolitan area of 280,000, is located on Lake Erie's beautiful Presque Isle Bay. The region offers many cultural, sports, and recreational resources, including Pennsylvanias most popular state park, Presque Isle. Erie County is a major industrial, medical, service, and tourism center, and is within a two hour drive of Cleveland, Pittsburgh and Buffalo. Our sincere appreciations go to the sponsorship from Los Alamos National Laboratory, Cummins, GE, Komatsu, LORD Corporation, National Science Foundation, HeroBX, nwIRC, Ben Franklin Technology Partners, AeroTech, the ASME Old Guard, and the Manufacturer & Business Association, without which the conference would not be successful. Finally, we would like to thank all of you for showing your support by attending the conference. We sincerely wish all of you a very enjoyable stay in Erie, Pennsylvania and hope you find inspiration and excitement in this stimulating manufacturing environment. John T. Roth, Ph.D. Assistant Director and Associate Professor School of Engineering Penn State Erie, The Behrend College MSEC 2010 Conference Organizer Kim Swistock 2010 MSEC Organizing Committee Co-Chair The Pennsylvania State University Ralph M. Ford, Ph.D. Director and Professor School of Engineering Penn State Erie, The Behrend College Rhonda Steg School of Engineering Penn State Erie, The Behrend College
Welcome
WELCOME FROM THE PROGRAM CHAIRS

Welcome to the ASME 2010 International Manufacturing Science and Engineering Conference (MSEC)! As you may see, our MSEC Program Committee has put together an excellent technical program and the host institution, Penn State Erie, The Behrend College, has arranged outstanding meeting and function venues to ensure the success of this conference. In addition to the technical and panel sessions, the program features poster presentations, lab and industrial tours, and exhibitions. On behalf of the organizing committee, we wish to extend our warmest welcome from Erie, Pennsylvania during this beautiful time of year. The MSEC proceedings includes 171 technical presentations in 20 symposia on topics ranging from traditional manufacturing areas such as machining and forming to new topics such as energy manufacturing and biomanufacturing. Four panel sessions also involve defining the future of manufacturing with discussions regarding Strategies to Reduce the Transportation Sector's Energy Consumption, Next Generation Composites and Textiles for Transportation Vehicles, Impact of Manufacturing Uncertainty on Commercializing Innovations in Transportation, and Advances in the Electrification of Transportation. In addition, a poster session is included for the third year to provide an opportunity for authors to present new results and exchange ideas. MSEC is truly an international conference, with authors from all over the world. Since its inception in its current format, MSEC has grown steadily to a premier conference in manufacturing in both quantity and quality. There are several individuals who we would like to acknowledge for their contributions to the conference. The symposium organizers, session chairs, reviewers and MED executive committee contributed a considerable amount of time and efforts to develop the conference and assure the quality of the papers and posters presented. Also, we would like to extend a special thanks to the sponsors of the conference, and their support and financial contributions assure the growth and vitality of MSEC. Moreover, we would also like to thank the National Science Foundation Manufacturing and Construction Machines and Equipment (MCME) program for providing student participants with generous travel funding. We would also like to send a special welcome to the undergraduate and graduate students attending the conference as well as the nine groups that participate in the student design competition. They represent the future of the manufacturing workforce. We hope you all enjoy the conference. Yong Huang 2010 MSEC Technical Program Chair Clemson University Kevin Chou 2010 MSEC Technical Program Co-Chair University of Alabama
ii
Welcome
WELCOME FROM THE ASME/MED CHAIR

On behalf of the ASME Manufacturing Engineering Division (MED), I would like to extend our sincere welcome to all of you to the ASME International Conference on Manufacturing Science and Engineering (MSEC). Many thanks to our host, Penn State Erie, The Behrend College, and the organizing committee led by Professors John T Roth and Ralph Ford, and to our program chairs, Professor Yong Huang of Clemson University and Professor Kevin Chou of University of Alabama. We also thank symposium organizers, reviewers, panelists, session chairs, and student volunteers The MED executive committee oversees the operation of the division with about 3,100 members with diverse manufacturing technology expertise. The expertise is represented in eight technical committees: Manufacturing Processes, Manufacturing Equipment, Manufacturing Systems, Quality and Reliability, Life Cycle Engineering, Nano/Micro/Meso Manufacturing, Biomanufacturing, and Textile & Composite Engineering. The breadth and depth of manufacturing technology represented by the MED membership make it one of the most important organizations in the United States and around the world to serve the manufacturing community. One of the primary tasks of the MED is to provide platforms for manufacturing researchers and practitioners to exchange new ideas, foster innovations, and forge professional networks and collaborations. This year, besides 20 technical symposia covering a wide range of manufacturing topics, three panels are convened to address what role manufacturing may play in reducing energy consumption in the transportation sector, in enabling next generation composites and textiles for vehicles, and making commercializing innovations in transportation feasible and attractive. The obvious theme on transportation is formulated in conjunction with local industry including GE Transportation and Komatsu America Corporation. Next year, MSEC will be collocated with NAMRC in Oregon State University. More effort will be made to bring in local industry participation. This years MSEC is held at a time the economy is still struggling with a higher unemployment rate. There have been concerted voices calling for an American industrial renewal driven by emphasis on manufacturing and exports, investment in new technology and research and development, innovation in key areas such as clean energy and affordable health care. The manufacturing community should take a new look at our mission and social responsibilities in the current economic environment. We should contribute more to the American manufacturing rebirth through technology innovations and development. Enjoy the conference and I look forward to your continuous support and active involvement in the MED activities.
Y. Lawrence Yao, Ph.D., FASME Columbia University Chair, ASME Manufacturing Engineering Division
iii
Table of Contents
TABLE OF CONTENTS
Sponsors.....................................................................................................................................inside front cover Welcome by the Host............................................................................................................................................ i Welcome from the Program Chairs ......................................................................................................................ii Welcome from The ASME/MED Chair ................................................................................................................iii Acknowledgements.............................................................................................................................................. 2 Committees.......................................................................................................................................................... 4 Student Manufacturing Design Competition........................................................................................................ 4 Keynote Speaker ................................................................................................................................................. 5 Invited Speakers .................................................................................................................................................. 6 Early Research Career Forum............................................................................................................................. 7 Program at a Glance............................................................................................................................................ 8 Conference Venue Map..................................................................................................................................... 10 Technical Program............................................................................................................................................. 11 Abstracts............................................................................................................................................................ 34 Author Index ...................................................................................................................................................... 96 Advertisements .................................................................................................................................................. 99 Advertisement from next year's host ......................................................................................... inside back cover
Acknowledgements
ACKNOWLEDGMENTS
A special thank you for all the hard work from the following individuals without whose support the conference would not have been successful: SYMPOSIUM ORGANIZERS
Jeffrey Abell, General Motors Mangilal Agarwal, Indiana University-Purdue University Indianapolis Leandro G. Barajas, General Motors R&D Randall Barron, Louisiana Tech University Torgny Brogrdh, ABB AB Corporate Research Ronald Bucinell, Union College Qing Cao, GE Global Research Gary J. Cheng, Purdue University Kevin Chou, University of Alabama Abhijit Deshmukh, Texas A&M University Dragan Djurdjanovic, Ph.D., University of Texas David Dornfeld, University of California-Berkeley Hazim El-Mounayri, IUPUI Changsheng Guo, United Technologies Research Center Y.B. Guo, The University of Alabama Karl R. Haapala, Oregon State University Jarred Heigel, KT Consulting, Inc. Andrew Honegger, Microlution Yong Huang, Clemson University Samuel S. Huang, Ph.D., University of Cincinnati Martin Jun, University of Victoria Serhat Kaya, RTI International Metals Inc. Ritesh Lakhkar, Caterpillar Inc. Lin Li, University of Michigan Wei Li, University of Washington Zhichao (Zinc) Li, North Carolina Agricultural & Technical State University Biaoyang Lin, Swedish Neuroscience Institute Ken Lingo, U. S. Cryogenics LLC Xinyu Liu, Lamar University Z.Q. Liu, Shandong University Gavin McIntyre, Ecovative Design, LLC Laine Mears, Clemson University Jian Mi, GE Global Research Shawn Moylan, National Institute of Standards and Technology Gracious Ngaile, North Carolina State University Brian K. Paul, Oregon State University Radu Pavel, Ph. D., TechSolve, Inc. Frank Pfefferkorn, University of Wisconsin-Madison Ihab Ragai, Hitachi Construction Truck Manufacturing Ltd. Jay C. Rozzi, Creare Incorporated Binil Starly, University of Oklahoma Harry Tempelman, Hitachi Daniel Tsai, Novana, Inc. Athulan Vijayaraghavan, System Insights Daniel Walczyk, Rensselaer Polytechnic Institute Chao Wang, Argonne National Laboratory Guofeng Wang, Indiana University Purdue University Indianapolis Hui Wang, University of Michigan Lihui Wang, University of Skvde Bin Wei, GE Hitomi Yamaguchi, University of Florida Donggang Yao, Georgia Institute of Technology Wenwu Zhang, GE GRC Xiaohong (Tina) Zhang, Seagate Technology LLC, USA
SESSION ORGANIZERS
Jeffrey Abell Fadi Abu-Farha John Agapiou, Ph.D. Mangilal Agarwal Samved Bhatnagar Cristina Bunget Richard Chiou Kevin Chou Hazim El-Mounayri William Emblom Huang Gao Robert Gao Changsheng Guo Jarred Heigel Andrew Honegger Yong Huang Samuel S. Huang, Ph.D. Said Jahanmir Serhat Kaya Gap-Yong Kim Tae Hyung Kim Brad Kinsey Yannis Korkolis Patrick Kwon, Ph.D. Yuan-Shin Lee Ji Li Zhichao (Zinc) Li Xinyu Liu Z.Q. Liu Yu Long Arif Malik Takashi Matsumura Laine Mears Shreyes N. Melkote, Ph.D. Scott Miller John Morehouse Gracious Ngaile Radu Pavel, Ph. D. Z.J. Pei Frank Pfefferkorn Petru A. Pop Ihab Ragai John T. Roth Jay C. Rozzi Loredana Santo Hua-Chu Shih Anil Srivastava, Ph.D. Matteo Strano Harry Tempelman Daniel Tsai Daniel Walczyk Hui Wang Lihui Wang Bin Wei Shing-Chung Wong Benxin Wu Cedric Xia Xun Xu Donggang Yao Y. Lawrence Yao Chang Ye Martin Y. Zhang Wenwu Zhang Xiaohong (Tina) Zhang Fu Zhao Jack G. Zhou Jun Zhou Liang Zhou John Ziegert
Acknowledgements REVIEWERS
Aini Z. Abdul K. Jeffrey Abell Fadi Abu-Farha John Agapiou Mangilal Agarwal Sung-Hoon Ahn Joseph S. Ajiboye Hassan Al-Atat Ahad Ali Harmen Altena Sam Anand Ivan Arriola Alessandro Ascari Tehseen Aslam Sri Atluru Amit Bagchi Emmanuel Baisie J. Banhart Leandro G. Barajas Mickael Barbelet Randall Barron Kurt Beiter Xiaotao Bi Norman Brinkman Rainer Britz Torgny Brogrdh Adam Brzezinski Ronald Bucinell Cristina Bunget Wayne Cai Qing Cao Merve Celen Elisabetta Ceretti Wenxuan Chai Pei Chen Yan Chen Gary J. Cheng Hao Ning Chiang Richard Chiou Neng-Hsin Chiu Michael Cholette Kevin Chou C.H. Chu Andres Clarens Weilong Cong April Cooke John P. Coulter Leo De Vin Mariusz Deja Dave DeLo Kaushal Desai Amit Deshpande Frederick Diekman Dragan Djurdjanovic Dragan Domazet David Dornfeld Catarina Dudas Raghu Echempati Sheryl Ehrman Hazim El-Mounayri Ravindranadh Eluri Tahany El-Wadarny William Emblom Toshiyuki Enomoto Yajun Fan Donald Farquhar Qiang Feng Xiaodong Feng Benito Fernandez Christian E. Fischer Alessandro Fortunato Thiago Frana Barry Fussell Yong Gan Yibo Gao M. Luisa Garcia-Romeu Nitin Garg Jenn-Terng Gau Brandon Gegg Masoud Ghaffari Angshuman Ghosh Nicholas Gianaris Bill Grant Changsheng Guo Y.B. Guo Karl R. Haapala Kotaro Hanada Jenny Harding Richard Hartel Rui He Jarred Heigel Miguel A. Hidalgo Toshiki Hirogaki Mike P. Hitchiner Andrew Honegger Jack Hu Zhaoli Hu Xu Huang Yong Huang Liu huran Daniel Hutchinson Robert Ivester Said Jahanmir Hamid Jahed I.S. Jawahir Robert Jerard Hongyuan Jiang Yibo Jiao Suwat Jirathearanat J. B. Jordon Suhas Joshi Martin Jun Guo Junqing Chen-Chun Kao Shiv G. Kapoor Serhat Kaya Mohsen Khajehzadeh Obadiah Kilonzo Dave Kim Gap-Yong Kim Tae Hyung Kim Brad Kinsey Randolph Kirchain Hossam Kishawy Kazuhiko Kitamura Muammer Koc James Kong Panjawat Kongsuwan Yannis Korkolis J. Kozak Matthew Krane Adarsh Krishnamurthy Hsin-Yu (Cindy) Kuo Patrick Kwon Ritesh Lakhkar Robert G. Landers Edzel Lapira Eric R. Larsen Patrice Lasne Yuan-Shin Lee Cheol Lee Shuting Lei Yong Lei Dongguo Li James Li Ji Li Jingjing Li Lin Li Sha Li W. Li Wei Li Xiaochun Li Zhichao (Zinc) Li Steven Liang Yiliang Liao Biaoyang Lin Yafu Lin Zhan Lin Ken Lingo C. Richard Liu Dihui Liu Mark Liu Xinyu Liu Yi Liu Yueping Liu Z.Q. Liu Haydar Livatyali Yu Long Ming-Chyuan Lu Howard Ludewig Yuefeng Luo Lei Ma Liang Ma Ning Ma Rajiv Malhotra Arif Malik Prakash Mangalgiri Sudhagar Mani Jin Mao Kenneth Marko Don Martin Troy Marusich Takashi Matsumura J. Rhett Mayor Sara McMains Laine Mears Jian Mi Zhongxing Mi Abbas Milani Sangkee Min Behnam Moetakef-Imani Shawn Moylan Brigid Mullany James A. Nemes Stephen T Newman Amos Ng Gracious Ngaile Keiji Ogawa David Okonski Shinpei Okumura Richard Onyancha Leonardo Orazi Tugrul Ozel Barath Palanisamy Simon Park John Patten Brian K. Paul Radu Pavel Lewis Payton Z.J. Pei Qing Peng Frank Pfefferkorn William W. Pflager A. Polishetty Petru A. Pop Vittal Prabhu Z. Pu Yue Qi Na Qin Jun Qu Ihab Ragai Ainissa Ramirez Arvind Rangarajan Ralph Resnick Sehun Rhee Yiming Rong Rich Roth Jay C. Rozzi M. Salahshoor Johnson Samuel Gen Satoh Tony Schmitz Max Shen Xinwei Shen Yu Shen Fan Shi Xinmei Shi Yung Shin H. Singh Inderdeep Singh Ramesh Singh William Sobel Shahab Sokhansanj Qinghua Song Patrick Spicer Anil Srivastava Matteo Strano William Studzinski Sathyan Subbiah Joshua Summers Gang Sun Jie Sun Xiaoguang Sun Murali Sundaram Murali Meenakshi Sundaram Chris Suprock Norikazu Suzuki Bruce L. Tai Akapot Tantrapiwat Curtis Taylor Charles Theurer Andrew Trimmer Daniel Tsai Huang-Chi Tseng Rajesh Vazhayil Govindan Athulan Vijayaraghavan Mike Vogler Rohit Voothaluru Daniel Walczyk Chaosheng Wang Hongliang Wang Hui Wang Lihui Wang Shuxin Wang Tianyi Wang Yongjun Wang Bin Wei Yanhu Wei Zhi Wei John Wentz Candace Wheeler Eric Whitenton Gloria Wiens Robert Williams David Willis Shing-Chung Wong Benxin Wu Jiejun Wu Yufeng Wu Cedric Xia Wei Xiao Chong Xie X.J. Xin Changxue Xu Xun Xu Hitomi Yamaguchi Jiwang Yan Yingling Yang Longxiang Yang Donggang Yao Y. Lawrence Yao Chang Ye Eugene Yen Zhu Yiguo Yosang Yoon Sirong Yu Wenqiao Yuan Stephen Yutkowitz Michael Zaeh Maciej Zavodniok Bi Zhang Jian Zhang Li Zhang Martin Y. Zhang Qingwei Zhang Shi-Hong Zhang Wenwu Zhang Xiaohong (Tina) Zhang Xueping Zhang Fu Zhao Jun Zhou Liang Zhou Yuanyuan Zhou Likun Zhu Xiaowei Zhu
Committees / Student Manufacturing Design Competition
COMMITTEES
MED Executive Committee Y. Lawrence Yao (Chair), Columbia University Matt Bement (Vice-Chair), Los Alamos National Lab Cedric Z. Xia (Program Chair), Ford Motor Company John T Roth (Secretary/Treasurer), Penn State Erie, The Behrend College Xiaoping Yang (Member), Cummins, Inc. Organizing Committee Yong Huang, Clemson University Kevin Chou, University of Alabama Ralph Ford, Penn State Erie, The Behrend College John T Roth, Penn State Erie, The Behrend College Rhonda Steg, Penn State Erie, The Behrend College Kim Swistock, The Pennsylvania State University, University Park
STUDENT MANUFACTURING DESIGN COMPETITION

We would like to congratulate all of our student manufacturing design competition finalists and welcome them to the MSEC Conference. We would also like to invite all conference participants to attend the presentations by these outstanding future engineers. WEDNESDAY, OCTOBER 13
Symposium Organizer: Yong Huang, Clemson University, Clemson, SC, United States Symposium Co-Organizer: Kevin Chou, University of Alabama, Tuscaloosa, AL, United States Session Chair: Cedric Xia, Ford Motor Company, Dearborn, MI, United States
Room 170B
1:30pm3:00pm
Room 170B
3:30pm5:00pm
Development of a Real-Time Laser-Based Machine Vision System (Southern Methodist University, Dallas, TX, United States) Athletic Tape Cutter and Cleat Wrench (Rensselaer Polytechnic Institute, Troy, NY, United States) Puckman Tape Dispenser (Rensselaer Polytechnic Institute, Troy, NY, United States) Specialized Elastomeric Tooling for Advanced Thermoset Composites (Rensselaer Polytechnic Institute, Troy, NY, United States) Design and Fabrication of Micro-Wedge Device for Compression and Cyclic Mechanical Testing of Microscale Metal Sheets (Northwestern University, Evanston, IL, United States)
Rapid Prototyping of a Juvenile Apatosaurus from 3D Scans (University of Oklahoma, Norman, OK, United States) Design of an Embedded Sensing System for On-Line Monitoring of Pressure Distributions at ToolWorkpiece Contact Interfaces in Stamping Processes (University of Connecticut, Storrs, CT, United States) Design & Fabrication of a Laboratory Tube Hydroforming Machine (University of New Hampshire, Durham, NH, United States) Vision-Based Tool Wear Monitoring System (University of Florida, Gainesville, FL, United States)
Keynote Speaker
KEYNOTE SPEAKER
David Grzelak, Chairman & CEO, Komatsu America Corp. Dave graduated from Penn State University in 1971 with a B.S. in Industrial Engineering. He then obtained his MBA from Gannon University in Erie, Pennsylvania. In 1992, Dave was inducted into Penn State Behrends Athletic Hall of Fame. Dave was honored with the Penn State University, College of Engineering highest award as Outstanding Engineering Alumnus Award in April 1999. In April of 2001, Dave was recognized by Gannon University with the Distinguished Masters Degree Alumni Award. In 2005, Penn State appointed Dave to the Board of the Leonhard Center for the Enhancement of Engineering Education. In 2006, Alamo Group selected Dave to its Board of Directors and a member of the Audit, Compensation and Nomination Committees. In November 2008, Dave was appointed a Non-Executive Director of Boart Longyear Ltd. Dave joined General Electric Transportation Systems in 1971 on their Manufacturing Management Training Program. He has held numerous assignments with increasing responsibility in the areas of manufacturing, marketing, sales and management. His last assignment at G.E. was Manager, Off-Highway Vehicles in which he had P+L responsibility for electric drive systems sales, service and parts worldwide. Dave joined Komatsu Dresser Company on January 1, 1991 as Vice President, Sales and assumed the additional responsibility of the Service organization as Vice President, Service and Sales in February, 1992. Dave was promoted to Vice President, Marketing in 1993, Executive Vice President in 1995, President and COO in 1997, Chief Executive Officer in 1998, Chairman and CEO in 1999, Global Officer, Komatsu Ltd. June, 1999 and Chairman and CEO of Komatsu Mining Systems in May, 2000. In April 2002, Dave was appointed as Chairman and CEO of Komatsu America Corp. with management responsibility of five U.S. Komatsu Operations related to the construction, utility and mining industries.
Invited Speakers
INVITED SPEAKERS
Kathy Dahlkemper, U.S. House Representative Congresswoman Dahlkemper is serving her first term in representing the 3rd District of Pennsylvania in the U.S. House of Representatives. She serves on the Committees for Agriculture, Science and Technology, and Small Business. Before serving in Congress, Rep. Dahlkemper helped run her family's small business, a landscaping firm in Erie, PA. A community leader long before she was an elected official, Kathy was a founder of the Lake Erie Arboretum at Frontier Park (LEAF) and a volunteer with the Worldwide Marriage Encounter through the Erie Diocese. She also worked with the Erie-based Nonprofit Partnership and the local Girl Scouts of America. Rep. Dahlkemper is a member of the fiscally conservative Blue Dog Coalition, a group dedicated to balancing the federal budget and reducing the national debt. She is also a vocal advocate of prevention and wellness. She is the first dietitian ever elected to Congress. Congresswoman Kathy Dahlkemper (PA-3), a member of the House Committee on Science & Technology, will discuss the role of Congress and the federal government in our country's manufacturing sector, including creating a national manufacturing strategy, advancing research and development, investment in education and bringing the benefits of new technologies to businesses and consumers.
Jack McDougle, Senior Vice President, U.S. Council on Competitiveness U.S. manufacturing faces intense and accelerating competition from all corners of the globe. Long-term national and economic security in the United Statesand our ability to create wealth and new jobscritically depends on innovative and agile manufacturing capabilities deployed at scale. Current economic conditions and challenges have accelerated the need to push for a robust and adaptive manufacturing ecosystem that supports the generation and translation of ideas into high-value goods and services that serve U.S. and global markets. The United States needs a new vision for the future of manufacturing. Jack will discuss the Councils new flagship initiative to strengthen U.S. manufacturing in the 21st Century. He brings to this role expertise in manufacturing, business and economic issues, cultivated from experience in both the private sector and federal government. The Council, composed of leaders from industry, academia, national labs and organized labor, will use its extensive networks and convening power to build on existing work and recommendations but will implant innovative enhancements and approaches to the development and implementation of policy solutions for manufacturing competitiveness. Jack will specifically highlight the release of the first Annual Global Manufacturing Competitiveness Index, a Council/Deloitte joint venture. The Index represents the attitudes and perspectives of more than 400 leading CEOs and business executives around the world on manufacturing competitiveness. Specifically, the Index focuses on three key areas: 1. Assessment of manufacturing competitiveness drivers 2. Countries deemed to be most competitive now, and a five year outlook 3. The role government and policy plays in driving or impeding competitiveness
Early Research Career Forum
EARLY RESEARCH CAREER FORUM

Sponsored by ASME OLDGUARD
Please consider attending this free Forum at Penn State Behrend in Room 180, Jack Burke Research and Economic Development Center (Burke Center). You may choose to attend during your 2010 ASME/MSEC registration. Tuesday, Oct. 12th from noon - 5 pm (just prior to the start of MSEC) at Penn State Behrend. Buses will leave the Bayfront Convention Center at 11:15 a.m. and depart Penn State Behrend at 5:15 p.m. If you are driving from the Convention Center: Depart the convention center by turning left onto the Bayfront Parkway. Take E Bayfront Pkwy and PA-290 E/Bayfront Connector approximately 8 miles to the entrance of the Penn State Behrend campus. Turn right at the traffic light at College Drive and position your vehicle in the left lane. Take the left "Y" onto Jordan Road (this occurs quickly) and proceed up the hill where you will see the Burke Research and Economic Development Center on your left. At the intersection of Technology Drive (only a few hundred feet) turn left, proceed to the parking ramp, park and enter the building. Description of the Event: The forum will discuss research positions in industry, academia, and national laboratories and how to be successful professionally in the various settings. The target audience for the forum is recent advanced degree graduates as well as current Master's and Ph.D. students. Cost for attendees: $0 (so why not attend) Schedule: (Buses will leave the Bayfront Convention Center at 11:15 a.m. and depart Penn State Behrend at 5:15 p.m.) noon - 1:30 pm: lunch with speaker 1:30 - 2:30 pm: panel of academia speakers 2:30 - 2:45 pm: break 2:45 - 3:45 pm: panel of industrial speakers 3:45 - 4:00 pm: break 4:00 - 5:00 pm: panel of national lab speakers (The reception for the conference begins at 6:00 pm at the Bayfront Convention Center; attendees should plan on staying after for more networking and discussions.) Presentation format: Speaker will give about a 20 minute presentation that will discuss topics such as how to search for a job, career management, funding for research, etc. The panel also includes two additional panelists. The panelists will be able to contrast the speaker's presentation from their organizations (e.g., different national laboratories, big and small industrial research labs, Research I versus primarily teaching universities, etc.) Ample time will be provided for questions and answers. Panelists: Academia: Frank Pfeffercorn (University of Wisconsin, presenting), Larry Yao (Columbia University), Jian Cao (Northwestern University), and Richard Onyancha (Rose-Hulman Institute of Technology). Industry: Cedric Xia (Ford, presenting), Mary Toney (currently a NSF program officer but worked in Spaulding Composites R&D for most of her professional career), Radu Pavel (TechSolve), and Angie Trudell (GE Global Research Human Resources). National Lab: Rob Ivester (NIST, presenting), Kershed Cooper (Naval Research Laboratory) and Lysle Serna (Sandia). Questions can be answered by contacting Brad Kinsey email: bkinsey@unh.edu
Program-at-a-Glance
PROGRAM AT A GLANCE
Tuesday (10/12) 12:00pm 1:00pm 1:30pm 2:30pm 4:00pm 5:00pm 6:00pm 5:00pm 8:00pm 3:30pm 4:30pm 6:00pm 6:00pm 8:00pm Early Research Career Forum (Penn State Erie, The Behrend College) Registration (Lobby) Hero BX Tour 1, leave from Bayfront Convention Center Hero BX Tour 2, leave from Bayfront Convention Center Penn State Behrend Tours, leave from Bayfront Convention Center NAMRI Board Meeting (Room 150) Welcome Reception, Bayfront Convention Center
Wednesday (10/13) 7:00am 7:00am 8:00am 9:00am 10:00am 10:30am 10:30am 12:00pm 8:00am 5:00pm 9:00am 10:00am 10:30am 11:30am 12:00pm 1:30pm Breakfast (Lobby) Registration (Lobby) Welcoming Remarks (West Ballroom) Keynote Presentation - David Grzelak, Chairman/CEO, Komatsu America Corp. (West Ballroom) Refreshment Break (Lobby) MED Executive Meeting (Room 150) Technical Sessions (Breakout Rooms) Lunch + Invited Speaker - Kathy Dahlkemper, US House Rep and member of Committees for Agriculture, Science and Technology and Small Business, (West Ballroom) Technical Sessions and Student Manufacturing Design Competition (Breakout Rooms) Refreshment Break (Lobby) Technical Sessions (Breakout Rooms) Penn State Behrend Tours, leave from Bayfront Convention Center Membership Meeting ASME (Room 160A) Membership Meeting SME (Room 160A) ASME Fellow Recognition & Manufacturing Engineering Awards Banquet (West Ballroom)
1:30pm 3:00pm 3:30pm 5:15pm 5:15pm 6:15pm 7:15pm
3:00pm 3:30pm 5:00pm 6:15pm 6:15pm 7:15pm 10:00pm
Program-at-a-Glance Thursday (10/14) 7:00am 7:00am 8:00am 8:00am 5:00pm 9:00am Breakfast (Lobby) Registration (Lobby) Plenary Panel: Strategies to Reduce the Transportation Sector's Energy Consumption (West Ballroom) Refreshment Break (Lobby) Technical Sessions (Breakout Rooms) Refreshment Break (Lobby) Technical Sessions (Breakout Rooms) Lunch + Invited Talk Jack McDougle, Senior Vice President, U.S. Council on Competitiveness (West Ballroom) Plenary Panel: Next Generation Composites and Textiles for Transportation Vehicles (West Ballroom) Break Technical Sessions (Breakout Rooms) and Poster Sessions (Lobby) Break Technical Sessions (Breakout Rooms) Cummins Jamestown Engine Plant Tour, leave from Bayfront Convention Center
9:00am 9:15am 10:15am 10:30am 11:45am 12:30pm
9:15am 10:15am 10:30am 11:30am 12:30pm 1:30pm
1:30pm 1:45pm 3:15pm 3:30pm 5:15pm
1:45pm 3:15pm 3:30pm 5:00pm 8:00pm
Friday (10/15) 7:00am 7:00am 8:00am 8:00am 9:00am 9:00am Breakfast (Lobby) Registration (Lobby) Plenary Panel Impact of Manufacturing Uncertainty on Commercializing Innovations in Transportation (West Ballroom) Refreshment Break (Lobby) Technical Sessions (Breakout Rooms) Lunch (West Ballroom) Plenary Panel Advances in the Electrification of Transportation (West Ballroom) Technical Sessions (Breakout Rooms) Eriez Manufacturing Company Tour, leaving from Bayfront Convention Center
10:00am 10:30am 12:00pm 1:00pm 2:00pm 3:30pm
10:30am 12:00pm 1:00pm 2:00pm 3:30pm 6:00pm
Transportation will be provided to/from the Early Career Forum and for all tours. All transportation will depart from and return to the Bayfront Convention Center.
Conference Venue Map
CONFERENCE VENUE MAP
10
Technical Program
TUESDAY, OCTOBER, 12 SYMP 21 Conference Events

Symposium Organizer: Yong Huang, Clemson University, Clemson, SC, United States Symposium Co-Organizer: Kevin Chou, University of Alabama, Tuscaloosa, AL, United States
SYMP 21 Conference Events

21-7 NAMRI BOARD MEETING Room 150
5:00pm6:00pm
21-4 EARLY RESEARCH CAREER FORUM Penn State Behrend 12:00pm5:00pm

Session Chair: Brad Kinsey, University of New Hampshire, Durham, NH, United States
Session Chair: Steven Hayashi, GE Global Research, Niskayuna, NY, United States
WEDNESDAY, OCTOBER, 13 SYMP 21 Conference Events


21-15 HERO BX TOUR 1 21-16 HERO BX TOUR 2
1:30pm3:30pm 2:30pm4:30pm
21-23 WELCOMING REMARKS West Ballroom
8:00am9:00am
Session Chair: John T. Roth, Penn State Erie, The Behrend College, Erie, PA, United States


21-17 PENN STATE BEHREND TOURS 1 4:00pm6:00pm

21-13 KEYNOTE PRESENTATION DAVID W. GRZELAK, KOMATSU AMERICA CORP. West Ballroom 9:00am10:00am


21-31 WELCOME RECEPTION
7:30pm
21-5 MED EXECUTIVE COMMITTEE MEETING Room 150 10:30am11:30am

Session Chair: Y. Lawrence Yao, Columbia University, New York, NY, United States
11
Wednesday, October 13
SYMP 3 Advances in Nontraditional Manufacturing

Symposium Organizer: Hitomi Yamaguchi, University of Florida, Gainesville, FL, United States Symposium Co-Organizer: Bin Wei, GE, Niskayuna, NY, United States
SYMP 7 Smart Machining

Symposium Organizer: Radu Pavel, TechSolve, Inc., Cincinnati, OH, United States Symposium Co-Organizer: Samuel S. Huang, University of Cincinnati, Cincinnati, OH, United States, Jarred Heigel, KT Consulting, Inc., Lexington, KY, United States
3-1 ADVANCES IN NONTRADITIONAL MANUFACTURING 1 Room 170B 10:30am12:00pm

Session Chair: Takashi Matsumura, Tokyo Denki University, Tokyo, Tokyo, Japan Session Co-Chair: Bin Wei, GE, Niskayuna, NY, United States Experimental Investigation of Coefficient of Friction during the Friction Stir Processing of Aluminum Technical Publication. MSEC2010-34106 Scott Miller, Lee A. Arnold, University of Hawaii at Manoa, Honolulu, HI, United States, Grant Kruger, University of Michigan, Ann Arbor, MI, United States Fabrication of PCD Microtools Using Block EDM Method and Their Application to Different Microstructures in Brittle and Hard Materials Technical Publication. MSEC2010-34243 Asma Perveen, Y. S. Wong, Mustafizur Rahman, National University of Singapore, Singapore, Singapore, Singapore Experimental Study of Microtools Fabricated Electrochemical Machining Technical Publication. MSEC2010-34105 Ronnie Mathew, Sagil James, Murali Sundaram, University of Cincinnati, Cincinnati, OH, United States by
7-1 MACHINING AND GRINDING 1 Room 160A 10:30am12:00pm

Session Chair: Radu Pavel, TechSolve, Inc., Cincinnati, OH, United States Session Co-Chair: John Agapiou, General Motros, R&D Center, Warren, MI, United States Combining Process Dynamics and Tool Wear in the Milling Super Diagram Technical Publication. MSEC2010-34034 Jaydeep Karandikar, Raul Zapata, Tony Schmitz, University of Florida, Gainesville, FL, United States An Experimental Investigation into the High-Speed Turning of Ti-6Al-4V Titanium Alloy Technical Publication. MSEC2010-34205 Anil Srivastava, Jon Iverson, TechSolve, Inc., Cincinnati, OH, United States Current Status of Peel Grinding Technology Technical Publication. MSEC2010-34219 Mike P. Hitchiner, Saint-Gobain Abrasives, Romulus, MI, United States Dry Turning of Commercially Pure Aluminum with Carbide Tools Technical Publication. MSEC2010-34064 Xin Wang, Patrick Kwon, Michigan State University, East Lansing, MI, United States Pose Estimation and Force Prediction of Nonrigid Endoscopic Tool Technical Publication. MSEC2010-34046 Yang Lei, Scott Miller, University of Hawaii at Manoa, Honolulu, HI, United States
Magnetic Field-Assisted Finishing of Silicon MEMS Micropore X-Ray Optics Technical Publication. MSEC2010-34121 Raul Riveros, Hitomi Yamaguchi, Taylor Boggs, University of Florida, Gainesville, FL, United States, Ikuyuki Mitsuishi, Japan Aerospace Exploration Agency, Sagamihara, Japan, Utako Takagi, Kensuke Ishizu, Teppei Moriyama, Yuichiro Ezoe, Tokyo Metropolitan University, Minami-Osawa, Japan, Kazuhisa Mitsuda, Japan Aerospace Exploration Agency, Sagamihara, Japan
12
Technical Program
SYMP 9 Advances in Materials Forming

Symposium Organizer: Gracious Ngaile, North Carolina State University, Raleigh, NC, United States Symposium Co-Organizer: Serhat Kaya, RTI International Metals Inc., Niles, OH, United States
SYMP 10 Advances in Modeling, Analysis, and Simulation of Manufacturing Processes

Symposium Organizer: Ihab Ragai, Hitachi Construction Truck Manufacturing Ltd., Guelph, ON, Canada Symposium Co-Organizer: Laine Mears, Clemson University, Greenville, SC, United States, Harry Tempelman, Hitachi, Guelph, ON, Canada
9-1 INCREMENTAL SHEET FORMING Room 160B 10:30am12:00pm

Session Chair: William Emblom, Univeristy of Louisiana at Lafayette, Lafayette, LA, United States Session Co-Chair: Gracious Ngaile, North Carolina State University, Raleigh, NC, United States Deformation Analysis of Multistage Incremental Sheet Forming Technical Publication. MSEC2010-34040 Zhen Cui, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu Province,China, Feng Ren, Cedric Xia, Ford Motor Company, Dearborn, MI, United States, L. Gao, Nanjing University of Aeronautics & Astronautics, Nanjing, Jiangsu, China Fracture-Based Formability Prediction in Incremental Forming Technical Publication. MSEC2010-34223 Rajiv Malhotra, Liang Xue, Jian Cao, Northwestern University, Evanston, IL, United States Stress and Strain Analysis on Incremental Sheet Metal Forming with Multiple-Head Tool Technical Publication. MSEC2010-34280 Yongjun Wang, Xudong Xiao, Zhenyi Yuan, Weichao Wu, Northwestern Polytechnical University, Xian, Shaanxi, China, Jian Cao, Northwestern University, Evanston, IL, United States Desktop Single-Point Incremental Forming System Technical Publication. MSEC2010-34290 Shuping Chen, Northeastern University, Shenyang, Liaoning, China, Yang Wang, Liaoning University of Petroleum and Chemical Technology, Fushun, Liaoning, China, Maohua Chen, Sany Heavy Equipment Ltd., Shenyang, Liaoning, China
10-1 CASTING Room 160C
10:30am12:00pm
Session Chair: Harry Tempelman, Hitachi, Guelph, ON, Canada Session Co-Chair: Laine Mears, Clemson University, Greenville, SC, United States Identification for Control of Low-Pressure Die Casting Technical Publication. MSEC2010-34063 Xinmei Shi, Daan Maijer, Guy Dumont, UBC, Vancouver, BC, Canada Simulation of the Heat Treatment of an Automotive Cast Part Technical Publication. MSEC2010-34152 Patrice Lasne, Mickael Barbelet, Olivier Jaouen, Frederic Coste, Transvalor S.A., Mougin, France, Harry Tempelman, Hitachi, Guelph, ON,Canada, Ihab Ragai, Hitachi Construction Truck Manufacturing Ltd., Guelph, ON, Canada A Variable Search Technique for Multiple Control Valves Used in Melt Modulation during Injection Molding Technical Publication. MSEC2010-34238 John P. Coulter, Lehigh University, Bethlehem, PA, United States, Akapot Tantrapiwat, King Mongkut Inst. Ladkrabang, Bangkok, Thailand Effects of Container Geometry on Energy Consumption during Hardening in Ice Cream Manufacturing Technical Publication. MSEC2010-34103 William C. Cromer, Mark Miller, X. J. Xin, Z. J. Pei, Karen Schmidt, Kansas State University, Manhattan, KS, United States
13
SYMP 11 Laser Based Manufacturing

Symposium Organizer: Wenwu Zhang, GE GRC, Schenectady, NY, United States Symposium Co-Organizer: Gary J. Cheng, Purdue University, West Lafayette, IN, United States, Ritesh Lakhkar, Caterpillar Inc., Peoria, IL, United States

11-1 LASER MICRO/NANO PROCESSING Room 170A 10:30am12:00pm

Session Chair: Loredana Santo, University of Rome Tor Vergata, Rome, Italy Session Co-Chair: Chang Ye, Purdue, West Lafayette, IN, United States Nanosecond Laser Ablation of Titanium in Air and Water: The Time-Resolved Observation and Postprocess Characterizations Technical Publication. MSEC2010-34109 Yun Zhou, Yibo Gao, Benxin Wu, Illinois Institute of Technology, Chicago, IL, United States Laser Beam Propagation through Three-Dimensional High-Aspect-Ratio Microholes Technical Publication. MSEC2010-34111 Sha Tao, Benxin Wu, Illinois Institute of Technology, Chicago, IL, United States, Shuting Lei, Kansas State University, Manhattan, KS, United States Femtosecond Laser-induced Surface Texturing and Crystallization of a-Si:H Thin Film Technical Publication. MSEC2010-34271 Hongliang Wang, Panjawat Kongsuwan, Gen Satoh, Y. Lawrence Yao, Columbia University, New York, NY, United States Study of Effect of Multiple Pulses on the Deformation Behavior of Ultrathin Metal Foils in 3D Microscale Laser Dynamic Forming Technical Publication. MSEC2010-34299 Ji Li, Purdue University, West Lafayette, IN, United States
21-14 LUNCH + INVITED SPEAKER KATHY DAHLKEMPER, U.S. HOUSE REPRESENTATIVE West Ballroom 12:00pm1:30pm
SYMP 2 Sustainable Manufacturing of Advanced Composites

Symposium Organizer: Daniel Walczyk, Rensselaer Polytechnic Institute, Troy, NY, United States Symposium Co-Organizer: Ronald Bucinell, Union College, Schenectady, NY, United States, Gavin McIntyre, Ecovative Design, LLC, Green Island, NY, United States, Jian Mi, GE Global Research, Niskayuna, NY, United States
2-1 SUSTAINABLE MANUFACTURING OF ADVANCED COMPOSITES Room 170A 1:30pm3:00pm

Session Chair: Daniel Walczyk, Rensselaer Polytechnic Institute, Troy, NY, United States Session Co-Chair: Scott Miller, University of Hawaii at Manoa, Honolulu, HI, United States Curing and Consolidation of Advanced Thermoset Composite Laminate Parts by Pressing between a Heated Mold and Customized Rubber-Faced Mold Technical Publication. MSEC2010-34054 Daniel Walczyk, Jaron Kuppers, Casey Hoffman, Rensselaer Polytechnic Institute, Troy, NY, United States Development of Self-adhesive Bamboo Fiber Composite with Three-Dimensional Shape Using Fibers Extracted with Machining Center Technical Publication. MSEC2010-34134 Sachiko Ogawa, Doshisha University, Kyotanabe, Japan, Keiji Ogawa, The University of Shiga Prefecture, Hikone-shi, Japan, Toshiki Hirogaki, Eiichi Aoyama, Doshisha University, Kyotanabe-shi, Japan, Mitsuaki Taniguchi, Doshisha University, Kyotanabe, Kyoto, Japan, Hiromichi Nobe, Mifuji Kikai Seisakusho, Ltd., Gunma, Japan Study of Manufacturing Process Optimization of Rigid Boards of LDPE/Al Composite Recycled Technical Publication. MSEC2010-34303 Miguel A. Hidalgo, Universidad Autonoma de Occidente, Cali, Valle, Colombia
14
Technical Program
Analysis on Filament Winding Sphere Surface Component with Multiple Polar Holes Technical Publication. MSEC2010-34307 Rong Min, Yongjun Wang, Weichao Wu, Junbiao Wang, Northwestern Polytechnical University, Xian, Shaanxi, China


10-2 FORMING Room 160C
1:30pm3:00pm
9-2 SHEET AND TUBE HYDROFORMING-I Room 160B 1:30pm3:00pm

Session Chair: Serhat Kaya, RTI International Metals Inc., Niles, OH, United States Session Co-Chair: Petru A. Pop, University of Oradea, Oradea, Bihor, Romania Database for Real-Time Loading Path Prediction for Tube Hydroforming Using Multidimensional Cubic Spline Interpolation Technical Publication. MSEC2010-34099 Angshuman Ghosh, Gracious Ngaile, North Carolina State University, Raleigh, NC, United States Optimization on the Production of Variable Thickness Aluminium Tubes Technical Publication. MSEC2010-34145 Reza Bihamta, Aluminium Research CentreREGAL, Laval University, Quebec, QC, Canada, Guillaume DAmours, NRC - Aluminium Technology Centre, Saguenay, QC, Canada, Quang-Hien Bui, Aluminium Research CentreREGAL, Laval University, Quebec, QC, Canada, Ahmed Rahem, NRC - Aluminium Technology Centre, Saguenay, QC, Canada, Michel Guillot, Mario Fafard, Aluminium Research CentreREGAL, Laval University, Quebec, QC, Canada Metal Foam-Filled Hydroformed Tubes: Production and FEM Simulation Technical Publication. MSEC2010-34210 Matteo Strano, Politecnico di Milano - Dipartimento di Meccanica, Milan, Italy A New Bending Technique for Very Thin Metal Tubes Technical Publication. MSEC2010-34278 Shi-Hong Zhang, Institute of Metal Research, Chinese Academy of Sciences, Shenyang, China, Shi-Qing Chen, Han Xiao, School of Materials Science and Engineering, Dalian University of Technology, Dalian, China, Hai Liu, Institute of Metal Research, Chinese Academy of Sciences, Shenyang, China Manufacture of Aerospace Components with Pressure Welding Technical Publication. MSEC2010-34056 Ho-Sung Lee, Jong-Hoon Yoon, Y. M. Yi, Korea Aerospace Research Institute, Daejeon, Korea (Republic)
Session Chair: Laine Mears, Clemson University, Greenville, SC, United States Session Co-Chair: Harry Tempelman, Hitachi, Guelph, ON, Canada Spring Back in Sheet Metal Forming of Stainless Steel 410 Technical Publication. MSEC2010-34045 Ihab Ragai, Hitachi Construction Truck Manufacturing Ltd., Guelph, ON, Canada, James A. Nemes, The Pennsylvania State University, Great Valley, Malvern, PA, United States Investigation on Sheet Hydroforming Process of Titanium/Aluminum Clad Metal Housing Technical Publication. MSEC2010-34047 Huang-Chi Tseng, Zong-Chun Wu, Chinghua Hung, National Chiao Tung University, Hsinchu, Taiwan, Ming-Hu Lee, Metal Industries Research & Development Centre, Kaohsiung, Taiwan Process Control Model for Tube Hydroforming Technical Publication. MSEC2010-34200 Obadiah Kilonzo, North Carolina State University, Raleigh, NC, United States A Straightening Method Investigation Based on Rolling Caused Stress Redistribution for Distorted Monolithic Components Technical Publication. MSEC2010-34044 Jie Sun, Jianfeng Li, Shandong University, Jinan, Shandong,China, Zhongqiu Wang, Shandong Academy of Science, Qingdao, Shandong, China
15
SYMP 12 Advances in Micro/Meso Mechanical Manufacturing

Symposium Organizer: Xinyu Liu, Lamar University, Beaumont, TX, United States Symposium Co-Organizer: Andrew Honegger, Microlution, Chicago, IL, United States, Hazim El-Mounayri, IUPUI, Indianapolis, IN, United States

12-1 MICRO/MESO MECHANICAL MANUFACTURING (I) Room 160A 1:30pm3:00pm

Session Chair: Xinyu Liu, Lamar University, Beaumont, TX, United States Session Co-Chair: Said Jahanmir, Mohawk Innovative Technology, Inc., Albany, NY, United States Effect of Grain Size and Specimen Size on Deformation during Microbending Technical Publication. MSEC2010-34038 Sunal Parasiz, Sakarya University, Sakarya,Turkey, Reid VanBenthysen, Brad Kinsey, University of New Hampshire, Durham, NH, United States Development of an Axisymmetric Pressure Application Method for Cylindrical Laminated Device Fabrication Technical Publication. MSEC2010-34227 James H. Vlieg, Brian K. Paul, Richard B. Peterson, Oregon State University, Corvallis, OR, United States Laser-Induced Plasma Micromachining Technical Publication. MSEC2010-34242 Kumar Pallav, Kornel F. Ehmann, Northwestern University, Evanston, IL, United States
21-2 STUDENT MANUFACTURING DESIGN COMPETITION - A Room 170B 1:30pm3:00pm

Session Chair: Cedric Xia, Ford Motor Company, Dearborn, MI, United States See page 4 for more information

7-2 MACHINING AND GRINDING 2 Room 160A 3:30pm5:00pm

Session Chair: Anil Srivastava, TechSolve, Inc., Cincinnati, OH, United States Session Co-Chair: Samuel S. Huang, University of Cincinnati, Cincinnati, OH, United States Toward Data-Driven Sustainable Machining: Combining MTConnect Production Data and Discrete Event Simulation Technical Publication. MSEC2010-34178 Nils Bengtsson, PMC, Gothenburg, Sweden, John Michaloski, Frederick Proctor, NIST, Gaithersburg, MD, United States, Sid Venkatesh, Boeing, Seattle, WA, United States, Guodong Shao, NIST, Gaithersburg, MD, United States Emergent Structure Detection for Multiaxis Machining Technical Publication. MSEC2010-34329 Joseph Petrzelka, Massachusetts Institute of Technology, Cambridge, MA, United States, Matthew Frank, Iowa State University, Ames, IA, United States A Sequential Greedy Search Algorithm with Bayesian Updating for Testing in High-Speed Milling Operations Technical Publication. MSEC2010-34048 Mike Traverso, University of Illinois at UrbanaChampaign, Urbana, IL, United States, Raul Zapata, Jaydeep Karandikar, Tony Schmitz, University of Florida, Gainesville, FL, United States, Ali Abbas, University of Illinois at Urbana-Champaign, Urbana, IL, United States Tool Wear Analysis on Dual- and Triple-Layer-Coated Carbide Tool in Face Milling of AISI 1045 Steel Technical Publication. MSEC2010-34066 Kyunghee Park, Patrick Kwon, Michigan State University, East Lansing, MI, United States
16
Technical Program


9-3 ELECTRICAL ASSISTED FORMING AND ULTRASONIC ASSISTED FORMING Room 160B 3:30pm5:00pm
Session Chair: Fadi Abu-Farha, Penn State Erie, Erie, PA, United States Session Co-Chair: Hua-Chu Shih, United States Steel Corporation, Troy, MI, United States Modeling and Quantification of the Electroplastic Effect When Bending Stainless Steel Sheet Metal Technical Publication. MSEC2010-34043 Wesley A. Salandro, Cristina Bunget, Laine Mears, Clemson University, Greenville, SC, United States A Process Comparison of Simple Stretch Forming Using both Conventional and Electrically Assisted Forming Techniques Technical Publication. MSEC2010-34144 Joshua J. Jones, Clemson University International Center for Automotive Research, Greenville, SC, United States, Laine Mears, Clemson University, Greenville, SC, United States Micropin Extrusion of Metallic Materials Assisted by Ultrasonic Vibration Technical Publication. MSEC2010-34159 Zhehe Yao, Gap-Yong Kim, LeAnn Faidley, Qingze Zou, Iowa State University, Ames, IA, United States, Deqing Mei, Zichen Chen, Zhejiang University, Hangzhou, China Effect of Severe Prior Deformation on ElectricalAssisted Compression of Copper Specimens Technical Publication. MSEC2010-34276 Michael Siopis, Brad Kinsey, University of New Hampshire, Durham, NH, United States, Nithyanand Kota, O. Burak Ozdoganlar, Carnegie Mellon University, Pittsburgh, PA, United States Tribological Aspects in Electrically Assisted Forming Technical Publication. MSEC2010-34249 Cristina Bunget, International Center for Automotive Research, Clemson University, Greenville, SC, United States, Wesley A. Salandro, Laine Mears, Clemson University, Greenville, SC, United States
10-3 MACHINING Room 160C
3:30pm5:00pm
Session Chair: John Ziegert, Clemson University, Greenville, SC, United States Session Co-Chair: Ihab Ragai, Hitachi Construction Truck Manufacturing Ltd., Guelph, ON, Canada Prediction the Effect of Vibration on Machining Distortion in High-Speed Milling Aeronautical Monolithic Components Technical Publication. MSEC2010-34091 Qinghua Song, Xing Ai, Z. Q. Liu, Shandong University, Jinan, Shandong Province, China Study on the Influence of Different Tool Edge Radius on Milling Ti6Al4V Technical Publication. MSEC2010-34118 Yueping Liu, Jianfeng Li, Jie Sun, Feng Jiang, Shandong University, Jinan, Shandong, China Experimental Investigation of Interactions between Abrasive Tool and Workpiece in Honing Technical Publication. MSEC2010-34122 Qiang Feng, C. Z. Ren, Yong Zhao, Tianjin University, Tianjin, Tianjin, China, Z. J. Pei, Kansas State University, manhattan, KS, United States New Advances in the Machining of Hard Metals using Physics-Based Modeling Technical Presentation Only. MSEC2010-34165 Troy Marusich, Third Wave Systems, Minneapolis, MN, United States Dimension Error in the Presence of Process and Machine Error in End Milling Technical Publication. MSEC2010-34229 Hao Ning Chiang, J. J. Wang, National Cheng Kung University, Tainan, Taiwan, Fu-Chuan Hsu, Metal Industries Research & Development Centre (MIRDC), Kaohsiung, Taiwan, Yu Ju Li, National Cheng Kung University, Taichung, R.O.C., Taiwan
17

Symposium Organizer: Wenwu Zhang, GE GRC, Schenectady, NY, United States Symposium Co-Organizer: Gary J. Cheng, Purdue University, West Lafayette, IN, United States, Ritesh Lakhkar, Caterpillar Inc., Peoria, IL, United States

11-2 LASER INDUCED PLASTIC DEFORMATION Room 170A 3:30pm5:00pm

Session Chair: Benxin Wu, Illinois Institute of Technology, Chicago, IL, United States Session Co-Chair: Ji Li, Purdue University, West Lafayette, IN, United States Finite Element Analysis of the Effect of Overlapping Impacts of Laser Shock Peening within Annealed AISI 1053 Steel Technical Publication. MSEC2010-34164 Rohit Voothaluru, C. Richard Liu, Purdue University, West Lafayette, IN, United States Formability of Open-Cell Aluminum Foams by Laser Technical Publication. MSEC2010-34282 Loredana Santo, Alessandro Guglielmotti, Fabrizio Quadrini, University of Rome Tor Vergata, Rome,Italy Nucleation of Highly Dense Nanoscale Precipitates Based on an Innovative Process: Warm Laser Shock Peening Technical Publication. MSEC2010-34297 Yiliang Liao, Chang Ye, Gary J. Cheng, Purdue University, West Lafayette, IN, United States Fatigue Performance Improvement by Dynamic Strain Aging and Dynamic Precipitation in Warm Laser Shock Peening of AISI 4140 Steel Technical Publication. MSEC2010-34301 Chang Ye, Gary J. Cheng, Purdue University, West Lafayette, IN, United States
21-3 STUDENT MANUFACTURING DESIGN COMPETITION - B Room 170B 3:30pm5:00pm

Session Chair: Cedric Xia, Ford Motor Company, Dearborn, MI, United States See page 4 for more information

21-6 MED MEMBERSHIP MEETING Room 160A 5:15pm6:15pm

Session Chair: Y. Lawrence Yao, Columbia University, New York, NY, United States
21-18 PENN STATE BEHREND TOURS 2 5:15pm6:15pm


21-8 NAMRC MEMBERSHIP MEETING Room 160A 6:15pm7:15pm


21-21 MANUFACTURING ENGINEERING AWARDS BANQUET West Ballroom 7:15pm10:00pm

18
Technical Program
THURSDAY, OCTOBER, 14 SYMP 21 Conference Events

SYMP 6 Advances of Abrasive Machining in Semiconductor Industry

Symposium Organizer: Zhichao (Zinc) Li, North Carolina Agricultural & Technical State University, Greensboro, NC, United States Symposium Co-Organizer: Xiaohong (Tina) Zhang, Seagate Technology LLC, USA, Bloomington, MN, United States
21-9 PLENARY PANEL - STRATEGIES TO REDUCE THE TRANSPORTATION SECTORS ENERGY CONSUMPTION West Ballroom 8:00am9:00am
6-1 ADVANCES OF ABRASIVE MACHINING IN SEMICONDUCTOR INDUSTRY Room 160B 9:15am10:15am

Session Chair: Zhichao (Zinc) Li, North Carolina Agricultural & Technical State University, Greensboro, NC, United States Session Co-Chair: Liang Zhou, University of Michigan, Ann Arbor, MI, United States, Xiaohong (Tina) Zhang, Seagate Technology LLC, USA, Bloomington, MN, United States Simulation Model for the Shape Error Estimation during Machining with Flat Lapping Kinematics Technical Publication. MSEC2010-34262 Mariusz Deja, Gdansk University of Technology, Gdansk, Gdansk, Poland Wear of a Tool in Double-Disk Lapping of Silicon Wafers Technical Publication. MSEC2010-34323 Mariusz Deja, Adam Barylski, Gdansk University of Technology, Gdansk, Gdansk, Poland Drilling of Silicon-Based Solar Panels: A Review Technical Publication. MSEC2010-34324 Weilong Cong, Qiang Feng, Z. J. Pei, Kansas State University, Manhattan, KS, United States
SYMP 1 Manufacturing with Soft Materials

Symposium Organizer: Donggang Yao, Georgia Institute of Technology, Atlanta, GA, United States Symposium Co-Organizer: Daniel Tsai, Novana, Inc., Alpharetta, GA, United States
1-1 MANUFACTURING WITH SOFT MATERIALS I Room 170B 9:15am10:15am

Session Chair: Shing-Chung Wong, University of Akron, Akron, OH, United States Session Co-Chair: Daniel Tsai, Novana, Inc., Alpharetta, GA, United States Processing of Nanodiamond Loaded Poly(Lactic Acid) Co-Continuous Porous Structures Technical Publication. MSEC2010-34181 Wei Zhang, Tom Wyatt, Georgia Institute of Technology, Atlanta, GA, United States, Qingwei Zhang, Drexel University, Philadelphia, PA, United States, Donggang Yao, Georgia Institute of Technology, Atlanta, GA, United States, Jack G. Zhou, Drexel University, Philadelphia, PA, United States Soft Biomaterial Study for 3-D Tissue Scaffold Printing Technical Publication. MSEC2010-34274 Chris G. Geisler, Ho-Lung Li, Drexel University, Philadelphia, PA, United States, David M. Wootton, Cooper Union, New York, NY, United States, Peter I. Lelkes, Jack G. Zhou, Drexel University, Philadelphia, PA, United States Instantaneous Phase Separation at the Contact Surface in Compression Molding of Immiscible Polymer Blends Technical Publication. MSEC2010-34183 Wei Zhang, Min Li, Sarang Deodhar, Donggang Yao, Georgia Institute of Technology, Atlanta, GA, United States, Jack G. Zhou, Drexel University, Philadelphia, PA, United States
SYMP 8 Green Energy System Manufacturing

Symposium Organizer: Jeffrey Abell, General Motors, Warren, MI, United States Symposium Co-Organizer: Hui Wang, University of Michigan, Ann Arbor, MI, United States
8-1 MANUFACTURING PROCESS FOR GREEN ENERGY SYSTEM Room 160A 9:15am10:15am
Session Chair: Jeffrey Abell, General Motors, Warren, MI, United States Session Co-Chair: Tae Hyung Kim, University of Michigan, Ann Arbor, MI, United States Benchmarking of High-Capacity Battery Module/Pack Design for Automatic Assembly System Technical Publication. MSEC2010-34114 Sha Li, Hui Wang, University of Michigan, Ann Arbor, MI, United States, Yhu-tin Lin, Jeffrey Abell, General Motors, Warren, MI, United States, Jack Hu, University of Michigan, Ann Arbor, MI, United States
19
Thursday, October 14
Joining Technologies for Automotive Lithium-Ion Battery Manufacturing: A Review Technical Publication. MSEC2010-34168 S. Shawn Lee, Tae Hyung Kim, Jack Hu, University of Michigan, Ann Arbor, MI, United States, Wayne Cai, Jeffrey Abell, General Motors, Warren, MI, United States Product And Process Characteristics For Manufacturing: Evidence From Indian SMES Technical Publication. MSEC2010-34077 Perminderjit Singh, PEC University of Technology,(Formely Punjab Engineering College), Chandigarh, India, K.S. Sangwan, Birla Institute of Technology & Science, Pilani, Rajasthan, India Green
SYMP 16 Data Driven Manufacturing

Symposium Organizer: Athulan Vijayaraghavan, System Insights, Berkeley, CA, United States Symposium Co-Organizer: David Dornfeld, University of California-Berkeley, Berkeley, CA, United States
16-1 DATA DRIVEN MANUFACTURING Room 160C 9:15am10:15am

Session Chair: Jun Zhou, Penn State Erie, The Behrend College, Erie, PA, United States Session Co-Chair: Yong Huang, Clemson University, Clemson, SC, United States Reproduction of Lustrous Object and Cutter Location Using the Normal Vector-Generated by Photometric Stereo Method Technical Publication. MSEC2010-34124 Seishi Nakamura, Doshisha University, Kyotanabe, Kyoto, Japan, Toshiki Hirogaki, Eiichi Aoyama, Doshisha University, Kyotanabe-shi, Japan, Hiromichi Nobe, Mifuji Kikai Seisakusho, Ltd., Gunma, Japan Cutting Condition Decision Methodology Based on Data-Mining of Tool Catalog Data Technical Publication. MSEC2010-34199 Hiroyuki Kodama, Doshisha University, Kyoto, Japan, Toshiki Hirogaki, Doshisha University, Kyotanabe-shi, Japan, Keiji Ogawa, The University of Shiga Prefecture, Hikone-shi, Japan, Eiichi Aoyama, Doshisha University, Kyotanabe-shi, Japan Transient Analysis of Downtime Event in Manufacturing Systems Technical Publication. MSEC2010-34254 Qing Chang, New York Institute of Technology, Old Westbury, NY, United States, Jianbo Liu, Michigan State University, East Lansing, MI, United States, Stephan Biller, Guoxian Xiao, General Motors Research and Development Center, Warren, MI, United States
Effects of Ultrasonic Treatments on Cellulose in Cellulosic Biofuel Manufacturing: A Literature Review Technical Publication. MSEC2010-34180 Pengfei Zhang, Z. J. Pei, Kansas State University, Manhattan, KS, United States
SYMP 14 Sustainable Nanomanufacturing

Symposium Organizer: Karl R. Haapala, Oregon State University, Corvallis, OR, United States Symposium Co-Organizer: Brian K. Paul, Oregon State University, Corvallis, OR, United States, Wenwu Zhang, GE GRC, Schenectady, NY, United States
14-1 SUSTAINABLE NANOMANUFACTURING Room 170A 9:15am10:15am

Session Chair: Fu Zhao, Purdue University, West Lafayette, IN, United States Session Co-Chair: Samved Bhatnagar, Sandvik Mining and Construction LLC, Shenendoah, TX, United States Addressing Uncertainty in the Environmental Analysis of Nickel Nanoparticle Production Technical Publication. MSEC2010-34251 Malcolm O. Brown, Karl R. Haapala, Brian K. Paul, Oregon State University, Corvallis, OR, United States, Richard D. Glover, James E. Hutchison, University of Oregon, Eugene, OR, United States Three-Dimensional Simulation of Cross-Flow Microfilter Fouling in Tortuous Pore Profiles with Semi-Synthetic Metalworking Fluids Technical Publication. MSEC2010-34269 Bingyi Yu, Shiv G. Kapoor, Richard E. DeVor, University of Illinois at Urbana-Champaign, Champaign, IL, United States Fabrication of Nanoporous Ni-Zr Anode for Solid Oxide Fuel Cells by Electrochemical Method Technical Publication. MSEC2010-34225 Surya Pothula, Yong Gan, University of Toledo, Toledo, OH, United States

Symposium Organizer: Donggang Yao, Georgia Institute of Technology, Atlanta, GA, United States Symposium Co-Organizer: Daniel Tsai, Novana, Inc., Alpharetta, GA, United States
1-2 MANUFACTURING WITH SOFT MATERIALS II Room 170B 10:30am11:30am

Session Chair: Jack G. Zhou, Drexel University, Philadelphia, PA, United States Session Co-Chair: Donggang Yao, Georgia Institute of Technology, Atlanta, GA, United States Manufacturing Ultrafine Filaments by Cold Air Attenuation Technical Publication. MSEC2010-34330 Jun Jia, Donggang Yao, Youjiang Wang, Georgia Institute of Technology, Atlanta, GA, United States
20
Technical Program
Biomimetic Design, Modeling, and Manufacturing of Chitosan/Gelatin Scaffolds for 3D Vascularized Liver Tissue Construct Technical Publication. MSEC2010-34277 Haibo Gong, Qingwei Zhang, Peter I. Lelkes, Jack G. Zhou, Drexel University, Philadelphia, PA, United States, Dichen Li, Xian Jiaotong University, Xian, China Multifunctional Behavioral Analysis of Al-SiC Metal Matrix Composite Foam Produced by (TiH2CaCO3) Dual Foaming Agent Technical Publication. MSEC2010-34258 Vinay Sharma, Joyjeet Ghose, Surender Kumar, Birla Institute of Technology, Ranchi, India
SYMP 15 Advances in Pervasive Sensing and Computing for Manufacturing Systems

Symposium Organizer: Qing Cao, GE Global Research, Niskayuna, NY, United States Symposium Co-Organizer: Abhijit Deshmukh, Texas A&M University, College Station, TX, United States
15-1 SENSOR DATA ACQUISITION, ANALYSIS AND WIRELESS COMMUNICATION Room 160B 10:30am11:30am
Session Chair: Kevin Chou, University of Alabama, Tuscaloosa, AL, United States Session Co-Chair: Jun Zhou, Penn State Erie, The Behrend College, Erie, PA, United States Spatial Blending Functions for Improved Estimation of Contact Pressure Distribution at the ToolWorkpiece Interface Technical Publication. MSEC2010-34107 Sripati Sah, Timothy Kurp, Robert Gao, University of Connecticut, Storrs, CT, United States Wireless Acquisition of Temperature Data from PCBN Embedded Thin-Film Sensors Technical Publication. MSEC2010-34177 Anshuman Guha, Xiaochun Li, Dirk Werschmoeller, University of Wisconsin-Madison, Madison, WI, United States Transmissibility of 802.15.1Compliant Radio in Machining Enclosures in Industrial Environments Technical Publication. MSEC2010-34192 Richard Sowles, Heidenhain Corporation, Jamestown, NY, United States, Derek A. Suen, David Loker, John T. Roth, Penn State Erie, The Behrend College, Erie, PA, United States

Symposium Organizer: Wenwu Zhang, GE GRC, Schenectady, NY, United States Symposium Co-Organizer: Gary J. Cheng, Purdue University, West Lafayette, IN, United States, Ritesh Lakhkar, Caterpillar Inc, Peoria, IL, United States
11-3 LASER ENGINEERED FUNCTIONAL SURFACES Room 170A 10:30am11:30am

Session Chair: Jun Zhou, Penn State Erie, The Behrend College, Erie, PA, United States Session Co-Chair: Huang Gao, Purdue University, West lafayette, IN, United States Characterization and Prediction of Texture in Laser Annealed NiTi Shape Memory Thin Films Technical Publication. MSEC2010-34250 Gen Satoh, Columbia University, New York, NY, United States, Xu Huang, Ainissa Ramirez, Yale University, New Haven, CT, United States, Y. Lawrence Yao, Columbia University, New York, NY, United States Improving Biocompatibily of Laser Micromachined Silicon Wafer by Surface Coating with Poly(Ethylene Glycol) Diacrylate and Diamondlike Carbon for Biomedical Devices Technical Publication. MSEC2010-34283 Yuan-Shin Lee, North Carolina State University, Raleigh, NC, United States Laser Coating of HAp/Ti Nanoparticles on Metal Implants: Interfacial Bonding Strength, Chemical Analysis and Biocompatibility Technical Publication. MSEC2010-34295 Martin Y. Zhang, Gary J. Cheng, Purdue University, West Lafayette, IN, United States
21
SYMP 18 Advances in Biomanufacturing

Symposium Organizer: Wei Li, University of Washington, Seattle, WA, United States Symposium Co-Organizer: Biaoyang Lin, Swedish Neuroscience Institute, Seattle, WA, United States, Binil Starly, University of Oklahoma, Norman, OK, United States

18-1 ADVANCES IN BIOMANUFACTURING Room 160A 10:30am11:30am

Session Chair: Scott Miller, University of Hawaii at Manoa, Honolulu, HI, United States Session Co-Chair: Yong Huang, Clemson University, Clemson, SC, United States Study of Double-Layered Microcapsule Formation in Compound Nozzle Jetting Technical Publication. MSEC2010-34127 Wei Wang, C. Leigh Herran, Nicole Coutris, Yong Huang, Clemson University, Clemson, SC, United States, Vladimir Mironov, Roger R. Markwald, Medical University of South Carolina, Charleston, SC, United States Synchronous Polygon Turning for Implant Manufacturing Technical Publication. MSEC2010-34246 Frank Chuang, Ko-Yu Lin, Yuheng Chen, National Chung-Hsing University, Taichung, Taiwan A Perfused Two-Chamber System for Anticancer Drug Screening Technical Publication. MSEC2010-34326 Liang Ma, Wei Li, Jeremy Barker, Changchun Zhou, University of Washington, Seattle, WA, United States, Biaoyang Lin, Swedish Neuroscience Institute, Seattle, WA, United States
21-22 LUNCH + INVITED TALK JACK MCDOUGLE, U.S. COUNCIL ON COMPETITIVENESS West Ballroom 11:45am12:30pm

21-10 PLENARY PANEL - NEXT-GENERATION COMPOSITES AND TEXTILES FOR TRANSPORTATION VEHICLES West Ballroom 12:30pm1:30pm

3-2 ADVANCES IN NONTRADITIONAL MANUFACTURING 2 Room 170B 1:45pm3:15pm

Session Chair: Anil Srivastava, TechSolve, Inc., Cincinnati, OH, United States Session Co-Chair: Z. J. Pei, Kansas State University, Manhattan, KS, United States Comparison of Superabrasive Tools in Rotary Ultrasonic Machining of Stainless Steel Technical Publication. MSEC2010-34154 Weilong Cong, Qiang Feng, Z. J. Pei, Kansas State University, Manhattan, KS, United States Effects of Tool Design on Edge Chipping in UltrasonicVibration-Assisted Grinding Technical Publication. MSEC2010-34182 Na Qin, Z. J. Pei, Weilong Cong, Kansas State University, Manhattan, KS, United States, D. M. Guo, Dalian University of Technology, Dalian, China
22
Technical Program
Digital Manufacturing of Makyoh-Magic-Mirror for Difficult-to-Machine Material to Process Technical Publication. MSEC2010-34203 Kazuya Sawa, Doshisha University, Kyoutanabe, Kyoto, Japan, Eiichi Aoyama, Toshiki Hirogaki, Kazuya Okubo, Doshisha University, Kyotanabe, Kyoto, Japan, Keiji Ogawa, The University of Shiga Prefecture, Hikone-shi, Japan A Study on Ultrasonic Elliptical Vibration Cutting of Hardened Steel Using PCD Tools Technical Publication. MSEC2010-34239 Xinquan Zhang, National University of Singapore, Singapore, Singapore, Chandra Nath, Singapore Institute of Manufacturing Technology, Singapore, Singapore, A. Senthil Kumar, Mustafizur Rahman, National University of Singapore, Singapore, Singapore, Kui Liu, Singapore Institute of Manufacturing Technology, Singapore, Singapore Deburring of Microscale Structures Machined in Milling Technical Publication. MSEC2010-34149 Takashi Matsumura, Tsuyoshi Konno, Shouta Tobe, Tokyo Denki University, Tokyo, Tokyo, Japan, Takafumi Komatsu, Komatsu Seiki Kosakusho Co., Ltd., Suwa, Nagano, Japan On Predicting Residual Stress and Chip Morphology in Prestressed Hard Turning Technical Publication. MSEC2010-34072 Heping Wang, Shenfeng Wu, Xueping Zhang, Shanghai Jiao Tong University, Shanghai, China, C. Richard Liu, Industry Engineering, Purdue University, West Lafayette, IN, United States Predicting the Effects of Nose Radius and Tool Lead Angle on Hard Turning Process Using 3D Finite Element Method Technical Publication. MSEC2010-34129 Xueping Zhang, Heping Wang, Shanghai Jiao Tong University, Shanghai, China, C.Richard Liu, Industry Engineering, Purdue University, West Lafayette, IN, United States Multiphase FE Model for Machining Inconel 718 Technical Publication. MSEC2010-34233 Yu Long, Changsheng Guo, United Technologies Research Center, East Hartford, CT, United States, Santosh Ranganath, Ronald Talarico, Pratt and Whitney, East Hartford, CT, United States

SYMP 5 Surface Integrity and Performance of Components by Multiscale Mfg

Symposium Organizer: Y. B. Guo, University of Alabama, Tuscaloosa, AL, United States Symposium Co-Organizer: Z. Q. Liu, Shandong University, Jinan, Shandong Province, China, Changsheng Guo, United Technologies Research Center, East Hartford, CT, United States
7-3 SENSING AND MONITORING 1 Room 160A 1:45pm3:15pm

Session Chair: Patrick Kwon, Michigan State University, East Lansing, MI, United States Session Co-Chair: Radu Pavel, TechSolve, Inc., Cincinnati, OH, United States Measurement of Tool Internal Temperatures in the ToolChip Contact Region by Embedded Thin-Film Microthermocouples Technical Publication. MSEC2010-34176 Dirk Werschmoeller, Xiaochun Li, University of Wisconsin-Madison, Madison, WI, United States On-Line Monitoring of End Milling Forces Using a ThinFilm-Based Wireless Sensor Module Technical Publication. MSEC2010-34272 Lei Ma, Shreyes N. Melkote, John Morehouse, Georgia Institute of Technology, Atlanta, GA, United States, James Castle, James Fonda, The Boeing Company, St. Louis, MO, United States
5-1 NUMERICAL SIMULATIONS OF SURFACE INTEGRITY AND PERFORMANCE Room 170A 1:45pm3:15pm
Session Chair: Z. Q. Liu, Shandong University, Jinan, Shandong Province, China Session Co-Chair: Yu Long, United Technologies Research Center, East Hartford, CT, United States Predicting the Effects of Rake Angle, Cutting Speed, and Feed Rate on Chip Morphology in Hard Turning Technical Publication. MSEC2010-34071 Shenfeng Wu, Xueping Zhang, Shanghai Jiao Tong University, Shanghai, China, C. Richard Liu, Industry Engineering, Purdue University, West Lafayette, IN, United States
23
The Effects of Emissivity and Camera Point-Spread Function on the Temperature Measurement of Segmented Chip Formation Using Infrared Thermography Technical Publication. MSEC2010-34275 Jarred Heigel, KT Consulting, Inc., Lexington, KY, United States, Eric Whitenton, National Institute of Standards and Technology, Gaithersburg, MD, United States A Novel Sensor Using Tool Coating and Its Substrate as Thermocouple to Measure Cutting Temperatures Technical Publication. MSEC2010-34027 Shijun Zhang, Z. Q. Liu, Shandong University, Jinan, Shandong, China

10-4 NONTRADITIONAL PROCESSES Room 160C 1:45pm3:15pm

Session Chair: Ihab Ragai, Hitachi Construction Truck Manufacturing Ltd., Guelph, ON, Canada Session Co-Chair: Arif Malik, Saint Louis University, St. Louis, MO, United States Virtual 3D Model Simulation for Design and Implementation of Automated Processes Technical Publication. MSEC2010-34089 Richard Chiou, Drexel University, Philadelphia, PA, United States, Yongjin Kwon, Sang C. Park, Ajou University, Suwon, Korea (Republic), Robin Kizirian, Yueh-Ting Yang, Matthew Dordai, Drexel University, Philadelphia, PA, United States Effects of Airflow, Draw Temperature, and Boundary Conditions on Hardening in Ice Cream Manufacturing Technical Publication. MSEC2010-34104 Nicholas Rauth, Mark Miller, X. J. Xin, Z. J. Pei, Karen Schmidt, Kansas State University, Manhattan, KS, United States Simulation of Diamond Disk Conditioning in Chemical Mechanical Polishing: Effects of Conditioning Parameters on Pad Surface Shape Technical Publication. MSEC2010-34264 Emmanuel Baisie, Zhichao (Zinc) Li, North Carolina Agricultural & Technical State University, Greensboro, NC, United States, Xiaohong (Tina) Zhang, Seagate Technology LLC, USA, Bloomington, MN, United States A Review of Modeling in Pelleting of Cellulosic Biomass Technical Publication. MSEC2010-34201 Na Qin, Z. J. Pei, Kansas State University, Manhattan, KS, United States

9-4 FORMABILITY AND FRACTURE CRITERIA Room 160B 1:45pm3:15pm

Session Chair: Brad Kinsey, University of New Hampshire, Durham, NH, United States Session Co-Chair: Cedric Xia, Ford Motor Company, Dearborn, MI, United States The Effects of AHSS Shear Edge Conditions on Edge Fracture Technical Publication. MSEC2010-34062 Hua-Chu Shih, Constantin Chiriac, Ming Shi, United States Steel Corporation, Troy, MI, United States Ductility Enhancement in Pulsed Uniaxial Tension of Stainless Steel 304 Technical Publication. MSEC2010-34160 Graham W. Cullen, Yannis Korkolis, University of New Hampshire, Durham, NH, United States Practical Methods Used for Determination of Elastic Characteristics of Gypsum Materials Technical Publication. MSEC2010-34167 Petru A. Pop, Patricia A. Ungur, Liviu Lazar, Florin M. Marcu, University of Oradea, Oradea, Bihor, Romania In Pursuit of an Integrated Methodology for Accurate Elevated Temperature and Superplastic Tensile Testing Technical Publication. MSEC2010-34284 Fadi Abu-Farha, Joshua Sabo, Craig Herring, Penn State Erie, Erie, PA, United States
24
Technical Program

21-1 POSTER SESSION Lobby of Convention Center
1:45pm3:15pm
Surface Generation of Hard Brittle Materials by Polishing with Closed Link Compact Machine Poster. MSEC2010-34355 Shinpei Okumura, Toshiki Hirogaki, Eiichi Aoyama, Doshisha University, Kyotanabe-shi, Kyoto, Japan, Keiji Ogawa, The University of Shiga Prefecture, Hikone-shi, Japan, Yoshiaki Onchi, Mizuho Co., Ltd., Osaka, Japan, Sachiko Ogawa, Doshisha University, Kyotanabe, Japan Integrating Lightweight Materials - Component Manufacture in Titanium Poster. MSEC2010-34337 Mathew Kuttolamadom, Joshua J. Jones, Clemson University International Center for Automotive Research, Greenville, SC, United States, Laine Mears, John Ziegert, Clemson University, Greenville, SC, United States, Thomas R. Kurfess, Clemson University - International Center for Automotive Research, Greenville, SC, United States Sinter Joining in Metal Injection Molding (MIM) Poster Presentation Only. MSEC2010-34339 Thomas Martens, Laine Mears, Clemson University, Greenville, SC, United States An Electrically Activated Silver-Based Antibacterial Surface System Poster. MSEC2010-34346 Rohan Shirwaiker, Richard Wysk, Robert Voigt, The Pennsylvania State University, University Park, PA, United States Investigation of the Effect of Cutting Tool Coatings on Temperature Distribution in Orthogonal Metal-Cutting Processes by Using Finite Element Modeling Poster. MSEC2010-34351 Kamuran Yesilkaya, Tubitak Defense Industries Research And Development Institute, Ankara, Turkey Development of Self-Adhesive Bamboo Fiber Composite with Three-Dimensional Shape Using Fibers Extracted with Machining Center Poster. MSEC2010-34356 Sachiko Ogawa, Doshisha University, Kyotanabe, Japan, Keiji Ogawa, The University of Shiga Prefecture, Hikone-shi, Japan, Toshiki Hirogaki, Eiichi Aoyama, Mitsuaki Taniguchi, Doshisha University, Kyotanabe, Kyoto, Japan, Hiromichi Nobe, Mifuji Kikai Seisakusho, Ltd., Gunma, Japan
Session Chair: Yong Huang, Clemson University, Clemson, SC, United States Session Co-Chair: Kevin Chou, University of Alabama, Tuscaloosa, AL, United States Use-Phase Energy Impact of Two Toasters: Toward Sustainable Selective Disassembly Planning Poster. MSEC2010-34336 Raghunathan Srinivasan, Gaurav Ameta, Washington State University, Pullman, WA, United States Ultrasonic Vibration-Assisted Pelleting of Cellulosic Biomass For Bioethanol Manufacturing Poster. MSEC2010-34342 Pengfei Zhang, Qiang Feng, Eric Zinke, Weilong Cong, Meng Zhang, Xiaoxu Song, Qi Zhang, Z. J. Pei, Donghai Wang, Kansas State University, Manhattan, KS, United States A Thermally Activated Modular SPM Probe Multifunctional Applications Poster. MSEC2010-34344 Bijoyraj Sahu, Curtis Taylor, University of Florida, Gainesville, FL, United States, Kam K. Leang, Robert Riddle, University of NevadaReno, Reno, NV, United States for
Fundamental Study on Size Reduction of Poplar for Biofuel Manufacturing Poster. MSEC2010-34352 Meng Zhang, Xiaoxu Song, Pengfei Zhang, Qi Zhang, Emily Jones, Timothy W. Deines, Z. J. Pei, Donghai Wang, Kansas State University, Manhattan, KS, United States Manufacturing-Line Design with Product-ChangeDependent Intertask Times Poster. MSEC2010-34353 Jeonghan Ko, Ehsan Nazarian, University of NebraskaLincoln, Lincoln, NE, United States
25
Sizing the Cryogenic Conditioning on the Young Modulus and CTE Properties In Case of Polymeric Multiphase Composites Poster. MSEC2010-34340 Dana Luca Motoc, Transilvania University of Brasov, Brasov,Romania, Petru A. Pop, University of Oradea, Oradea, Bihor, Romania, Gheorghe Bejinaru, Transilvania University of Brasov, Brasov, Romania Algorithms to Calculate Orientations of Fibers in LFRT Poster. MSEC2010-34343 Petru A. Pop, University of Oradea, Oradea, Bihor,Romania, Juan Lopez Martinez, Polytechnic University of Valencia, Alcoy, Alicante, Spain, Flavius Ardelean, University of Oradea, Oradea, Bihor, Romania, Santiago Ferrandiz Bou, Polytechnic University of Valencia, Alcoy, Spain The Influence of Substrate Surface Pretreatments on the Adhesion of Diamond-Coated Cutting Tools Poster. MSEC2010-34354 Humberto Gomez, University of South Florida, Tampa, FL, United States, Kevin Chou, University of Alabama, Tuscaloosa, AL, United States, Xingcheng Xiao, General Motors Corporation, Warren, MI, United States, Robert Johnson, Seki Technotron USA, Santa Clara, CA, United States, Ashok Kumar, University of South Florida, Tampa, FL, United States Manufacture of Aerospace Components with Pressure Welding Poster. MSEC2010-34338 Ho-Sung Lee, Jong-Hoon Yoon, Y. M. Yi, Korea Aerospace Research Institute, Daejeon, Korea (Republic) Material Property Determination Meso- and Microscale Bulge Test Poster. MSEC2010-34335 Richard Jones, Jr., University of Louisiana at Lafayette, New Iberia, LA, United States, William Emblom, Univeristy of Louisiana at Lafayette, Lafayette, LA, United States The Design and Production of a Reusable Friction Stir Welding (FSW) Tool Poster Presentation Only. MSEC2010-34341 Christopher Murosky, Michael A. Ragen, Penn State Behrend, Erie, PA, United States Multifuncitional Behavioral Analysis of Al-SiC Metal Matrix Composite Foam Produced by (TiH2CaCO3) Dual Foaming Agent Poster. MSEC2010-34345 Joyjeet Ghose, Vinay Sharma, Surender Kumar, Birla Institute of Technology, Ranchi, Jharkhand, India

3-3 ADVANCES IN NONTRADITIONAL MANUFACTURING 3 Room 170B 3:30pm5:00pm

Session Chair: Gap-Yong Kim, Iowa State University, Ames, IA, United States Session Co-Chair: Wenwu Zhang, GE GRC, Schenectady, NY, United States Ultrasonic Vibration-Assisted Pelleting of Cellulosic Biomass: Effects of Moisture Content Technical Publication. MSEC2010-34172 Xiaoxu Song, Meng Zhang, Z. J. Pei, Timothy Deines, Kansas State University, Manhattan, KS, United States Ultrasonic Vibration-Assisted Pelleting of Sorghum: Effects of Pressure and Ultrasonic Power Level Technical Publication. MSEC2010-34173 Qi Zhang, Timothy W. Deines, Donghai Wang, Xiaorong Wu, Graham Pritchett, Z. J. Pei, Pengfei Zhang, Kansas State University, Manhattan, KS, United States Ultrasonic Vibration-Assisted Pelleting of Biomass: A Designed Experimental Investigation on Pellet Quality and Sugar Yield Technical Publication. MSEC2010-34179 Pengfei Zhang, Daniel Nottingham, Timothy W. Deines, Donghai Wang, Xiaorong Wu, Z. J. Pei, Kansas State University, Manhattan, KS, United States Effects of Operating Conditions on Thin-Film Deposition Performance in Air Atomizing Spray Pyrolysis Technical Publication. MSEC2010-34128 Changxue Xu, Yong Huang, Yafu Lin, Clemson University, Clemson, SC, United States
26
Technical Program


7-4 SENSING AND MONITORING 2 Room 160A 3:30pm5:00pm

Session Chair: Shreyes N. Melkote, Georgia Institute of Technology, Atlanta, GA, United States Session Co-Chair: Jarred Heigel, KT Consulting, Inc., Lexington, KY, United States Condition Monitoring with Round Ceramic Inserts While Face Milling Using Acceleration Data Technical Publication. MSEC2010-34188 Justin L. Milner, John T. Roth, Penn State Erie, The Behrend College, Erie, PA, United States Method for Evaluating Machining Tool-HolderSpindle Unbalance Due to Chips at the Tool-Holder Interface Technical Publication. MSEC2010-34232 John Agapiou, General Motros, R&D Center, Warren, MI, United States Short-Time Fourier Transform Method in AE Signal Analysis for Diamond Coating Failure Monitoring in Machining Applications Technical Publication. MSEC2010-34305 Ping Lu, Kevin Chou, University of Alabama, Tuscaloosa, AL, United States, Raymond Thompson, Vista Engineering, Birmingham, AL, United States Experimental Setup for Multisensor Fusion and Data Correlation Analysis during CNC Steel Turning Technical Publication. MSEC2010-34308 Manuel Hernandez, Andrew Joslin, Erick Deane, Schadrick Collins, Chengying Xu, University of Central Florida, Orlando, FL, United States, Don F. Wilson, Breakthrough Management Group International, Longmont, CO, United States Development of Sound-Based Tool Wear Monitoring System in Micromilling Technical Publication. MSEC2010-34240 Ming-Hsing Lee, Ming-Chyuan Lu, Jhy-Cherng Tsai, National Chung Hsing University, Taichung, Taiwan, Taiwan
10-5 FORMING, MACHINING, AND NONTRADITIONAL PROCESSES Room 160C 3:30pm5:00pm

Session Chair: Ihab Ragai, Hitachi Construction Truck Manufacturing Ltd., Guelph, ON, Canada Session Co-Chair: John Morehouse, Manufacturing Research Center, Georgia Institute of Technology, Atlanta, GA, United States Self-Consistent Model of Laminated Composites Technical Publication. MSEC2010-34029 Zhu Yiguo, Zhao Dan, Hu Ping, Dalian University of Technology, Dalian, China Forming Force Prediction in Two-Point Incremental Forming Using Backpropagation Neural Networks in Combination with Genetic Algorithms Technical Publication. MSEC2010-34142 M. Luisa Garcia-Romeu, University of Girona, Girona,Spain, Elisabetta Ceretti, Antonio Fiorentino, Universit degli Studi di Brescia, Brescia, Italy, Claudio Giardini, University of Bergamo, Dalmine, Bergamo, Italy Using an Airy Function to Predict Stresses in Wound Metal Strip Having Asymmetric Thickness Profile Technical Publication. MSEC2010-34162 Jantzen Hinton, Paul Gross, Kevin Hoos, Wright State University, Dayton, OH, United States, Arif Malik, Saint Louis University, St. Louis, MO, United States, Ramana Grandhi, Wright State University, Dayton, OH, United States
27

Symposium Organizer: Wenwu Zhang, GE GRC, Schenectady, NY, United States Symposium Co-Organizer: Gary J. Cheng, Purdue University, West Lafayette, IN, United States, Ritesh Lakhkar, Caterpillar Inc, Peoria, IL, United States

Symposium Organizer: Xinyu Liu, Lamar University, Beaumont, TX, United States Symposium Co-Organizer: Andrew Honegger, Microlution, Chicago, IL, United States, Hazim El-Mounayri, IUPUI, Indianapolis, IN, United States
11-4 LASER MATERIAL INTERACTIONS Room 170A 3:30pm5:00pm

Session Chair: Yuan-Shin Lee, North Carolina State University, Raleigh, NC, United States Session Co-Chair: Martin Y. Zhang, Purdue University, West Lafayette, IN, United States Nanosecond Laser Ablation of Silicon Carbide at Infrared Wavelength Technical Publication. MSEC2010-34110 Yibo Gao, Yun Zhou, Benxin Wu, Illinois Institute of Technology, Chicago, IL, United States Investigation on Porosity Formation in AA6082 Hybrid Laser-GMAW Welding Technical Publication. MSEC2010-34247 Alessandro Ascari, Alessandro Fortunato, University of Bologna, Bologna, Italy, Leonardo Orazi, University of Modena and Reggio Emilia, Reggio Emilia, Italy, Giampaolo Campana, Giovanni Tani, University of Bologna, Bologna, Italy Investigation of Fluid Flow and Heat Transfer in 3-D Dual Beam Laser Welding Technical Publication. MSEC2010-34252 Jun Zhou, Penn State Erie, The Behrend College, Erie, PA, United States, Hai-Lung Tsai, Missouri University of Science and Technology, Rolla, MO, United States A Dislocation Dynamics-Based Constitutive Model and Experimental Validations by 3D Microscale Laser Dynamic Forming of Metallic Thin Films Technical Publication. MSEC2010-34300 Huang Gao, Gary J. Cheng, Purdue University, West Lafayette, IN, United States
12-2 MICRO/MESO MECHANICAL MANUFACTURING (II) Room 160B 3:30pm5:00pm

Session Chair: Brad Kinsey, University of New Hampshire, Durham, NH, United States Session Co-Chair: Andrew Honegger, Microlution, Chicago, IL, United States Ultrahigh-Speed Micromachining Technical Publication. MSEC2010-34174 Said Jahanmir, Mohawk Innovative Technology, Inc., Albany, NY, United States Development of A Small Five-Axis Micromilling Center FOR Parts up to 100 mm in Diameter Technical Publication. MSEC2010-34221 Deepkishore Mukhopadhyay, Andrew Honegger, Abhinandan Tulsian, Andy Phillip, Elizabeth Creighton, Microlution Inc., Chicago, IL, United States Experimental Investigation of Micromilling Accuracy Using On-Machine Measurement System Technical Publication. MSEC2010-34245 Xinyu Liu, Lamar University, Beaumont, TX, United States An Investigation into Fixture Error Compensation in Micromilling Using Tool-Based Conductive Touch-Off Technical Publication. MSEC2010-34273 Jacob Kunz, J.Rhett Mayor, Angela Sodemann, Georgia Institute of Technology, Atlanta, GA, United States Machinability Study of SiC Nanoparticles Reinforced Magnesium Nanocomposites during Micromilling Processes Technical Publication. MSEC2010-34294 Juan Li, Jian Liu, Chengying Xu, University of Central Florida, Orlando, FL, United States

21-19 TOUR OF CUMMINS JAMESTOWN ENGINE PLANT 5:15pm8:00pm

28
Technical Program
FRIDAY, OCTOBER, 15 SYMP 21 Conference Events

Ice Crystallization in Ice Cream Manufacturing by Coupled Computational Fluid Dynamics and Population Balance Method Technical Publication. MSEC2010-34218 Mark Miller, X. J. Xin, Z. J. Pei, Karen Schmidt, Kansas State University, Manhattan, KS, United States Microquantity Internal Cooling (MQuIC) of Cutting Tools for Increased Productivity While Machining TI-6AL-4V Technical Publication. MSEC2010-34265 Samved Bhatnagar, Sandvik Mining and Construction LLC, Shenendoah, TX, United States, William J. Endres, Michigan Technological University, Houghton, MI, United States
21-11 PLENARY PANEL - IMPACT OF MANUFACTURING UNCERTAINTY ON COMMERCIALIZING INNOVATIONS IN TRANSPORTATION West Ballroom 8:00am9:00am
Session Chair: Robert Ivester, National Institute of Standards and Technology, Gaithersburg, MD, United States
SYMP 5 Surface Integrity and Performance of Components by Multiscale Manufacturing

Symposium Organizer: Y. B. Guo, University of Alabama, Tuscaloosa, AL, United States Symposium Co-Organizer: Z. Q. Liu, Shandong University, Jinan, Shandong Province, China, Changsheng Guo, United Technologies Research Center, East Hartford, CT, United States
SYMP 4 Thermally Enhanced Processes and Materials

Symposium Organizer: Frank Pfefferkorn, University of Wisconsin-Madison, Madison, WI, United States Symposium Co-Organizer: Jay C. Rozzi, Creare Inc., Hanover, NH, United States, Randall Barron, Louisiana Tech University, Ruston, LA, United States, Ken Lingo, U. S. Cryogenics LLC, Nashville, TN, United States
5-2 EXPERIMENTAL STUDY OF SURFACE INTEGRITY AND PERFORMANCE Room 170A 10:30am12:00pm
Session Chair: Changsheng Guo, United Technologies Research Center, East Hartford, CT, United States Session Co-Chair: Richard Chiou, Drexel University, Philadelphia, PA, United States Microstructural Study on Strain-Induced Transformation in Austempered Ductile Iron Using Heat Tinting Technical Publication. MSEC2010-34085 Ashwin Polishetty, Bing (Bill) Pan, Timotius Pasang, Guy Littlefair, AUT University, Auckland, New Zealand Noncontact Surface Roughness Measurement for Remote Quality Control Technical Publication. MSEC2010-34090 Richard Chiou, Drexel University, Philadelphia, PA, United States, Yongjin Kwon, Ajou University, Suwon, Korea (Republic), Yueh-Ting Yang, Robin Kizirian, Drexel University, Philadelphia, PA, United States, Bill Tseng, The University of Texas at El Paso, El Paso, TX, United States Microstructural Changes of AZ31 Magnesium Alloys Induced by Cryogenic Machining and Its Influence on Corrosion Resistance in Simulated Body Fluid for Biomedical Applications Technical Publication. MSEC2010-34234 Z. Pu, O. W. Dillon, Jr., I. S. Jawahir, D. A. Puleo, University of Kentucky, Lexington, KY, United States
4-1 THERMALLY ENHANCED PROCESSES AND MATERIALS #1 Room 170B 10:30am12:00pm

Session Chair: Ken Lingo, U. S. Cryogenics LLC, Nashville, TN, United States Session Co-Chair: Kevin Chou, University of Alabama, Tuscaloosa, AL, United States Cryogenically Treated Round Silicon Carbide WhiskerReinforced Alumina Inserts for Face Milling Hardened Steel Technical Publication. MSEC2010-34187 Justin L. Milner, John T. Roth, Penn State Erie, The Behrend College, Erie, PA, United States, Jason Goldsmith, Greenleaf Corporation, Saegertown, PA, United States The PlasmaSidewall Interactions during Femtosecond Laser Drilling of High-Aspect-Ratio Microholes Technical Publication. MSEC2010-34108 Benxin Wu, Sha Tao, Illinois Institute of Technology, Chicago, IL, United States, Shuting Lei, Kansas State University, Manhattan, KS, United States Application of Electric Current in Friction Stir Welding Technical Publication. MSEC2010-34166 Matthew Pitschman, Jacob Delocki, Jun Zhou, Garret Johns, John T. Roth, Penn State Erie, The Behrend College, Erie, PA, United States
29
Friday, October 15
Machining Characteristics of High-Speed Dry Milling of Biodegradble Magnesium-Calcium Alloy Technical Publication. MSEC2010-34310 M. Salahshoor, Y. B. Guo, University of Alabama, Tuscaloosa, AL, United States A Statistically Based Determination of the Depth of the Machining Affected Zone in Nickel-Based Superalloys using Matlab Technical Publication. MSEC2010-34327 B.J. Richardson, Clemson University - International Center for Automotive Research, Greenville, SC, United States, Cristina Bunget, Clemson University, Greenville, SC, United States, Thomas R. Kurfess, Clemson University - International Center for Automotive Research, Greenville, SC, United States

9-5 EQUIPMENT AND CONTROL OF FORMING PROCESSES Room 160B 10:30am12:00pm

Session Chair: Yannis Korkolis, University of New Hampshire, Durham, NH, United States Session Co-Chair: Gap-Yong Kim, Iowa State University, Ames, IA, United States Development of Fuzzy Inference System with Learning Algorithm and Database for Determining Press-Forming Conditions Technical Publication. MSEC2010-34020 Shoichiro Yoshihara, Atsushi Takahashi, University of Yamanashi, Yamanashi, Yamanashi, Japan, Masato Saito, Topy Industries, Ltd., Kanagawa, Japan, Bryan J. MacDonald, Dublin City University, Dublin, Ireland, Kenichi Manabe, Tokyo Metropolitan University, Tokyo, Japan Hot Forming Technique and Its Equipments for Ultrahigh-Strength Steel Technical Publication. MSEC2010-34033 Ning Ma, Hu Ping, Dalian University of Technology, Dalian, Liaoning, China The Development of a Complex Control Methodology for an Intelligent Stamp Forming Die Technical Publication. MSEC2010-34196 William Emblom, Univeristy of Louisiana at Lafayette, Lafayette, LA, United States, Klaus J. Weinmann, University of California, Berkeley, CA, United States The Application of Horizontal Rotational Forming Process in Fabrication of Thermoplastic Sliding Bearings Technical Publication. MSEC2010-34228 Petru A. Pop, University of Oradea, Oradea, Bihor,Romania, Juan Lopez Martinez, Polytechnic University of Valencia, Alcoy, Alicante, Spain, Gheorghe Bejinaru-Mihoc, Transilvania University, Brasov, Brasov, Romania, Mircea Gordan, University of Oradea, Oradea, Bihor, Romania Advantages of Servo Presses in Metal Forming with a Focus on Warm Forming Technical Publication. MSEC2010-34208 Serhat Kaya, RTI International Metals Inc., Niles, OH, United States, Taylan Altan, The Ohio State University, Columbus, OH, United States

Symposium Organizer: Jeffrey Abell, General Motors, Warren, MI, United States Symposium Co-Organizer: Hui Wang, University of Michigan, Ann Arbor, MI, United States
8-2 BIO-FUEL MANUFACTURING Room 160A 10:30am12:00pm

Session Chair: Z. J. Pei, Kansas State University, Manhattan, KS, United States Session Co-Chair: Hui Wang, University of Michigan, Ann Arbor, MI, United States Effects of Particle Size on Cellulosic Biomass Pellets: A Literature Review Technical Publication. MSEC2010-34080 Qi Zhang, Z. J. Pei, Pengfei Zhang, Kansas State University, Manhattan, KS, United States Effects of Mechanical Comminution on Enzymatic Conversion of Cellulosic Biomass in Biofuel Manufacturing: A Review Technical Publication. MSEC2010-34082 Meng Zhang, Xiaoxu Song, Z. J. Pei, Kansas State University, Manhattan, KS, United States An Experimental Study on Temperature in Ultrasonic Vibration-Assisted Pelleting of Cellulosic Biomass Technical Publication. MSEC2010-34148 Qiang Feng, Tianjin University, Tianjin, Tianjin, China, Weilong Cong, Meng Zhang, Z. J. Pei, Kansas State University, Manhattan, KS, United States, C.Z. Ren, Tianjin University, Tianjin, Tianjin, China Effects of Carrier Material and Design on Microalgae Attachment for Biofuel Manufacturing: A Literature Review Technical Publication. MSEC2010-34150 Yan Cui, Wenqiao Yuan, Z. J. Pei, Kansas State University, Manhattan, KS, United States
30
Technical Program


21-12 PLENARY PANEL - ADVANCES IN THE ELECTRIFICATION OF TRANSPORTATION West Ballroom 1:00pm2:00pm
10-6 MACHINING 2 Room 160C
10:30am12:00pm
Session Chair: Laine Mears, Clemson University, Greenville, SC, United States Session Co-Chair: Ihab Ragai, Hitachi Construction Truck Manufacturing Ltd., Guelph, ON, Canada Simulation of Facing Processes of Profiles with Hexagon Cross Section Technical Publication. MSEC2010-34137 Rainer Britz, Technischen Universitt Mnchen, Mnchen, Bayern, Germany, Heinz Ulbrich, Technischen Universitt Mnchen, Garching, Germany Thermal Modeling of Workpiece Temperature in MQL Deep-hole Drilling Technical Publication. MSEC2010-34141 Bruce L. Tai, David A. Stephenson, Albert J. Shih, University of Michigan, Ann Arbor, MI, United States Cutting Force Modeling When Milling Nickel-Base Superalloys Technical Publication. MSEC2010-34325 Andrew Henderson, Clemson University - International Center for Automotive Research, Greenville, SC, United States, Cristina Bunget, Clemson University, Greenville, SC, United States, Thomas R. Kurfess, Clemson University - International Center for Automotive Research, Greenville, SC, United States A 3D Finite Element Study on Material Flow under the Cutting Edge in Hard Milling Technical Publication. MSEC2010-34309 H. Singh, Y. B. Guo, University of Alabama, Tuscaloosa, AL, United States

9-6 SHEET AND TUBE HYDROFORMING-II Room 160B 2:00pm3:30pm

Session Chair: Matteo Strano, Politecnico di Milano Dipartimento di Meccanica, Milan, Italy Session Co-Chair: Cristina Bunget, International Center for Automotive Research, Clemson University, Greenville, SC, United States Die Design and Axial Feeding in the Tube-Hydroforming Process Technical Publication. MSEC2010-34113 Fuh-Kuo Chen, Sin-Liang Lin, National Taiwan University, Taipei, 106,Taiwan Y-Joint THF Simulation Using Asymmetric Feeding Lengths Technical Publication. MSEC2010-34147 Elisabetta Ceretti, Antonio Fiorentino, Roberto Marzi, University of Brescia, Brescia, Italy, Claudio Giardini, University of Bergamo, Dalmine, Bergamo, Italy Experimental and Numerical Analysis of Titanium Microtube Elliptical Flaring Technical Publication. MSEC2010-34184 Weichao Wu, Northwestern University, Evanston, IL, United States, Ying Huang, Wuhan University of Technology, Wuhan, Hubei, China, Rajiv Malhotra, Northwestern University, Evanston, IL, United States, Yongjun Wang, Northwestern Polytechnical University, Xian, Shaanxi, China, Jian Cao, Northwestern University, Evanston, IL, United States Reverse Bulging in Hydro/Pneumatic Sheet Metal Forming Operations: Is It Worth It? Technical Publication. MSEC2010-34285 Fadi Abu-Farha, Penn State Erie, Erie, PA, United States
31
Friday, October 15
Effects of Deformation Speed and Type of Alloy on Friction and Lubrication by Tip Test Technical Publication. MSEC2010-34298 Joseph S. Ajiboye, University of Lagos, Lagos, Nigeria, Lagos, Nigeria
SYMP 13 Fabrication Process of Nanomaterials and Nanodevices

Symposium Organizer: Guofeng Wang, Indiana University Purdue University Indianapolis, Indianapolis, IN, United States Symposium Co-Organizer: Mangilal Agarwal, Indiana University-Purdue University Indianapolis, Indianapolis, IN, United States, Chao Wang, Argonne National Laboratory, Argonne, IL, United States

13-1 FABRICATION OF NANOMATERIALS Room 160A 2:00pm3:30pm

Session Chair: Mangilal Agarwal, Indiana UniversityPurdue University Indianapolis, Indianapolis, IN, United States Session Co-Chair: Hazim El-Mounayri, IUPUI, Indianapolis, IN, United States Fabrication of Al6061-CNT Composite by Mechanical Alloying Followed by Semi-Solid Powder Processing Technical Publication. MSEC2010-34074 Yufeng Wu, Gap-Yong Kim, Iowa State University, Ames, IA , United States AFM-Based Nanomachining for Nanofabrication Processes: MD Simulation and AFM Experimental Verification Technical Publication. MSEC2010-34115 Rapeepan Promyoo, Hazim El-Mounayri, IUPUI, Indianapolis, IN, United States, Ashlie Martini, Purdue University, West Lafayette, IN, United States Layer-by-Layer Nanoassembly of CIS Nanoparticles Technical Publication. MSEC2010-34157 Mangilal Agarwal, Sudhir Shrestha, Parvin Ghane, Kody Varahramyan, Indiana University-Purdue University Indianapolis, Indianapolis, IN, United States Rationalizing Fabrication Conditions of Nanoporous Gold Technical Publication. MSEC2010-34226 Shruti Baharani, Yong Gan, University of Toledo, Toledo, OH, United States Fabrication and Characterization of Bulk Nanocrystalline Layer on Steel Components with Different Microstructures by Air-Blast Shot Peening Technical Publication. MSEC2010-34311 Rahul Waikar, Y. B. Guo, University of Alabama, Tuscaloosa, AL, United States
10-7 MACHINING 3 Room 160C
2:00pm3:30pm
Session Chair: John Morehouse, Manufacturing Research Center, Georgia Institute of Technology, Atlanta, GA, United States Session Co-Chair: Harry Tempelman, Hitachi, Guelph, ON, Canada Case Studies of Diamond-Coated Tool-Cutting Simulations: Coating Thickness and Cutting Speed Effects Technical Publication. MSEC2010-34306 Feng Qin, Kevin Chou, University of Alabama, Tuscaloosa, AL, United States Utilizing Recurrence Quantification Analysis for Chatter Detection in Turning Technical Publication. MSEC2010-34222 Rajesh Vazhayil Govindan, KMEA Engineering College, Cochin Kerala, India, Narayanan Namboothiri V N, Cochin University of Science and Technology, Cochin, India Sensitivity of Steady State Intermittent Cutting Motion to Workpiece Characteristics Technical Publication. MSEC2010-34186 Brandon Gegg, Steve Suh, Texas A&M University, College Station, TX, United States
32
Technical Program
SYMP 17 Challenges in Adaptive Manufacturing Planning and Control

Symposium Organizer: Lihui Wang, University of Skvde, Skvde, Sweden Symposium Co-Organizer: Torgny Brogrdh, ABB AB Corporate Research, Vasteras, Sweden
SYMP 19 Manufacturing System Maintenance

Symposium Organizer: Dragan Djurdjanovic, University of Texas, Austin, TX, United States Symposium Co-Organizer: Leandro G. Barajas, General Motors R&D, Warren, MI, United States, Lin Li, University of Michigan, Ann Arbor, MI, United States
17-1 CHALLENGES IN ADAPTIVE MANUFACTURING PLANNING AND CONTROL Room 170B 2:00pm3:30pm
Session Chair: Lihui Wang, University of Skvde, Skvde, Sweden Session Co-Chair: Xun Xu, The University of Auckland, Auckland, New Zealand A Statistic Review of Computer-Aided Process Planning Research Technical Publication. MSEC2010-34022 Jin Mao, Xun Xu, University of Auckland, Auckland,New Zealand, Lihui Wang, University of Skvde, Skvde, Sweden, Stephen T. Newman, University of Bath, Bath, United Kingdom Smart Machining Simulation Based on High-Level Data Technical Publication. MSEC2010-34037 Aini Z. Abdul K., Xun Xu, The University of Auckland, Auckland, New Zealand An Integrated Approach to Spot-Welding Sequence Planning and Optimization Technical Publication. MSEC2010-34049 Mohammad Givehchi Yazdi, Amos Ng, Lihui Wang, University of Skvde, Skvde, Sweden Autonomous Distributed AGV System Based on Taxi Transportation Strategy: Effect of Multiple-load AGVs on Conveyance Efficiency Technical Publication. MSEC2010-34088 Takahiro Kono, Doshisha University, Kyotanabe, Japan, Keiji Ogawa, The University of Shiga Prefecture, Hikoneshi, Japan, Toshiki Hirogaki, Eiichi Aoyama, Doshisha University, Kyotanabe-shi, Japan Development of Multiple Melt-Modulation Valves for Enhanced Injection Molding Technical Publication. MSEC2010-34236 Akapot Tantrapiwat, King Mongkut Inst. Ladkrabang, Bangkok, Thailand, John P. Coulter, Lehigh University, Bethlehem, PA, United States
19-1 METROLOGY, DIAGNOSIS, OPERATIONS, AND MAINTENANCE Room 170A 2:00pm3:30pm

Session Chair: Jun Zhou, Penn State Erie, The Behrend College, Erie, PA, United States Session Co-Chair: Scott Miller, University of Hawaii at Manoa, Honolulu, HI, United States Adaptive Anomaly Detection Using a Hidden Markov Model Technical Publication. MSEC2010-34169 Seungchul Lee, Lin Li, Jun Ni, University of Michigan, Ann Arbor, MI, United States Investigation of Contact Characteristics of Long-fiber Reinforced Plastic Gears Based on Observation with a High-speed Camera Technical Publication. MSEC2010-34116 Tomoki Otawa, Toshiki Hirogaki, Eiichi Aoyama, Doshisha University, Kyotanabe-shi, Japan The Development of a Novel On-Line Optical Inspection System for Tool Conditions in Machining Processes Technical Publication. MSEC2010-34312 W. Li, Y. B. Guo, University of Alabama, Tuscaloosa, AL, United States

21-20 ERIEZ MANUFACTURING COMPANY TOUR 3:30pm6:00pm

33
Abstracts

1-1 MANUFACTURING WITH SOFT MATERIALS I
MSEC2010-34181
Processing of Nanodiamond Loaded Poly (Lactic Acid) Co-Continuous Porous Structures Wei Zhang Georgia Institute of Technology Tom Wyatt Georgia Institute of Technology Qingwei Zhang Drexel University Donggang Yao Georgia Institute of Technology Jack G. Zhou Drexel University
Porous poly(lactic acid) PLA materials are highly demanded as scaffolding templates in tissue engineering applications. In this study, a protocol for creating co-continuous porous PLA structures with nanodiamond (ND) as additive was investigated. First, a ternary blend of PLA/PS/ND was prepared with different mixing ratios under different mixing conditions. Next, a postannealing stage was applied to coarsen the phase structure. Finally, the PS phase was sacrificially extracted, leaving a porous matrix. The experimental results showed that ND can be an effective compatiblizer for increasing the miscibility between PS and PLA and reducing the phase size. It was further found that the postannealing conditions significantly affect the distribution of ND particles in the blend and, finally, in the porous PLA structure.
performed to numerically study the effects of compression on phase structure evolution in binary blends. If harnessed appropriately, this phase separation process may be utilized for creating innovative material structures.
MSEC2010-34274
Soft Biomaterial Study for 3-D Tissue Scaffold Printing Chris G. Geisler Drexel University Ho-Lung Li Drexel University David M. Wootton Cooper Union Peter I. Lelkes Drexel University Jack G. Zhou Drexel University
In 3-D scaffold printing, it is critical to finding a material that is suitable for your printing method, printing speed, and ease of use. For a biomaterial to best suit solid free-form fabrication techniques, it must: 1) be a low-viscous solution before being printed, 2) involve easily joined on-substrate mixing to form a homogenous gel, 3) have a short solution to-gel transition time, 4) be a mechanically strong gel, and 5) have an irreversible gelation process. Ionic crosslinkable, photo-cross-linkable, and thermosensitive hydrogels have all been investigated and found to not fully satisfy our every requirement for SFF printing. Ionic crosslinking hydrogels can gel rapidly but tend to involve additional steps for cross-linking, like freeze drying, stirring, and shaking, while some form beads, not homogenous gels. Some photo-cross-linkable hydrogels would not work due to the concern for viability of cells in initial gel layers receiving copious amount of UV light. Thermosensitive hydrogels meet most of the requirements except that they are reversible gels. A new type of gel that obtains the qualities of a photo-cross-linkable and thermosensitive hydrogel satisfies every requirement. A PEG-PLGA-PEG thermosensitive triblock copolymer additionally cross-linked with photo-cross-linkable Irgacure 2959 allows for quick transition from solution to gel with a postprocessing step utilizing UV light would add additional cross-links to the gel structure, resulting in an irreversible hydrogel.
MSEC2010-34183
Instantaneous Phase Separation at the Contact Surface in Compression Molding of Immiscible Polymer Blends Wei Zhang Georgia Institute of Technology Min Li Georgia Institute of Technology Sarang Deodhar Georgia Institute of Technology Donggang Yao Georgia Institute of Technology Jack G. Zhou Drexel University
Immiscible polymer blends with a co-continuous phase structure (CPS) can yield synergistic material properties. In this study, a 50/50 wt % PLA/PS blend with CPS was used as a model system to explore the influence of compression molding conditions (including compression rate, compression ratio, and mold surface characteristics) on the final phase structure of the molded part. The microscopic characterization clearly demonstrated the instantaneous formation of a PLA-rich layer at the mold contact surface when a high compression ratio and fast compression rate were applied during molding. CFD simulations were
34
Abstracts
1-2 MANUFACTURING WITH SOFT MATERIALS II

MSEC2010-34258
Multifunctional Behavioral Analysis of Al-SiC Metal Matrix Composite Foam Produced by (TiH2 CaCO3) Dual Foaming Agent Vinay Sharma Birla Institute of Technology Joyjeet Ghose Birla Institute of Technology Surender Kumar Birla Institute of Technology
Aluminum alloy composite foams reinforced by 5% vol. SiC particles were fabricated with melt foaming route using TiH2-CaCO3 dual foaming agent. The compressive modulus and strength of two different relative density aluminum foams were investigated experimentally. An empirical relationship was established between normalized change in density and strain, using experimental data of compression tests up to different strain levels. Sound absorption property of the developed material was found out by impedance tube method. Acoustic test results indicate the potential of the material as sound absorber
the biocompatibility is maintained through the manufacturing process and 3D channels improved cell in-growth.
MSEC2010-34330
Manufacturing Ultrafine Filaments by Cold Air Attenuation Jun Jia Georgia Institute of Technology Donggang Yao Georgia Institute of Technology Youjiang Wang Georgia Institute of Technology
Ultrafine fibers, with a linear density below 1 denier, are high value products for textile, industrial and biomedical applications. Traditionally ultrafine fibers are produced by extrusion followed by mechanical drawing. In this study, a customized fiber extrusion line was designed and set up with the inclusion of a jet nozzle in the spinneret pack. With only cold air attenuation, we were able to obtain drawing ratios exceeding 2500 and produce subdenier continuous filaments. We have conducted parametric studies to investigate the fiber attenuation mechanism and determine the optimal process window for making continuous microfibers. Different characterization methods were carried out to examine the resulting fiber properties, including microstructures, thermal properties, mechanical properties, orientation, and crystallinity. Theoretical analysis of cold air drawing is discussed in this paper.
MSEC2010-34277
Biomimetic Design, Modeling, and Manufacturing of Chitosan/Gelatin Scaffolds for 3D Vascularized Liver Tissue Construct Haibo Gong Drexel University Qingwei Zhang Drexel University Peter I. Lelkes Drexel University Jack G. Zhou Drexel University Dichen Li Xi'an Jiaotong University
Despite the significant progress in engineering fairly thin tissues that contain or acquire vascular structures (e.g., skin, cartilage, and bladder), it has been markedly difficult to construct metabolically demanding organs with thicker and more complex structures (e.g., heart, lung, kidney, and liver). This research explores a new generation of clinically 3 significant (500 cm ) liver tissue constructs made of a new natural polymer composite, imbedded with an optimized network of flow channels, and manufactured using innovative structured porogen and lost-wax molding methods to receive a 3D vascularized liver tissue construct. Biomimetic designed liver scaffolds with a 3D network of flow channels were optimized based on simulation of fluid flow inside the channel network. Combining the structured porogen method, lost-wax molding, and freeze-drying technique, both the macro- (1 cm) and microscale (500 m) structures were achieved in chitosan/gelatin liver scaffolds. Liver parenchymal cells were seeded in the 3D scaffolds and cultured for 3 days. Evident cell growth was found both at the bottom and center of the scaffolds, which indicates
SYMP 2 Sustainable Manufacturing of Advanced Composites

2-1 SUSTAINABLE MANUFACTURING OF ADVANCED COMPOSITES
MSEC2010-34054
Curing and Consolidation of Advanced Thermoset Composite Laminate Parts by Pressing between a Heated Mold and Customized Rubber-Faced Mold Daniel Walczyk Rensselaer Polytechnic Institute Jaron Kuppers Rensselaer Polytechnic Institute Casey Hoffman Rensselaer Polytechnic Institute
The major bottleneck in manufacturing of advanced thermoset composite laminate parts is consolidating and curing using an autoclave. In this paper, an alternative process to autoclaving, called thermal pressing, is proposed and demonstrated using a two-dimensional (2-D) mold shape. The process essentially involves consolidating and curing a laminate part by pressing it between a matched mold setconsisting of a heated rigid mold (called the curing mold) and a matching rubber-faced mold (called a base mold with a rubber mask)while drawing full vacuum
35
Abstracts
around the mold perimeter. The shape of the base mold and thickness distribution of the rubber mask are designed using a FEA-based algorithm to provide a uniform hydrostatic pressure, similar to autoclaving, when pressed with a specific force. The temperature-controlled curing mold provides a constant consolidating temperature to facilitate controlled resin flow and then is later elevated to a constant curing temperature. The process is demonstrated by creating an aluminum mold set with a 2-D axisymmetric shape. In one experiment, the effect of mask shape is demonstrated by measuring pressure distribution between the laminate part and curing mold using pressure-sensitive film. A second experiment shows the uniformity of curing mold temperature using an array of thermocouples. Finally, the potential for significant cost and energy reductions over autoclaving are discussed.
achievement of high-efficient fiber extraction, and (5) ecofriendly disposal of bamboo fiber products and high recyclable potential. In this report, we focus on the hot press forming process. Rectangular bamboo boards are formed with various forming temperature. Three-dimensional shape forming is also attempted as a case study of complicated shape forming, which is impossible from natural Japanese bamboo pipes. As a result, we manufactured a board by hot press forming only using bamboo fibers extracted with a machining center. Appropriate forming temperature was also obtained by investigation of the mechanical properties. The three-dimensional shape was formed with a press die, and good transcription of shape and the surface was obtained.
MSEC2010-34303
Study of Manufacturing Process Optimization of Rigid Boards of LDPE/Al Composite Recycled Miguel A. Hidalgo Universidad Autonoma de Occidente
This study investigates the feasibility of using recycled lowdensity polyethylene (LDPE) and aluminum of Tetra Pak, to manufacture an experimental composite rigid board. The rigid board was made through a hot press. The effects of the tensile, flexural, and water absorption process on LDPEAl plastic composites were studied. Based on the findings in this work, it appears that recycled materials can be used to manufacture value-added panels without having any significant adverse influence on board properties. It was also found that the compounds of LDPE/Al are significantly affected by the effect of compaction pressure during processing, especially in the tensile strength and water absorption, were significant. The composite presents low water absorption and acceptable tensile strength.
MSEC2010-34134
Development of Self-Adhesive Bamboo Fiber Composite with Three-Dimensional Shape Using Fibers Extracted with Machining Center Sachiko Ogawa Doshisha University Keiji Ogawa The University of Shiga Prefecture Toshiki Hirogaki Doshisha University Eiichi Aoyama Doshisha University Mitsuaki Taniguchi Doshisha University Hiromichi Nobe Mifuji Kikai Seisakusho, Ltd.
The use of bamboo material continues to increase in engineering research fields. We are concentrating on bamboo use as a sustainable and environmentally safe material by utilizing its fibers as a reinforcing material and its quick growth rate as a sustainable material. Bamboos maximum growth rate, 1 m a day, is higher than various natural materials. Effective use is expected to exploit this high growth rate. Furthermore, bamboo fiber has high specific strength and stiffness, which satisfies our expectations for engineering applications. Our research proposed a sustainable manufacturing system that focused on the above characteristics. In our proposed manufacturing system, bamboo materials are cut and brought from natural forests. Since natural bamboo pipe has irregularities, shape-controlled bamboo fibers are extracted by in situ measurement and numerically controlled end-milling. This extraction method addresses the issues of irregular fiber shape, heat damage, and inefficiency caused by such conventional extraction methods as crushing, steam explosion, and chemical treatment. The extracted fibers are hot pressed and formed into bamboo products made of 100% bamboo fibers without any polymer adhesive. In the proposed method, the following contributions for sustainable manufacturing are expected: (1) high growth rate of bamboo, (2) carbon dioxide (CO2) absorption while growing, (3) low environmental impact during fiber extraction and hot press forming using small-sized machines, (4) improvement of energy consumption by in situ measurement and
MSEC2010-34307
Analysis on Filament Winding Sphere Surface Component with Multiple Polar Holes Rong Min Northwestern Polytechnical University Yongjun Wang Northwestern Polytechnical University Weichao Wu Northwestern Polytechnical University Junbiao Wang Northwestern Polytechnical University
This paper presents a new filament winding process for multipolar holes componet. Some kinds of filament winding components work as connecting piece which has many holes. Traditionally, the hole is usually machined after the fabrication of composite components. This will lead to the fibers around the holes are cut off. In addition, it would also increase the risk of composites delamination and crack
36
Abstracts
around the area of the holes. In order to eliminate these defects, the multipolar holes filament winding process was proposed. The winding trajectories of a sphere with two nonaxial polar holes were designed and tested. Then, by calculating the area of fiber sparse zone and fiber volume fraction of this winding component, it was found that the radiuses of polar holes can significantly influence the area of fiber sparse zone and fiber volume fraction.
MSEC2010-34106
Experimental Investigation of Coefficient of Friction during the Friction Stir Processing of Aluminum Scott Miller University of Hawaii at Manoa Lee A. Arnold University of Hawaii at Manoa Grant Kruger University of Michigan
There is a lack in understanding of the frictional contact condition during friction stir processes. High temperature, force, and work material adhesion to and from the tool make the coefficient of friction difficult to measure. In this study, an experiment was set up to simultaneously measure the temperature and normal and frictional forces between a rotating tool and a stationary workpiece at steady state conditions. The coefficient of friction was measured for increasing temperature. A simple model was created to convert the thermocouple temperature measurement to the temperature at the point of contact between the tool and workpiece. It was found that the coefficient of friction had a decreasing trend as temperature approached the solidus temperature of the work material. The results and analysis of the experiments are presented.

3-1 ADVANCES IN NONTRADITIONAL MANUFACTURING 1
MSEC2010-34105
Experimental Study of Microtools Fabricated by Electrochemical Machining Ronnie Mathew University of Cincinnati Sagil James University of Cincinnati Murali Sundaram University of Cincinnati
Accurate and precise microtools are essential for the micromachining of highly complex features in a wide variety of engineering materials including metals and ceramics. Simple shapes like cylindrical rods with micrometer level dimensions are increasingly being used as microtools in processes such as microultrasonic machining. High aspect ratio tools are necessary to produce deep microholes and other high aspect ratio structures. Microtools produced by the well-known wire electrodischarge grinding suffer from deformation due to the thermal stresses. Therefore, alternate microtool manufacturing techniques are being explored actively. In this paper, the manufacturing of microtools by micro electrochemical machining (ECM) is discussed. The microtools are made under different experimental conditions using an in-house built micro ECM system and analyzed for tool tip radii and cone angles. Furthermore, the feasibility of extremely high aspect ratio microtools is studied. Using micro ECM, microtools having mean diameters of 10 m with tips as small as 50 nm and aspect ratios of the order of 300 are achieved.
37
Abstracts
MSEC2010-34121
Magnetic Field-Assisted Finishing of Silicon MEMS Micropore X-Ray Optics Raul Riveros University of Florida Hitomi Yamaguchi University of Florida Taylor Boggs University of Florida Ikuyuki Mitsuishi Japan Aerospace Exploration Agency Utako Takagi Tokyo Metropolitan University Kensuke Ishizu Tokyo Metropolitan University Teppei Moriyama Tokyo Metropolitan University Yuichiro Ezoe Tokyo Metropolitan University Kazuhisa Mitsuda Japan Aerospace Exploration Agency
An alternating magnetic field-assisted finishing (MAF) technique has been developed to finish the 520 mm wide pore sidewalls of micropore X-ray focusing optics fabricated using microelectromechanical systems (MEMS) techniques. To understand the material removal mechanism, this MAF technique is used to finish a silicon MEMS micropore X-ray optic that had previously undergone a hydrogen annealing treatment. Compared to the unfinished surface, distinctive surface features are observed on the finished surfaces using scanning electron microscopy, optical profilometry, and atomic force microscopy. This demonstrates the finishing characteristics and reveals the material removal mechanism on the nanometer scale. Moreover, the representative unfinished and finished micropore sidewall surfaces show a reduction in roughness due to finishing from 1.72 to 0.18 nm Rq.
triangular, circular, and semicircular tool from commercially available polycrystalline diamond rod using block electrodischarge machining method has been investigated, where the traditional block is replaced by specifically designed one. Multipass machining strategy has been taken to reduce the volumetric material removal and, thus, to diminish the possible electrode breakage. This is especially significant, as the size of electrode is of micron scale. Finally, this strategy of using specially designed block has been found to be feasible for producing microelectrodes of various symmetrical and nonsymmetrical sections down to few microns. In addition to this, the capabilities of these fabricated tools have been depicted by recommending few applications on both conductive and nonconductive material.

MSEC2010-34149
Deburring of Microscale Structures Machined in Milling Takashi Matsumura Tokyo Denki University Tsuyoshi Konno Tokyo Denki University Shouta Tobe Tokyo Denki University Takafumi Komatsu Komatsu Seiki Kosakusho Co., Ltd.
The microdeburring is presented to finish fine surfaces on the microscale structures machined in milling. 0.25 mm length rectangle pillars are machined at an increment of 0.5 mm on the aluminum alloy plates with the small-diameter end mills. Burr formation occurs at the edges on the pillars in heights more than 0.2 mm. Burrs on the microscale structures cannot be removed by conventional manners, such as the manual finishing or the additional cutting with the burr removal tools. The study tries to remove the burrs in burr-removal milling, polishing, and water jet finishing. Milling is performed to remove the burrs on the structures. The burrs are still left on the sides of the pillars, and the cutter traces are also left on the structures. Burr removal milling is not effective in burr removal. The polishing is applied to burr removal. The microscale structure made of aluminum alloy deforms easily. The edge shapes of the pillars are deteriorated by contact of polishing pad with the edges of the pillars. Therefore, a supporting device is manufactured to keep the pillars shapes. Although the burrs on the top of the pillars are polished with removing the burrs, the burrs are still left on the sides of the pillars and some burrs are also left between the pillars. Finally, water jet finishing is applied to remove the burrs on the pillars. Because the mechanical strength of the microscale pillars is small, the liquid is supplied at a low pressure. The water jet machine with a low-pressure pump is developed to remove
MSEC2010-34243
Fabrication of PCD Microtools Using Block EDM Method and Their Application to Different Microstructures in Brittle and Hard Materials Asma Perveen National University of Singapore Y. S. Wong National University of Singapore Mustafizur Rahman National University of Singapore
Fabrication of microelectrodes with different shape has become so important due to the high demand of industrial products not only with diversified shape but also of reduced dimension. However, in current research, fabrication of different shapes in a single setup is not possible and also need special indexing attachment. Hence, in this paper, a specially designed block containing three V slot of 60 90 120 has been designed and fabricated using wire cut machine to facilitate the fabrication of different shape microelectrode. Then, the feasibility of fabrication of microelectrodes with symmetrical and nonsymmetrical section, e.g., conical tool of angle 60 90 120, rectangular,
38
Abstracts
the burrs without deformation of the pillars. The burrs on the side of the pillars are removed completely to finish fine surfaces in the water jet finishing on the developed machine. The microscale structures are machined on ductile materials such as aluminum alloy as follows: (1) micromilling of profile of the pillars in the structure, (2) polishing on the top of the pillars with removing the burrs, and (3) water jet finishing for removing the burrs on the side of pillars. Those processes are verified by axiomatic design.
MSEC2010-34203
Digital Manufacturing of Makyoh-Magic-Mirror for Difficult-to-Machine Material to Process Kazuya Sawa Doshisha University Eiichi Aoyama Doshisha University Toshiki Hirogaki Doshisha University Kazuya Okubo Doshisha University Keiji Ogawa The University of Shiga Prefecture
The makyoh, translated as magic mirror, is a cast bronze mirror that originated in ancient Japan. Although the face of the mirror when seen with the naked eye is no different from an ordinary one, the makyoh reflects an image onto a distant wall or screen when parallel light, such as sunlight, shines on it. The image corresponds to the pattern on the back of the mirror. The makyoh phenomenon occurs as a result of the surface topography of the submicrometer order. Irregularities on the front side of the mirror converge and diffuse reflected light. The Japanese manufacturing industry has developed over the years with skill and technology. Craftsmen with a great deal of cumulative experience have produced the makyoh, and the skills of these craftsmen have continued to advance However, the problem of the decreasing number of craftsmen, which is not confined to those creating the makyoh, has drawn considerable attention. It is difficult to hand down makyoh skills to posterity. Attempts have been made to digitize the skills of craftsmen. To maintain traditions well into the future, it is important to assist producers with using traditional craftsmanship who have long supported Japanese industry. Therefore, we attempted to digitally manufacture makyoh using numerical control (NC) machining and polishing processes. In this study, we focused on products with a short processing time and found that it was possible to process complicated shapes. We examined the effect of the topography of a makyoh surface fabricated from three different materialsbrass, stainless steel, and titaniumon the projected image and found differences in the image depending on the material. We focused much attention on the processing of titanium, which is a difficult material to process. In traditional processing techniques, the back pattern is created first and the opposite side is polished. However, in this study, after prepolishing to obtain a mirrorfinished surface, we then processed the back surface. In the cutting process, a convex shape in the mirror surface developed in the thin-wall parts due to the thrust force. As a result: (1) With our method, it was possible to make the makyoh using all three materials; (2) the difference in contrast between cutting on the outer side and on the inner side was large with a decreasing radius of curvature R in circular cutting; (3) we succeeded in processing complicated shapes by using straight lines and curve lines.
MSEC2010-34154
Comparison of Superabrasive Tools in Rotary Ultrasonic Machining of Stainless Steel Weilong Cong Kansas State University Qiang Feng Kansas State University Z. J. Pei Kansas State University
Many experiments on rotary ultrasonic machining (RUM) have been conducted to study how input variables (including tool rotation speed, ultrasonic power, feed rate, and abrasive size) affect output variables (such as cutting force, torque, surface roughness, and edge chipping) by using diamond tools. However, a literature review has revealed that there is no reported study on CBN tools in RUM. This paper presents an investigation of RUM of stainless steel using CBN tools. First, an introduction of superabrasive materials and RUM principle was provided. After presenting the experiment procedures and workpiece properties, it reports the results on tool wear, cutting force, torque, and surface roughness in RUM of stainless. Finally, it discusses and compares the performances of diamond and CBN tools in RUM of stainless steel under certain conditions.
MSEC2010-34182
Effects of Tool Design on Edge Chipping in Ultrasonic-Vibration-Assisted Grinding Na Qin Kansas State University Z. J. Pei Kansas State University Weilong Cong Kansas State University D. M Guo Dalian University of Technology
Edge chipping is an important quality parameter in ultrasonic-vibration-assisted grinding (UVAG) of advanced ceramics. In this paper, effects of cutting tool design, including three different tool angles at the tool end surface and wall thickness of the cutting tool (core drills) on edge chipping are investigated using a finite element analysis (FEA) model. Experiments are also conducted to verify the FEA-predicted effects of process variables on edge chipping for the three cutting tools.
39
Abstracts
MSEC2010-34239
A Study on Ultrasonic Elliptical Vibration Cutting of Hardened Steel Using PCD Tools Xinquan Zhang National University of Singapore Chandra Nath Singapore Institute of Manufacturing Technology A. Senthil Kumar National University of Singapore Mustafizur Rahman National University of Singapore Kui Liu Singapore Institute of Manufacturing Technology
Ultraprecision machining of hardened steel by the conventional cutting (CC) technique using diamond tools is impossible because of highly chemical affinity between carbon and iron at higher temperature during machining. An intermittently cutting technique, namely, an ultrasonic elliptical vibration cutting (UEVC) technique has been being applied for high-quality machining of various difficult-to-cut materials for the last decade. However, study on machining of hardened stainless steel using polycrystalline diamond (PCD) tools applying this cutting technique has not been reported yet. This study presents an experimental study on UEVC of hardened stainless steel (a typical Stavax of 49 HRC) using PCD tools. Face-cutting experiments have been carried out to investigate the effects of conventional machining parameters: depth of cut, feed rate, and spindle rotational speed on the performance parameters such as cutting force, tool flank wear, surface roughness, and chip formation. A minimum surface roughness Ra value of 10 nm, measured by a stylus profilometer, was achieved. It can be concluded that, while applying UEVC technique, the inexpensive PCD tools compared to the single-crystal diamond tools can be effectively applied to obtain optical surface for producing precise dies and molds from hardened steel.
spray pyrolysis, which uses compressed air to disrupt the liquid stream into droplets, has been favored in scientific and engineering communities. However, the effects of operating conditions, such as liquid flow rate, atomizing air pressure, fan air pressure, and air gap, on the geometric properties of deposited thin film are still not systematically studied. The objective of this study is to experimentally investigate the effects of air spraying operating conditions on the surface roughness and thickness of deposited zinc oxide (ZnO) thin film. It is found 1) The surface roughness increases with the liquid flow rate, but decreases with the atomizing air pressure, fan air pressure, and air gap; 2) the surface roughness decreases along both the X and Y directions under any given operating condition; 3) the thickness increases with the liquid flow rate and the atomizing air pressure, but decreases with the fan air pressure and the air gap; and 4) the thickness generally changes differently along the X and Y directions. Along the X direction, it decreases monotonically; however, along the Y direction, it increases first then decreases as in a saddle shape. While ZnO film deposition is studied, it is expected that the above conclusions may be applicable in air spraying other materials.
MSEC2010-34172
Ultrasonic Vibration-Assisted Pelleting of Cellulosic Biomass: Effects of Moisture Content Xiaoxu Song Kansas State University Meng Zhang Kansas State University Z. J. Pei Kansas State University Timothy Deines Kansas State University
Cellulosic biomass is an important source for making biofuels. However, there are several barriers to costeffective manufacturing of biofuels using cellulosic biomass. One such barrier is related to the high transportation cost due to the low density of cellulosic biomass. Pelleting of cellulosic biomass is one way to increase its density. This paper reports an experimental study on ultrasonic vibrationassisted pelleting of cellulosic biomass. The study was focused on the effects of moisture content (MC) on pellet density of three kinds of cellulosic biomass (wheat straw, switchgrass, and sorghum). The experimental results show that sorghum has the highest density with three levels of MC among these biomass materials. The highest density was found with sorghum of 20% MC.

MSEC2010-34128
Effects of Operating Conditions on Thin-Film Deposition Performance in Air Atomizing Spray Pyrolysis Changxue Xu Clemson University Yong Huang Clemson University Yafu Lin Clemson University
Thin films have been finding more and more applications in electronics, optical devices, and energy conversion and storage devices, to name a few. As one of the most promising thin-film deposition techniques, air atomizing
40
Abstracts
MSEC2010-34173
Ultrasonic Vibration-Assisted Pelleting of Sorghum: Effects of Pressure and Ultrasonic Power Level Qi Zhang Kansas State University Timothy W. Deines Kansas State University Donghai Wang Kansas State University Xiaorong Wu Kansas State University Graham Pritchett Kansas State University Z. J. Pei Kansas State University Pengfei Zhang Kansas State University
Cellulosic biofuels can be used to replace the traditional liquid transportation fuels. Cellulosic biomass is the feedstock in the manufacturing of cellulosic biofuels. However, the low density of cellulosic biomass feedstock hinders the large-scale and cost-effective manufacturing of cellulosic biofuels. Another bottleneck factor in the manufacturing of cellulosic biofuels is the low efficiency of the enzymatic hydrolysis of the cellulosic biomass materials, resulting in a low sugar yield. Ultrasonic vibration-assisted (UV-A) pelleting can increase the density of the cellulosic biomass feedstocks via the combined effects of mechanical compression and ultrasonic vibration of the tool on the cellulosic biomass. Meanwhile, ultrasonic vibration may act as a beneficial pretreatment for enzymatic hydrolysis, which can possibly increase the efficiency of hydrolysis and obtain a higher sugar yield. The compressive pressure and the ultrasonic power are important parameters in UV-A pelleting. Their effects on pellet quality (density, durability, and stability) and sugar yield (after hydrolysis) are experimentally investigated.
sugar yield). Ultrasonic vibration-assisted (UV-A) pelleting can increase the density of cellulosic materials by compressing them into pellets. UV-A pelleting can also increase the sugar yield of cellulosic biomass materials in hydrolysis. At present, the effects of process variables in UV-A pelleting on pellet quality (density, durability, and stability) and sugar yield have not been adequately investigated. This paper reports an experimental investigation on UV-A pelleting of wheat straw. A 24 factorial design is employed to evaluate the effects of process variables (moisture content, particle size, pelleting pressure, and ultrasonic power) on output variables (pellet density, durability, stability, and sugar yield).
SYMP 4 Thermally Enhanced Processes and Materials

4-1 THERMALLY ENHANCED PROCESSES AND MATERIALS #1
MSEC2010-34108
The PlasmaSidewall Interactions during Femtosecond Laser Drilling of High-Aspect-Ratio Microholes Benxin Wu Illinois Institute of Technology Sha Tao Illinois Institute of Technology Shuting Lei Kansas State University
The drilling of high-aspect-ratio microholes has very important applications in automotive, aerospace, electronics, and other areas. However, this is difficult to realize with conventional mechanical machining or electrical discharge machining approaches. Femtosecond laser ablation can potentially provide a good solution to this, but it also involves many technical difficulties. One of these is that the laser-induced plasma, as it expands out of the microhole, may transfer its energy to the sidewall of the hole, which may affect the hole size and geometry. In this paper, the plasmasidewall interaction has been studied using a physics-based model, and the discovered characteristics of the interaction are discussed.
MSEC2010-34179
Ultrasonic Vibration-Assisted Pelleting of Biomass: A Designed Experimental Investigation on Pellet Quality and Sugar Yield Pengfei Zhang Kansas State University Daniel Nottingham Kansas State University Timothy W. Deines Kansas State University Donghai Wang Kansas State University Xiaorong Wu Kansas State University Z. J. Pei Kansas State University
Increasing demands and concerns for the reliable supply of liquid transportation fuels make it important to find alternative sources to petroleum-based fuels. One such alternative is cellulosic biofuels. However, several technical barriers have hindered large-scale, cost-effective manufacturing of cellulosic biofuels, such as the low density of cellulosic feedstocks (causing high transportation and storage costs) and the low efficiency of enzymatic hydrolysis process (causing longer processing time and low
41
Abstracts
MSEC2010-34166
Application of Electric Current in Friction Stir Welding Matthew Pitschman Penn State Erie, The Behrend College Jacob Delocki Penn State Erie, The Behrend College Jun Zhou Penn State Erie, The Behrend College Garret Johns Penn State Erie, The Behrend College John T. Roth Penn State Erie, The Behrend College
Friction stir welding (FSW) is a relatively new joining technique and has many applications. In FSW, heat generated due to friction between FSW tool and workpiece material softens the material and allows the materials in workpieces to be stirred and joined together. FSW allows the workpieces to be joined without reaching the melting point of the material, thus resulting in better welds. However, a large amount of mechanical energy has to be consumed for FSW of high-strength, difficult-to-weld metals such as titanium alloys. Hence, new FSW methods should be investigated to reduce the required energy. In this study, an innovative electrically enhanced friction stir welding (EEFSW) has been developed. Electric current is passed in welding coupons of Aluminum 6061 plates and its effect on the welding process and welds are examined. The results indicate that, with the aid of electric current, improvement in welding speed and reduction in energy consumption is obtainable, which enhances the productivity and widens the range of applications of FSW. Welds properties are found to be affected by the introduced currents as well.
tooling is one method that has been demonstrated to significantly increase the wear resistance of traditional tooling materials, such as steel and tungsten carbide, and is becoming more commonplace in industry. However, the effects of cryogenically treating advanced ceramic tooling are not well established, especially for machining-hardened steels and refractory metals. In addition, round geometry inserts were studied due to the rising popularity in industry, since there is an increase number of cutting edges. To help establish these effects, in this work, commercial-grade silicon carbide whisker-reinforced alumina cutting inserts, WG-300, were subjected to deep cryogenic temperatures at 170C. Face milling was conducted on AISI O1 hardened steel of 55 HRC to evaluate the cryogenic treatments effects on the wear of the ceramic inserts. More specifically, tool life and surface finish were analyzed to evaluate the performance improvements of the treated tooling. The study found that the flank wear of the deep cryogenically treated ceramic inserts was less than the corresponding wear of the untreated ceramic inserts. In addition, the surface finish produced by the treated ceramic inserts was finer than that of the untreated ceramic inserts.
MSEC2010-34218
Ice Crystallization in Ice Cream Manufacturing by Coupled Computational Fluid Dynamics and Population Balance Method Mark Miller Kansas State University X. J. Xin Kansas State University Z. J. Pei Kansas State University Karen Schmidt Kansas State University
Freezing is the single-most influential step of ice cream manufacturing. During freezing, multiphase flow, ice crystal nucleation and growth, phase change, and viscous shearing all play roles in ice cream crystallization. In this work, ice crystallization of a sucrose solution is investigated using a coupled computational fluid dynamics and population balance method. The dynamic freezing process that takes place in a scraped surface heat exchanger (SSHE) is simulated using a sucrose solution as a model material. Ice crystal nucleation and growth kinetics are described by population balance equations. Effects of multiphase, phase change, and shearing from scraping in a continuous freezer on ice cream formation are investigated, and the fluid flow, temperature distribution, and ice crystal size are predicted. The method predicts trends similar to experimental observations and provides insight into how processing conditions affect ice cream manufacturing.
MSEC2010-34187
Cryogenically Treated Round Silicon Carbide Whisker-Reinforced Alumina Inserts for Face Milling Hardened Steel Justin L. Milner Penn State Erie, The Behrend College John T. Roth Penn State Erie, The Behrend College Jason Goldsmith Greenleaf Corporation
One of the most cost-effective dimensionally accurate processes used in manufacturing today that is capable of producing a superior surface finish is machining. As tooling wears, however, the advantages of machining greatly diminish. In addition, the time lost changing out the tooling significantly affects the overall process efficiency. Therefore, methods that decrease the wear rate of tooling and thereby increase tool longevity are essential to improving the efficiency of machining. Cryogenically treating
42
Abstracts
MSEC2010-34265
Microquantity Internal Cooling (MQuIC) of Cutting Tools for Increased Productivity While Machining Ti-6Al-4V Samved Bhatnagar Sandvik Mining and Construction LLC William J. Endres Michigan Technological University
Machining of space-age materials like Ti-6Al-4V is associated with thermally activated wear mechanisms, which lead to rapid tool failure and increased machine downtime. The high strength and low thermal conductivity of Ti-6Al-4V can reduce tool life significantly at high cutting speeds, adding drastically to the per-unit cost. A new concept, microquantity internal cooling (MQuIC), has been developed to extend the tool life and/or enable higher cutting speeds while machining Ti-6Al-4V. The concept involves introducing flow (coolant) in a microduct placed inside the tool and close to the cutting edge, thus bringing the cooling source close to the heat source (chip-contact area). In this research, experiments have been conducted to compare the performance (wear rates) of cutting tools using the MQuIC concept with those run under dry or flood conditions. Furthermore, two levels of feed and cutting speed are selected for the experiments so as to be able to investigate the combined effect of parameters on tool performance. Physical testing employing coolant consumption of <5% of typical flood coolant rates proves the viability of the concept by demonstrating wear rates of 1/3 to 1/2 those of flood cooling. The testing also proves the application of the MQuIC concept to enable higher cutting speeds than the current industry standard for machining Ti6Al-4V. This paper presents the experimental setup, methodology, and results obtained while testing the feasibility of the concept.
SYMP 5 Surface Integrity and Performance of Components by Multiscale Manufacturing

5-1 NUMERICAL SIMULATIONS OF SURFACE INTEGRITY AND PERFORMANCE
MSEC2010-34071
Predicting the Effects of Rake Angle, Cutting Speed, and Feed Rate on Chip Morphology in Hard Turning Shenfeng Wu Shanghai Jiao Tong University Xueping Zhang Shanghai Jiao Tong University C. Richard Liu Purdue University
This paper proposes a thermomechanical orthogonal cutting finite element model (FEM) to investigate the variation of chip morphology from continuous chip to small and large sawtooth chips under positive and negative rake angles, low and high cutting speeds, and feed rates. The corresponding experiments of hard turning AISI 52100 steel are conducted to validate the predicted chip morphologies. The research suggests that chip morphology transit from continuous to sawtooth chip with increasing the feed rate and cutting speed, and changing a positive rake angle to a negative rake angle. There exists a critical cutting speed at which the chip morphology transfers from continuous to sawtooth chips. The sawtooth chip segmentation frequency decreases as the feed rate and negative rake angle value increase; otherwise, the frequency of sawtooth chip increases with the cutting speed. Larger negative rake angle and high cutting speed dominate the sawtooth chip morphology while positive rake angle and low cutting speed determine continuous chip morphology.
MSEC2010-34072
On Predicting Residual Stress and Chip Morphology in Prestressed Hard Turning Heping Wang Shanghai Jiao Tong University Shenfeng Wu Shanghai Jiao Tong University Xueping Zhang Shanghai Jiao Tong University C. Richard Liu Purdue University
To analyze AISI 52100 steel response in hard turning under prestressed conditions, an explicit dynamic thermomechanical finite element model (FEM) has been developed. The FEM adopts Johnson-Cook constitutive model to describe the workpiece material property; and Johnson-Cook failure model as chip separation criterion; a modified coulombs friction law determines the friction behavior at the tool/chip interface. 500 MPa of tensile and compressive prestress are imposed on the workpiece to simulate the pretension/-stress
43
Abstracts
and precompression/-stress conditions, respectively, in hard turning. The effect of prestress on hard turning is determined by analyzing and comparing the simulation results under the three different pr-stress conditions, in terms of sawtooth chip morphology, cutting forces, plastic strain distribution and temperature distribution on chip, plastic strain distribution and temperature distribution in a machined surface, and especially the residual stress in a machined surface. It identifies hard cutting under pretension-stress condition is an effective approach to generate a beneficial compressive residual stress profile in hard turning characterized by a bigger value of compressive residual stress and a deeper penetration depth into the hard turned surface which are helpful to enhance the fatigue life of machined components.
MSEC2010-34233
Multiphase FE Model for Machining Inconel 718 Yu Long United Technologies Research Center Changsheng Guo United Technologies Research Center Santosh Ranganath Pratt and Whitney Ronald Talarico Pratt and Whitney
Inconel 718 presents significant challenges in machining attributable to the secondary niobium and titanium carbide phases. Machined surfaces typically show a tendency of those brittle carbides to crack, drag, and smear under the cutting tool. These machining defects can severely reduce the fatigue life of the machined components. This paper presents a finite element modeling approach to predict the carbide cracking and distortion phenomenon. The influence of cutting process parameters and cutting edge geometry on carbide damages will be investigated with the model. The model results will be qualitatively compared to SEM observations of the machined surfaces.
MSEC2010-34129
Predicting the Effects of Nose Radius and Tool Lead Angle on Hard Turning Process Using 3D Finite Element Method Xueping Zhang Shanghai Jiao Tong University Heping Wang Shanghai Jiao Tong University C. Richard Liu Purdue University
The finite element method (FEM) has been qualified as an excellent method to analyze machining processes. Many researchers commonly adopt an orthogonal FE model to simulate hard turning process without considering the effect of tool nose radius and/or lead angle. However, the PCBN cutting tools usually possess a nose radius of 0.40.8 mm, which equals to the magnitude of cutting depth/feed in hard turning. To explore the effect of tool nose radius and rake angle on hard turning AISI 52100 steel process, an explicit dynamic thermomechanical three-dimensional (3D-FEM is developed. The model considers tool nose radius as 0.4 and 0.8 mm, respectively, with a tool lead angle of 0 and 7. The model successfully simulates 3D sawtooth chip morphology generated by periodic adiabatic shear and demonstrates the continuous and sawtooth chip morphology, chip characteristic line, and the material flow direction between the chip-tool interfaces. The predicted chip morphology, cutting temperature, plastic strain distribution, and cutting forces agree well with the experimental data. The oblique cutting process simulation reveals that larger lead angle enables work material deformation more severely, the maximum temperature on the chip-tool interface reaches 1289C, close to the measured average temperature of 1100C; the predicted average tangential force is 150 N, with 7% difference from the experimental data. When the cutting tool nose radius increases to 0.8 mm, the chips temperature and strain becomes relatively higher, and average tangential force increases 10 N. This paper also discusses the disagreement between the predicted and experimental cutting force.
5-2 EXPERIMENTAL STUDY OF SURFACE INTEGRITY AND PERFORMANCE

MSEC2010-34085
Microstructural Study on Strain-Induced Transformation in Austempered Ductile Iron Using Heat Tinting Ashwin Polishetty AUT University Bing (Bill) Pan AUT University Timotius Pasang AUT University Guy Littlefair AUT University
This work is an experimental study on the effect of microstructural change due to strain-induced transformation (SIT) of Austempered Ductile Iron (ADI) by heat tinting and corroborates the result with SIT related to machining of ADI. On machining ADI, the microstructure changes rapidly from austenite to martensite due to SIT. The analogy between SIT and machining is addressed in this paper. Evaluation to quantify the likely extent of SIT during machining of grades 900, 1050, 1200, and 1400 via heat tinting of plastically deformed samples has been conducted. Heat tinting causes coloration of the etched specimen, distinguishing each microstructural phase. The initial results appear to indicate the occurrence of SIT on all grades of ADI. SIT can be excessively seen on Grade 1400.
44
Abstracts
MSEC2010-34090
Noncontact Surface Roughness Measurement for Remote Quality Control Richard Chiou Drexel University Yongjin Kwon Ajou University Yueh-Ting Yang Drexel University Robin Kizirian Drexel University Bill Tseng The University of Texas at El Paso
This paper presents a new method of surface roughness measurement developed for use in a web-enabled production environment. This method employs an Internetbased vision system to measure and analyze the pattern of scattered light from a surface of an object to derive roughness parameters. The roughness parameters are obtained for a number of metal specimens that are machined to different roughnesses. A correlation curve is established between roughness parameters and the corresponding average surface roughness. The quality control data are monitored through the web browser while surface roughness parameters are inspected using a machine vision system. This allows the system to operate over the Internet since the machine vision system is integrated with CompactRIO, a LabVIEW-based logic controller.
MSEC2010-34310
Machining Characteristics of High-Speed Dry Milling of Biodegradble Magnesium-Calcium Alloy M. Salahshoor University of Alabama Y. B. Guo University of Alabama
Metallic degradable biomaterials have attracted a huge attention lately for orthopedic fixation applications. Binary magnesium and calcium (Mg-Ca) alloys have emerged as a promising choice in terms of biocompatibility to avoid stress shielding and provide sufficient mechanical strength. In this paper, efficient and ecologic machining of a lab-made MgCa alloy with 0.8 wt % calcium, cutting speeds of up to 47 m/s, and without coolant are investigated. Polycrystalline diamond inserts are applied, and the possibilities of flank built-up formation, chip ignition, and tool wear are sought during the cutting experiments with the aid of a developed on-line, optical monitoring system. Chip morphology characteristics produced by different combinations of cutting parameters, i.e., cutting speed, feed, and depth of cut are studied.
MSEC2010-34327
A Statistically Based Determination of the Depth of the Machining Affected Zone in Nickel-Based Superalloys Using Matlab B. J. Richardson Clemson University International Center for Automotive Research Cristina Bunget Clemson University Thomas R. Kurfess Clemson University International Center for Automotive Research
The surface integrity of the machined surface is a critical requirement. Multiple aspects are incorporated in surface integrity, such as surface finish, changes in microstructure, and consequently, residual stresses. This research focuses on detection of the presence of the subsurface damage and estimation of the depth of the damage, as related to the changes in microstructure. A statistically based methodology for estimation of the depth of the machined affected zone (MAZ) using scanning electron microscope (SEM) images is developed and incorporated in Matlab software, with the objective of having an automated method and also a more exact method than optical evaluation. The method is applied for estimation of the depth of MAZ for nickel-base alloy. This material was selected because of the high use in the aircraft industry for parts where the presence of subsurface damage is critical. In the future, this method can be used for an exact determination of the characteristics of MAZ and correlate with cutting conditions for establishing criteria for identifying the onset of subsurface damage, or determining the optimum parameters for minimum acceptable MAZ. Furthermore, this method can be extended for analyzing different aspects of
MSEC2010-34234
Microstructural Changes of AZ31 Magnesium Alloys Induced by Cryogenic Machining and its Influence on Corrosion Resistance in Simulated Body Fluid for Biomedical Applications Z. Pu University of Kentucky O. W. Dillon, Jr. University of Kentucky I. S. Jawahir University of Kentucky D. A. Puleo University of Kentucky
Poor corrosion resistance is one of the major disadvantages of magnesium alloys that inhibit their wide application. It was reported frequently that the alloys microstructure has a significant influence on their corrosion resistance. In this study, cryogenic machining is used as a severe plastic deformation tool to modify the surface and subsurface microstructures of an AZ31 Mg alloy. Liquid nitrogen is applied to suppress grain growth caused by large heat generation during machining. White layers, where grain boundaries were invisible, were shown to form on the surface and subsurface after machining. The hardness of this layer was about 60% larger than the bulk material. The tool edge radius and the cutting speed have profound influence on the microstructures. Preliminary results from immersion tests in simulated body fluid showed that the corrosion resistance of the AZ31 Mg alloy was enhanced due to the formation of white layer.
45
Abstracts
the microstructure (i.e., dimensions of grains) and estimate the amount of strain and residual stress in the damaged layer.
model can be applied for lapping or grinding with single or double disks lapping kinematics. Geometrical and kinematical relations with some simulation results are presented in this work.
SYMP 6 Advances of Abrasive Machining in Semiconductor Industry

6-1 ADVANCES OF ABRASIVE MACHINING IN SEMICONDUCTOR INDUSTRY
MSEC2010-34262
Simulation Model for the Shape Error Estimation during Machining with Flat Lapping Kinematics Mariusz Deja Gdansk University of Technology
The selection of a finishing process for a particular application depends on part shape and size, ease of fixturing, and requirements concerning the acceptable shape errors. Lapping is the basic flattening process that allows for achieving a high degree of flatness and parallelism of machined parts. It is still one of the most common processes to flatten the sliced silicon wafers. Grinding or wire-sawinginduced waviness can be effectively removed or reduced by lapping. Apart from lapping, grinding operations are also carried out for parts flattening with two basic tool-workpiece configurations: single-side grinding (SSG) and simultaneous double-side grinding (SDSG). These processes have some advantages comparing to lapping, e.g., lower cost and higher throughput, although there is still a problem with effective waviness removal by SSG and with a dimple in the center of the wafer after SDSG. Grinding with lapping kinematics also ensures a very good flatness due to the fact that the active surface of the tool is simultaneously the machining datum surface. A required high degree of the tool flatness is not maintained permanently. The active surface of the tool used for machining with lapping kinematics has some shape errors of concavity or convexity to the wear. This in turn influences the shape accuracy of the workpiece, and the tool flatness must be checked after machining of some workpiece batches. Depending on the tool shape error, either the facing operations are carried out to flatten the active surface of the tool or proper kinematical parameters are applied that allow for obtaining required workpiece flatness. Computer simulations can be useful to make o proper decision about achievable accuracy for actual tool shape error. Simulation model for the shape error estimation based on the kinematics of lapping and local shape errors of the tool is presented in the paper. The movement of the workpiece is analyzed, and the average distance from the workpiece surface, represented by discrete points, to the tool surface is calculated. Proposed
MSEC2010-34323
Wear of a Tool in Double-Disk Lapping of Silicon Wafers Mariusz Deja Gdansk University of Technology Adam Barylski Gdansk University of Technology
Lapping of plane surfaces is the technology that allows for achieving a high surface quality. It is evident that lapping is very effective in eliminating the waviness while surface grinding is not. Some technologies possess the advantages of both lapping and grinding. The better waviness removal can be obtained if the entire workpiece area is processed at the same time. Most suitable for processing, the workpieces with coplanar functional areas are manufacturing technologies that allow for both areas to be processed at the same time. Dual disk machines for the double-face lapping with planetary kinematics are examples of machines that enable such a processing task. Apart from lapping, grinding (flat honing, fine grinding) with the use of grinding wheels mounted on a double-disk lapping machine is widely used in practice. There is no thermal damage to the surface of the tool and the ground or lapped workpiece surface if the cutting speeds are low. Results of the tool wear in lapping of silicon wafers are the subject of this paper. Influence of parameters of planetary kinematics on the tool wear is shown. A simulation model based on the contact density between the workpiece and the tool is used. Simulation results are compared to experimental measurements, delivered by the company producing silicon wafers.
MSEC2010-34324
Drilling of Silicon-Based Solar Panels: A Review Weilong Cong Kansas State University Qiang Feng Kansas State University Z. J. Pei Kansas State University
Solar panels have been developed to convert the solar energy to electricity. Since most solar panels are silicon based, they inherit the mechanical properties of silicon, such as brittleness and hardness. These properties might lead to cracking in workpieces and low tool lives in traditional machining processes. In solar panel manufacturing, to increase the efficiency of solar cells, electrical contacts on the front side of the panel need to be connected to those on the back side. Therefore, holes of different sizes are required to drill in silicon solar panels for certain designs. This paper reviews the literature on different drilling processes for silicon solar panels and
46
Abstracts
summarizes merits, shortcomings, characteristics of each method.
and
special

7-1 MACHINING AND GRINDING 1
MSEC2010-34034
Combining Process Dynamics and Tool Wear in the Milling Super Diagram Jaydeep Karandikar University of Florida Raul Zapata University of Florida Tony Schmitz University of Florida
This paper describes the milling super diagram that incorporates limitations to milling productivity and part quality imposed by stability, surface location error (part errors due to forced vibrations), and tool wear. Combinations of axial depth of cut and spindle speed that offer stable cutting conditions with an acceptable, userdefined surface location error level are identified by a grayscale color-coding scheme. The effect of tool wear is included through the force model coefficients (that relate the cutting force to the chip area) used for process dynamics prediction. Because the force model coefficients vary as a function of the volume of material removed, a unique superdiagram is constructed for any user-defined volume of material removed with the selected cutter. For example, preferred operating conditions for a new tool can be compared to those for a worn tool. Additionally, user beliefs about data and model accuracy are applied to identify safety margins relative to the deterministic boundaries in the diagrams. Experimental results are provided for an inserted (carbide) cutter used to machine 1018 steel. The wear behavior is characterized as changes in the force model coefficients as a function of the volume of material removed. The flank wear is also measured using an on-machine microscope (to avoid tool removal from the spindle) and correlated to the force model coefficients. Stability diagrams are developed that correspond to the new and worn tool performance, and experimental results are provided to verify changes in the process stability due to tool wear.
hypothesized that an endoscope can be used to grind a predetermined amount of material to smooth the cracks on turbine blades in those cavities. By turning control knobs on the endoscope, the bending section can access a workpiece on its lateral direction. In this research, two models are built to estimate the pose (position and orientation) and force on a modified PENTAX ES-3801 endoscope. The experimental and estimated results prove that the pose and force of the flexible bending section can be predicted and monitored when subjected to varying loads.
MSEC2010-34064
Dry Turning of Commercially Pure Aluminum with Carbide Tools Xin Wang Michigan State University Patrick Kwon Michigan State University
A dry turning test was performed on commercial pure aluminum Al 1100 with two grades of carbide tools, fine grain and course grain. Without any significant amount of abrasives in Al 1100, no profound scoring marks have appeared and the resulting tool wear is mainly sliding wear on flank surface. The wear on both grades of carbide tools are insignificant. However, the fine-grain carbide tool had more wear than the coarse-grain carbide tool. In our experiment, the microfracture was only observed on the fine-grain carbide tool's nose due to its inherently low fracture resistance. Using confocal laser scanning microscopy (CLSM) and wavelet filtering, the built-up edge (BUE) evolution was analyzed. It was found that a more built-up edge on the tool was observed at the beginning of the machining. As the cobalt on the tool surface was worn down, the built-up edge became smaller at a relatively steady state. This happened after half-hour of turning. The fine-grain carbide tool have more built-up edge than the coarse-grain carbide tool because of the slightly higher cobalt content on the fine-grain carbide. Oxygen in the air plays an important role in the adhesion between the aluminum and the WC-Co tool. Two types of built-up edge were found in the experiment. The first type of BUE is huge and covers whole tool surface, which consists of mainly aluminum. The second type of BUE is very thin (~1 m), which covers a relatively small area of the tool surface. This location is characterized by both high temperature and the presence of oxygen from the air trapped between the tool and work material. This second type of BUE has a much better resistance to the NaOH solution, which consists of metal oxide (aluminum oxide or complex oxide, such as spinel). This may increase the adhesion between tool and work material. In general, the larger grain carbide performed better in dry turning commercial pure aluminum.
MSEC2010-34046
Pose Estimation and Force Prediction of Nonrigid Endoscopic Tool Yang Lei University of Hawaii at Manoa Scott Miller University of Hawaii at Manoa
Endoscopy is useful for inspecting features in hard-to-reach cavities, such as the blades inside a turbine engine with a flexible body and a semi-rigid bending section. It is
47
Abstracts
MSEC2010-34205
An Experimental Investigation into the HighSpeed Turning of Ti-6Al-4V Titanium Alloy Anil Srivastava TechSolve, Inc. Jon Iverson TechSolve, Inc.
Titanium and its alloys have seen increased utilization in military and aerospace applications due to combination of high specific strength, toughness, corrosion resistance, elevated-temperature performance and compatibility with polymer composite materials. Titanium alloys are difficult to machine due to their inherent low thermal conductivity and higher chemical reactivity with other materials at elevated temperatures. In general, temperature-related machining difficulties are encountered at production speeds in the range of 60 m/min and high-speed machining of these alloys has created considerable interest to researchers, tool manufacturers and end users. This paper provides recent results obtained during turning operation with the aim of improving machinability of titanium alloys. Several tests have been conducted using (i) micro-edge prep geometry of the inserts, (ii) ultra-hard PVD coated, and (iii) nanolayered coated inserts and the effects of speeds and feeds during turning of Ti-6Al-4V titanium alloy are discussed. The initial tests have been conducted under orthogonal (2-D) cutting conditions with no coolant application. Based on these results, several oblique cutting (3-D) tests have been designed and conducted to study the effect of various types of ultrahard and nanolayered coatings at higher cutting speeds under flooded coolant conditions. The effects of speed and feed on cutting force and tool wear are presented in this paper.
7-2 MACHINING AND GRINDING 2

MSEC2010-34048
A Sequential Greedy Search Algorithm with Bayesian Updating for Testing in High-Speed Milling Operations Mike Traverso University of Illinois at UrbanaChampaign Raul Zapata University of Florida Jaydeep Karandikar University of Florida Tony Schmitz University of Florida Ali Abbas University of Illinois at UrbanaChampaign
This paper describes a probabilistic greedy search optimization algorithm for stability testing in high-speed milling. The test parameters (i.e., the experiment setup decisions) consist of the axial depth of cut and the spindle speed. These parameters are selected to maximize the expected value of profit using a greedy search approach (an approach that maximizes the expected value of each stage one step at a time). After a test is performed, Bayesian updating is applied to determine the posterior distribution of stability. The algorithm is then repeated to identify a new test point. The motivation for this work is that, while deterministic models for milling stability prediction are available, uncertainty in the inputs always exists. In this study, it is assumed that the tool point frequency response function, which is required for stability lobe diagram development, is unknown. Therefore, the probability of stability over the selected axial depth-spindle speed domain must be determined experimentally. The greedy search algorithm identifies the maximum expected value of profit within the selected domain, where profit is determined from the product of the profit function and the stability cumulative distribution function, referred to as the probability of stability. This optimal point is then tested to evaluate stability. Whether stable or unstable, the results are used to update the probability of stability. A stable test updates all axial depths smaller than test depth to be stable at the selected spindle speed, while an unstable test specifies that all axial depths above the test depth are unstable. After updating, a new test point is selected by the greedy search algorithm and the process is repeated. This select/test/update sequence is repeated until a preselected stopping criterion is reached. This paper presents both numerical results and experimental validation that the optimization/updating approach quickly converges to the well-known stability lobe behavior described in the literature. However, in this probabilistic technique the issue of uncertainty is also addressed and results can be obtained even if no information about the dynamic system is available.
MSEC2010-34219
Current Status of Peel Grinding Technology Mike P. Hitchiner Saint-Gobain Abrasives
Paper reviews the development of peel grinding from what was once a highly specialized process for finishing small hardened ferrous materials involving CBN grain in an ultratough metal bonded wheel requiring ultrahigh work and wheel speeds in oil coolant for small batch production to replace plunge grinding. Recent developments are now questioning the need for the bond resilience with its attending difficulties of dressing, oil coolant, hard workpieces, or even high wheel or work speeds. The process has progressed to now challenge not only plunge grinding but other machining processes, including rough machining of billets, hard turning, and finish turning of steels in the soft state. The use of peel grinding is also considered in combination with other machining processes.
48
Abstracts
MSEC2010-34066
Tool Wear Analysis on Dual- and Triple-LayerCoated Carbide Tool in Face Milling of AISI 1045 Steel Kyunghee Park Michigan State University Patrick Kwon Michigan State University
Face milling tests on AISI 1045 steel were performed to study the flank wear of multilayered coated carbide tools. The cutting tools were dual (TiN/TiAlN) and triple (TiN/Al2O3/TiCN) layered, coated carbide inserts processed by PVD and CVD, respectively. As expected, the depth of cut (DOC) did not play an important role on the development of flank wear while the cutting speed had a significant role in the development of flank wear. Using confocal laser scanning microscopy (CLSM) and wavelet transform, the flank wear evolution was analyzed and abrasive wear was found to be a dominant tool wear mechanism. Adhesion of the work material was also observed after the carbide substrate was exposed. Edge chipping and microfracture were additional tool failure modes. After comparing the performance of the two inserts, we concluded that the dual-layer coating was superior to the triple-layer coating under various cutting conditions mainly due to the benefit coming from the coating processes themselves. It was claimed that the superior performance of the multilayer coating came from preventing the gross crack-induced removal of coating materials by propagating the fracture along the coating interfaces. However, no such observation was found in our milling experiment. The hardness of the coating material is affected by the processing technique as well as the inherent material property. Therefore, we can conclude the hardness of the coating materials is the most important criteria for the development of flank wear.
production data from Boeing shop floor machine tools was acquired and used to develop discrete event simulation models. We will discuss our implementation and analyze results of incorporating shop floor data directly in DES models.
MSEC2010-34329
Emergent Structure Detection for Multiaxis Machining Joseph Petrzelka Massachusetts Institute of Technology Matthew Frank Iowa State University
This paper examines the phenomenon of emergent structures that occur in the transient stock material during multiaxis rough machining from a plurality of fixed orientations. Taking the form of thin webs and strings, emergent structures are stock material conditions that can lead to catastrophic failure during machining, even when tool path verification is successful. We begin by discussing the motivation for use of fixed orientations in multiaxis machining using multiple automated setups via rotary axes, which enables fast processing and first part correct machining. Next, we demonstrate how unintended emergent structures occur in this paradigm of machining and can lead to catastrophic failure of the tool or work piece. Our original work focuses on the problem of geometric detection of these structures during process planning and prior to tool path planning, to the end of altogether avoiding emergent structure formation. To quickly simulate the machining process, we present an objectspace method for determining the transient state of stock material based on the inverse tool offset. To identify emergent structures within this transient stock state, we propose a metric based on the medial axis transformation. Finally, we present our implementation of these methods and demonstrate real-time computation appropriate for an optimization scheme to eliminate emergent structures. Our methods provide consistent and logical results, as demonstrated with several free-form component examples. This work enables the development of robust algorithms for autonomous tool path planning and machining in multiaxis environments.
MSEC2010-34178
Toward Data-Driven Sustainable Machining: Combining MTConnect Production Data and Discrete Event Simulation Nils Bengtsson PMC John Michaloski NIST Frederick Proctor NIST Sid Venkatesh Boeing Guodong Shao NIST
Recently there has been an increased focus on the environmental aspects of the manufacturing industry across the world. Boeing and NIST have studied the incorporation of life cycle assessments (LCA) parameters into discrete event simulation (DES) as a means to analyze sustainable performance in the manufacturing area. Accurate analysis of manufacturing processes using discrete event simulation requires detailed CNC production data. Using MTConnect,
49
Abstracts
7-3 SENSING AND MONITORING 1

MSEC2010-34027
A Novel Sensor Using Tool Coating and Its Substrate as Thermocouple to Measure Cutting Temperatures Shijun Zhang Shandong University Z. Q. Liu Shandong University
The ability to monitor, in real time, the thermal impact of sensors on cutting tools has been very appealing to the manufacturing industries. Several methods have been used to obtain tool-chip/workpiece contact temperature. However, special sensors to monitor coated tool temperatures are far and few between. In this paper, the sequence of fabricating a novel coating-substrate thermocouple and calibration setups to measure cutting temperature was proposed. The cutting experiments were carried out under different cutting conditions for 1045 steel. The experimental results showed that this novel technology for measuring cutting temperature is valid in manufacturing processes with coated cutting tools.
embedded thin-film sensors proved to be very robust during machining. The sensors exhibited good linearity and sensitivity. The instrumented PCBN inserts were applied in machining experiments of aluminum workpieces. The temperature distributions along the rake and flank face of the PCBN cutting insert were recorded at various cutting parameters, such as speeds, feeds, etc., and various distances from the toolwork interface. These data can be used to create a more comprehensive understanding of tool internal temperatures at different cutting conditions.
MSEC2010-34272
On-Line Monitoring of End Milling Forces Using a Thin-Film-Based Wireless Sensor Module Lei Ma Georgia Institute of Technology Shreyes N. Melkote Georgia Institute of Technology John Morehouse Georgia Institute of Technology James Castle The Boeing Company James Fonda The Boeing Company
A sensor module that integrates a thin-film PVDF piezoelectric strain sensor and a wireless data processing/transmitting platform has been designed and implemented for wireless monitoring of the feed force in the slot end milling process. The module, which is mounted on the tool shank, measures the dynamic strain produced in the tool shank and transmits data wirelessly to the receiver connected to a data acquisition computer. A first principles model based on the Euler-Bernoulli beam theory and constitutive equations of the piezoelectric sensor material is used to transform the wirelessly obtained data into the feed force acting on the tool in a slot milling operation. The wireless PVDF sensor signal is found to compare well with the expected (or theoretical) sensor signal computed from measured feed forces in slot milling experiments.
MSEC2010-34176
Measurement of Tool Internal Temperatures in the Tool-Chip Contact Region by Embedded Thin-Film Microthermocouples Dirk Werschmoeller University of WisconsinMadison Xiaochun Li University of Wisconsin-Madison
Conventional sensors applied to monitor the local machining conditions at the toolworkpiece interface are not suitable for routine on-line process monitoring and control as they are either destructively inserted and/or do not possess the necessary spatial and temporal resolution to monitor temperature during machining effectively. This paper presents the research progress on design and application of novel tool-embedded micro-thin-film thermocouple sensors. The sensors allow for the on-line investigation of temperature distribution at the rake and flank face of a polycrystalline cubic boron nitride (PCBN) cutting insert during machining. An array of 10 micro-thinfilm sensors has been fabricated and embedded into the rake and flank face of a PCBN tool (with a depth of embedding in the order of micrometers) by means of microfabrication and diffusion bonding techniques. Various parametric studies, along with scanning electron microscopy (SEM) were performed to determine optimal bonding parameters and investigate material interfacial interactions. Owing to their small size, the embedded thin film thermocouples show a very fast response time, as verified by rapid pulsed laser heating experiments. The
MSEC2010-34275
The Effects of Emissivity and Camera PointSpread Function on the Temperature Measurement of Segmented Chip Formation Using Infrared Thermography Jarred Heigel KT Consulting, Inc. Eric Whitenton National Institute of Standards and Technology
This paper uses simulation to investigate measurement errors resulting from the camera point-spread function (PSF) when measuring the temperature of segmented chip formation using infrared (IR) thermography. The PSF of the IR camera effectively filters the results, which can cause significant errors due to the large temperature gradients and abrupt transitions between features and their corresponding emissivity values. The different emissivity values of the tool,
50
Abstracts
workpiece, chip body, and shear band affect the apparent difference in the emitted energy of these different features. This decreases the measured temperature in the regions of most interest: along the toolchip interface and the periodic shear zone. The method in this study creates an appropriate emissivity map from postprocess measurements and applies it to results from the temperature distribution of the cutting zone predicted by commercial finite element analysis (FEA) software. Comparisons between the simulation results and experiment results show that the emissivity values obtained form the postprocess chip analysis lead to good agreement. The resulting radiant intensity distribution becomes the input for an IR camera simulation module developed by the authors and presented in earlier work. The earlier work used the true temperature distribution predicted by the FEA as the simulation module input, and did not incorporate the IR cameras PSF. Implementation of the actual IR cameras PSF allows the simulation module to more accurately represent the measurements of the IR camera and ultimately allow the comparison of the simulation results to the measurement results. Simulation results show that the PSF accounts for 45% of the 42C radiance temperature error at the tool-chip contact along the rake face. The PSF accounts for approximately 15% of the 46C radiance temperature measurement error at a point in the center of the catastrophic shear band. These errors consider the effects of motion blur (integration time) and magnification (size of source), as described in the earlier work.
successfully tracks the tools wear and is shown to be sensitive enough to provide sufficient time to replace the insert prior to damage of the machine tool, cutter, and/or workpiece.
MSEC2010-34232
Method for Evaluating Machining Tool-holder Spindle Unbalance Due to Chips at the ToolHolder Interface John Agapiou General Motors, R&D Center
Machining process monitoring method is developed for detecting and diagnosis of the presence of chips at the toolholderspindle interface. Although tool holders can be simply balanced before they are placed in the spindle, there can be some balancing problems remaining when one or more loose machining chips are attached at the tool-holder spindle interface(s) during a tool change. A method is developed by considering the natural and geometric unbalances of the tool-holderspindle system combined with an analysis of the tool-holder tilt due to the presence of loose machining chips at the tool-holderspindle interface. The method can be integrated on-line as a real-time expert diagnostic system for tool-holder unbalance due to the presence of loose machining chips at the tool-holder spindle interface. The expert diagnostic system makes intelligent decisions on tool-holder unbalance and concerns with chips at the interface that result in unwanted vibrations. The tool unbalance algorithm was able to monitor the toolholder tilting according to the results of this study.
7-4 SENSING AND MONITORING 2

MSEC2010-34188
Condition Monitoring with Round Ceramic Inserts While Face Milling Using Acceleration Data Justin L. Milner Penn State Erie, The Behrend College John T. Roth Penn State Erie, The Behrend College
In order to automate machining operations, it is necessary to develop robust tool condition monitoring techniques. In this paper, a tool monitoring strategy for whisker-reinforced ceramic end-milling tools is presented based on the Fourier transform and statistical analysis of the vibrations of the tool during the machining operations. Using a low-cost triaxial piezoelectric accelerometer, the presented algorithm demonstrates the ability to accurately monitor the condition of the tools as the wear increases during linear milling operations. One benefit of using accelerometer signals to monitor the cutting process is that the sensor does not limit the machines capabilities, as a workpiece-mounted dynamometer does. To demonstrate capabilities of the technique, four tool wear-life tests were conducted under various conditions. The indirect method discussed herein
MSEC2010-34240
Development of Sound-Based Tool Wear Monitoring System in Micromilling Ming-Hsing Lee National Chung Hsing University Ming-Chyuan Lu National Chung Hsing University Jhy-Cherng Tsai National Chung Hsing University
A microtool wear monitoring system based on an audible sound signal was developed and studied in this report. Three modules featuring the signal transformation, feature selection, and classification, respectively, were included in this system. A micromilling experiment was conducted on a research platform, and the audible sound signals collected by the microphone during the cutting processes were obtained for system development and verification. In the system development, the audible sound was first transformed to the frequency domain and the best features for condition classification was selected based on the class scatter criteria. In classifier design, the Fisher linear discriminant (FLD) was used to identify the tool wear condition from the selected features. This study shows that the performance of system was affected by the bandwidth of the feature, as well as the number of features selected for
51
Abstracts
classification. With carefully selecting the parameters, >90% classification rate can be obtained by this system for microtool condition monitoring.
MSEC2010-34305
Short-Time Fourier Transform Method in AE Signal Analysis for Diamond Coating Failure Monitoring In Machining Applications Ping Lu University of Alabama Kevin Chou University of Alabama Raymond Thompson Vista Engineering
Coating failures due to delaminations are the primary lifelimiting criteria of diamond-coated tools in machining. Process monitoring to capture coating failures is thus desired to prevent from poor part quality and possible production disruption. Following previous studies of AE signal analysis for diamond-coating failure monitoring in machining applications, this research applied a short-time Fourier transformation (STFT) method to capture the coating failure transition during cutting. The method uses subdivided signal segments, in a continuous manner, for the fast Fourier transform (FFT) analysis and computes the amplitude ratio of high vs. low frequencies as a function of cutting time during a cutting pass. The results show that during the coating failure pass, a clear sharp increase of amplitude ratio (value change over one) of high/low frequency occurs along the cutting time. On the other hand, the amplitude ratio only exhibits certain low-range fluctuations in other passes, e.g., initial cutting and prior to failure passes. Thus, it can be suggested that the applied STFT method has a potential for diamond-coating failure monitoring. However, for coating failure associated with a smaller tool wear (<0.8 mm flank wear-land width), the amplitude ratio plot from the STFT analysis may not clearly show the failure transition.
experiment (DOE) of three machining parameter factors was created in Minitab, and analysis of variance was performed, in order to determine which parameters influenced the machining process the most. Accelerometers, acoustic emission sensors, and force sensors have given researchers insights into the relationships between mechanical vibration and tool condition during the turning process. Similarly, correlations have been recognized between electrical power consumption, machining forces, tool temperature, and tool condition. While monitoring the machining process with sophisticated force and acceleration sensors is effective, implementation in a large-scale factory environment may not be an economical solution to on-line monitoring and control. Finding an ideal combination of sensors capable of monitoring significant factors that affect the CNC steel turning process will allow process optimization and reduce the cost of machining.

8-1 MANUFACTURING PROCESS FOR GREEN ENERGY SYSTEM
MSEC2010-34077
Product and Process Characteristics for Green Manufacturing: Evidence from Indian SMES Perminderjit Singh PEC University of Technology (formerly Punjab Engineering College) K. S. Sangwan Birla Institute of Technology & Science
With growing awareness of environmental issuesfrom global warming to local waste disposal and pollution problemsbusiness and government have come under increasing pressure to reduce the environmental impacts involved in the production and consumption of goods and services. However, organizations consider environmental assessment fairly late in the product-development process, which generates additional design constraints and increases the development costs. However, the integration of environmental requirements through life cycle stages of a product is a likely approach, leading to a new paradigm of green manufacturing. Empirical studies by various authors have indicated that SMEs find it difficult to implement environmental issues in product and process design because of lack of time, resources, expertise, and/or framework in comparison to large enterprises. This paper presents the results of an empirical study carried out on Indian SMEs to develop product and process characteristics of green manufacturing. Sixteen product and four process characteristics have been developed to be considered
MSEC2010-34308
Experimental Setup for Multisensor Fusion and Data Correlation Analysis during CNC Steel Turning Manuel Hernandez University of Central Florida Andrew Joslin University of Central Florida Erick Deane University of Central Florida Schadrick Collins University of Central Florida Chengying Xu University of Central Florida Don F. Wilson Breakthrough Management Group International
This paper discusses a preliminary setup for an ongoing research project with goals of off-line modeling and optimization for a CNC turning process of AISI 4137 steel alloy; followed by online monitoring, optimization, and control of the machining process. A full factorial design of
52
Abstracts
during the product and process design to address the environmental issues for the life cycle of the product. These characteristics provide an easy to use self-assessment framework to the SMEs to address the various environmental issues during the product and process design. The characteristics identified from the literature have been validated by using SPSS for Windows statistical tool. The reliability of the data has been assessed by the Cronbach alpha. The results provide sure evidence that the developed characteristics are highly reliable having with Cronbach alpha values of >0.9. A high value of Pearson correlation coefficients also reflects the high correlation among the developed characteristics. The study highlights the various environmental issues to be considered by the SMEs during the product design and development phase.
MSEC2010-34168
Joining Technologies for Automotive Lithium-Ion Battery Manufacturing: A Review S. Shawn Lee University of Michigan Tae Hyung Kim University of Michigan Jack Hu University of Michigan Wayne Cai General Motors Jeffrey Abell General Motors
Automotive battery packs for electric vehicles (EV), hybrid electric vehicles (HEV), and plug-in hybrid electric vehicles (PHEV) typically consist of a large number of battery cells. These cells must be assembled together with robust mechanical and electrical joints. Joining of battery cells presents several challenges, such as welding of highly conductive and dissimilar materials, multiple sheets joining, and varying material thickness combinations. In addition, different cell types and pack configurations have implications for battery joining methods. This paper provides a comprehensive review of joining technologies and processes for automotive lithium-ion battery manufacturing. It details the advantages and disadvantages of the joining technologies as related to battery manufacturing, including resistance welding, laser welding, ultrasonic welding, and mechanical joining, and discusses corresponding manufacturing issues. Joining processes for electrode-totab, tab-to-tab (tab-to-bus bar), and module-to-module assembly are discussed with respect to cell types and pack configuration.
MSEC2010-34114
Benchmarking of High-Capacity Battery Module/Pack Design for Automatic Assembly System Sha Li University of Michigan Hui Wang University of Michigan Yhu-tin Lin General Motors Company Jeffrey Abell General Motors Jack Hu University of Michigan
Electric vehicles (EV), including plug-in hybrid and extendrange EVs, rely on high-power and high-capacity batteries, such as lithium-ion batteries, as the main source of propulsion energy. The EV battery technology is progressing rapidly as a plurality of battery designs in cells, modules, and packs are emerging on the market. Current EV battery-pack assembly is mostly manual and has faced significant challenges in coping with such fast development of automotive batteries. Meanwhile, there is a lack of systematic study on the implications of varieties in battery designs on assembly system. This paper reviews various battery module or pack designs and characterizes them from the assembly-process perspective, and discusses their implications with respect to assembly methods, process flexibility, and automation feasibility. The associated cost, quality, and safety issues of the assembly are also addressed, and research opportunities and innovations are discussed. This study can assist in creating guidelines on the development of new generations of battery products that enable highly efficient and responsive battery assembly.
MSEC2010-34180
Effects of Ultrasonic Treatments on Cellulose in Cellulosic Biofuel Manufacturing: A Literature Review Pengfei Zhang Kansas State University Z. J. Pei Kansas State University
Cellulosic biofuels are one type of renewable energy and have been proposed to replace traditional liquid transportation fuels. Cellulosic biomass is the feedstocks in cellulosic biofuel manufacturing. Cellulose accounts for ~30% of the total weight in cellulosic biomass. Glucose, one type of monosaccharide convertible to ethanol, can be obtained by hydrolyzing the polymeric structure of cellulose. Currently, enzymatic methods are the most common for the hydrolysis of cellulose. However, the low efficiency of enzymatic hydrolysis increases production cost and hinders the large-scale manufacturing of cellulosic biofuels. Ultrasonic treatments applied on cellulosic biomass were found to improve the efficiency of hydrolysis and subsequently increase the sugar yield of hydrolysis. To understand the effects of ultrasonics on cellulose, investigations have been conducted on the effects on cellulose characteristics caused by ultrasonic treatments
53
Abstracts
during hydrolysis. This paper reviews the effects of ultrasonic treatments on cellulose during hydrolysis in terms of sugar yield and some characteristics of cellulose, such as accessibility, crystallinity, degree of polymerization, and morphological structure.
characteristics of each method and future research directions.
MSEC2010-34148
An Experimental Study on Temperature in Ultrasonic Vibration-Assisted Pelleting of Cellulosic Biomass Qiang Feng Tianjin University Weilong Cong Kansas State University Meng Zhang Kansas State University Z. J. Pei Kansas State University C. Z. Ren Tianjin University
As one of the near- to midterm alternatives to fossil fuels, cellulosic biofuels can cut greenhouse gas emissions while continuing to meet liquid transportation fuel needs. By processing cellulosic biomass into pellets, density and handling efficiencies of cellulosic feedstocks will be improved, resulting in a reduction in transportation and handling costs in biofuel manufacturing. Temperature of biomass during the pelleting process can affect the quality of the pellet. But the effects of pelleting variables on biomass temperature during UV-A pelleting are still unknown. This paper reports an experimental investigation on temperature of biomass in UV-A pelleting. It studies the effects of moisture content of the biomass and pelleting variables (ultrasonic power, tool travel distance, and feed rate). The results will be helpful in understanding the effects of ultrasonic vibration on biomass temperature, compaction mechanism, and biofuel conversion.
8-2 BIO-FUEL MANUFACTURING

MSEC2010-34080
Effects of Particle Size on Cellulosic Biomass Pellets: A Literature Review Qi Zhang Kansas State University Z. J. Pei Kansas State University Pengfei Zhang Kansas State University
Among all renewable energy sources, biofuel is an attractive alternative source to replace the liquid transportation fuel. Cellulosic biomass is an important feedstock source for biofuel manufacturing due to its merits. However, high transportation and storage cost of biomass due to its low density and durability hinders the large-scale and cost-effective manufacturing of cellulosic biofuel. Pelleting or briquetting methods can be used to produce biomass pellets with relatively high density and durability. Biomass is milled into particles with different sizes before pelleting. Particle size is an important parameter affecting pellet quality. This paper reviews the effects of particle size on biomass pellet quality in terms of density and durability. Investigated biomass materials, range of particle size, milling processes, and pelleting processes are summarized, and the various measurement approaches for pellet density and durability are reviewed.
MSEC2010-34150
Effects of Carrier Material and Design on Microalgae Attachment for Biofuel Manufacturing: A Literature Review Yan Cui Kansas State University Wenqiao Yuan Kansas State University Z. J. Pei Kansas State University
Continuous use of petroleum-derived fuels is widely recognized as unsustainable due to depleting supplies and the accumulation of greenhouse gases in the environment. Renewable, carbon neutral transport fuels are needed for environmental and economic sustainability. Algae have been demonstrated to be one of the most promising sources for biofuel production. However, large-scale algae production and harvesting for energy manufacturing are too costly using existing methods. The approach of growing algae on solid carriers is innovative and can potentially lead to cost-effective manufacturing of algae biofuels. As cells approach to the solid surface, many factors come in to influence microbial attachment, such as the surface wettability, free energy, polarity, roughness, and topography. Surface wettability plays an important role in
MSEC2010-34082
Effects of Mechanical Comminution on Enzymatic Conversion of Cellulosic Biomass in Biofuel Manufacturing: A Review Meng Zhang Kansas State University Xiaoxu Song Kansas State University Z. J. Pei Kansas State University
It is imperative to develop alternative fuels to replace current petroleum-based liquid transportation fuels. Biofuel produced from cellulosic biomass (forest products and residues, agricultural residues, and dedicated energy crops) is one such alternative. Manufacturing biofuels from cellulosic biomass requires reduction of the material size using mechanical comminution methods. This paper reviews these mechanical comminution methods. It presents their effects on biomass particle size, cellulose crystallinity, and sugar yield. It also discusses the
54
Abstracts
the initial cell attachment. For further contact, surface free energy and polarity are more directly related to cellsubstratum attachment strength. Surface roughness and texture are species-specific parameters and have been applied widely in attachment studies.
MSEC2010-34223
Fracture-Based Formability Prediction In Incremental Forming Rajiv Malhotra Northwestern University Liang Xue Northwestern University Jian Cao Northwestern University
In recent years, considerable research has been done in incremental forming due to its greater process flexibility and higher forming limits. In incremental forming, the formability depends to a great extent on the tool path via the incremental depth being used. A lack of fracture models to accurately predict failure in this process has hampered the utilization of incremental forming as an industrial-level forming process. This paper deals with the use of a new fracture model in which both the effects of hydrostatic pressure and shear on damage are incorporated to accurately predict fracture in single-point incremental forming.

9-1 INCREMENTAL SHEET FORMING
MSEC2010-34040
Deformation Analysis of Multistage Incremental Sheet Forming Zhen Cui Nanjing University of Aeronautics and Astronautics Feng Ren Ford Motor Company Cedric Xia Ford Motor Company L. Gao Nanjing University of Aeronautics and Astronautics
This paper presents an analytical and numerical study of deformation analysis for multistage incremental sheetforming processes, with a truncated conical part is used as an example. Unlike in the single-pass incremental forming where the sheet deformation is dominantly plane strain in the axial direction when forming a conical part, the sheet is also deformed in the circumferential direction when it is incrementally formed subsequently. Ideal deformation kinetics is assumed in the analytical derivations of strain distributions, which should be valid as long as the increment in deformation from one stage to the next is small. Numerical simulations with LS-DYNA are also conducted in an effort to understand the fundamental deformation mechanics of multistage incremental forming. The simulation result for a five-stage incremental forming process is presented. It is also used to correlate the analytical solution. An improved analytical equation for strain distributions is derived, which compares favorably to simulation results.
MSEC2010-34280
Stress and Strain Analysis on Incremental Sheet Metal Forming with Multiple-Head Tool Yongjun Wang Northwestern Polytechnical University Xudong Xiao Northwestern Polytechnical University Zhenyi Yuan Northwestern Polytechnical University Weichao Wu Northwestern Polytechnical University Jian Cao Northwestern University
A new method of incremental forming was introduced and investigated, which used a tool with multiple heads turning around holding mandrels freely. In order to investigate the advantages of this method, experiment and forming analysis were done. In this process, some truncated components were made from thin Al2024-O aluminum plate with inward tool path. An analysis model of tool path was created with geometric method. A calculation of strain and stress distribution was developed and compared to experimental results. And an investigation of forming limit was made by experiments with truncated pyramid and strip shape. The results agreed with each other. It has been shown that this method can easily improve the forming efficiency and surface roughness.
55
Abstracts
MSEC2010-34290
Desktop Single-Point Incremental Forming System Shuping Chen Northeastern University Yang Wang Liaoning University of Petroleum and Chemical Technology Maohua Chen Sany Heavy Equipment Ltd.
This paper proposes a novel thin-shell curved surface forming method by dieless single-point forming technology embodying the thought of the parallel running for both design and manufacture. And a sheet metal superplastic forming prototype system with a heterogeneous masterslave manipulator by force-reflecting control has been developed. The system mainly consists of mechanical transmission components, servo system, online optical scaler for the measurement, and the path planning of the forming tool. The final ideal forming experiment has physically testified the feasibility of the mutual-forming method for the shell sample of a panda model. This paper brings up the tentative idea of real object modification with the use of heptic force feedback.
MSEC2010-34099
Database for Real-Time Loading Path Prediction for Tube Hydroforming Using Multidimensional Cubic Spline Interpolation Angshuman Ghosh North Carolina State University Gracious Ngaile North Carolina State University
Tube hydroforming (THF) is a metal-forming process that uses a pressurized fluid in place of a hard tool to plastically deform a given tube into a desired shape. In addition to the internal pressure, the tube material is fed axially toward the die cavity. This process has various applications in the automotive, aerospace, and bicycle industries. Accurate coordination of the fluid pressure and axial feed, collectively referred to as a loading path, is critical to THF. Workable loading paths are currently determined by trial and error, which can be time consuming. This paper discusses an innovative technique for developing an interactive, real-time database that would be able to predict loading paths for typical classes of THF products and hence reduce the computational time required. By classifying most of the commercial THF parts into families, parameters such as material properties, part geometry, and tribological factors were simulated by category and stored in the database. Multidimensional cubic spline interpolation was implemented to enable an end user to request from the database a loading path for a wide range of conditions. Test results from the database for different THF families were shown to approximate the simulated results. In addition, by reducing the computation time, the use of interpolation techniques eliminates the need for carrying out multiple simulations for similar THF parts.
9-2 SHEET AND TUBE HYDROFORMING-I

MSEC2010-34056
Manufacture of Aerospace Components with Pressure Welding Ho-Sung Lee Korea Aerospace Research Institute Jong-Hoon Yoon Korea Aerospace Research Institute Y. M. Yi Korea Aerospace Research Institute
Pressure welding technology is a solid state bonding process and generally involves heating the metal surfaces to a plastic state and then applying a suitable amount of axial pressure. In this state, the metal components being joined undergo only microscopic deformation and the joining region is homogeneous and complete metallurgical bonding is possible without secondary materials or liquid phases. In the present work, pressure welding of titanium alloys has been investigated to fabricate several aerospace components with various complex configuration. The result shows that the pressure-welding method has been successfully applied with blow forming for near net shape forming of aerospace components, including a highpressure tank for attitude control of spacecraft and other lightweight structural panels.
56
Abstracts
MSEC2010-34145
Optimization on the Production of Variable Thickness Aluminium Tubes Reza Bihamta Aluminium Research Centre REGAL, Laval University Guillaume D'Amours NRC - Aluminium Technology Centre Quang-Hien Bui Aluminium Research Centre REGAL, Laval University Ahmed Rahem NRC - Aluminium Technology Centre Michel Guillot Aluminium Research Centre REGAL, Laval University Mario Fafard Aluminium Research Centre REGAL, Laval University
The variable-thickness tube drawing is a new modification in the tube-drawing methods that enables production of axially variable-thickness tubes faster and easier in comparison to other similar methods like radial forging or indentation forging. The production of this type of tubes can be used in optimum design of mechanical parts that do not necessarily need constant thickness along the axis of tube, and this method can strikingly reduce the overall weight of parts and mechanical assemblies like cars. In this paper, the variablethickness tube drawing were parametrized in a MATLAB code and optimized with the Ls-Opt software as an optimization engine and Ls-Dyna as a FE solver. The final objective of this optimization study is to determine the minimum thickness that can be produced in one step by this method with various tube dimensions (tube thickness and outer diameter). For verification of results, some experiments were performed in the tube-drawing machine, which was fabricated by this research group, and acceptable correspondence was observed between numerical and experimental results.
performance of these composite parts must be predicted by means of FEM calculation. The optimal combination of tube and metal foam properties must be found. While FEM simulation of bending and hydroforming is state of the art, the accurate FEM simulation of the mechanical behavior of metal foams cannot be considered fully established. In the first part of this paper, the foam-filling production cycle of a simple hydroformed aluminum part is shown in order to discuss some of the design and manufacturing issues that can be faced in FEM-based product/process analysis, concerning the thermal effects on the tube materials, the ability of completely filling the tube, the foam/tube interface conditions, and the uniformity of cell distribution. A few potential applications of foam-filled hydroformed tubes are also presented. In the second part of the paper, the common methods and formulations for FEM simulation of foam-based structures are discussed and a new and very promising method is proposed.
MSEC2010-34278
A New Bending Technique for Very Thin Metal Tubes Shi-Hong Zhang Chinese Academy of Sciences Shi-Qing Chen Dalian University of Technology Han Xiao Dalian University of Technology Hai Liu Chinese Academy of Sciences
A new bending technique was presented for forming very thin metal tubes, which is characterized by ball filler in the tube as force-transferring media during the bending process. Due to the good flow capacity and nonuniform pressure, ball filler is considered as an alternative filler to bend very thin tubes. The experiments of ball-filler push bending were carried out for very thin copper tubes. The results indicate that the back pressure and lubrication condition have great effects on the forming quality of the tubes. As the back pressure increases and/or lubrication condition improves, the tube surface quality is improved. The ovality of the bent tube is small, and the intrados and extrados wall thickness are both thickened and changed uniformly, which indicates that the new process applied to form the very thin tubes is feasible.
MSEC2010-34210
Metal Foam-Filled Hydroformed Tubes: Production and FEM Simulation Matteo Strano Politecnico di Milano
The marriage of the tube hydroforming (THF) process with metal foams is interesting for different reasons: (a) THF parts are naturally suited as cases to be filled by an internal metallic foam reinforcement and, therefore, for structural applications, and (b) the possibility to increase the mechanical strength of hydroformed parts allows one to plan the THF process more freely and flexibly. These components, made of an outer hollow thin compact metal skin and a cellular lightweight core, may find several applications in different industrial fields. In order to allow for an efficient and effective product/process design with a concurrent engineering approach, the structural
57
Abstracts
9-3 ELECTRICAL ASSISTED FORMING AND ULTRASONIC ASSISTED FORMING

MSEC2010-34043
Modeling and Quantification of the Electroplastic Effect When Bending Stainless Steel Sheet Metal Wesley A. Salandro Clemson University Cristina Bunget Clemson University Laine Mears Clemson University
Automotive manufacturers are continuously striving to meet economic demands by designing and manufacturing more efficient and better performing vehicles. To aid this effort, many manufacturers are using different design strategies to reduce the overall size/weight of certain automotive components without compromising strength or durability. Stainless steel is a popular material for such uses (i.e., bumpers and fuel tanks) since it possesses both high strength and ductility and is relatively light for its strength. However, with current forming processes (e.g., hot working, incremental forming, and superplastic forming), extremely complex components cannot always be easily produced, thus, limiting the potential weight-saving and performance benefits that could be achieved otherwise. Electrically assisted manufacturing (EAM) is an emerging manufacturing technique that has been proven capable of significantly increasing the formability of many automotive alloys, hence the electroplastic effect. In this technique, electricity can be applied in many ways (e.g., pulsed, cycled, or continuous) to metals undergoing different types of deformation (e.g., compression, tension, bending). When applied, the electricity lowers the required deformation forces, increases part displacement or elongation, and can reduce or eliminate spring back in formed parts. Within this study, the effects of EAM on the bending of 304 stainless steel sheet metal will be characterized and modeled for different die widths and electrical flux densities. In previous works, EAM has proven to be highly successful on this particular material. Comparison of three-point bending force profiles for nonelectrical baseline tests and various EAM tests will help to illustrate electricitys effectiveness. An electroplastic bending coefficient will be introduced and used for modeling an electrically assisted bending process. Additionally, the springback reductions attained from EAM will be quantified and compared. From this work, a better overall understanding of the effects and benefits of EAM on bending processes will be explained.
MSEC2010-34144
A Process Comparison of Simple Stretch Forming Using both Conventional and Electrically Assisted Forming Techniques Joshua J. Jones Clemson University International Center for Automotive Research Laine Mears Clemson University
A common manufacturing process typically used to create large surface contours in sheet metal is stretch forming. With this process, the ability to create geometrically accurate parts and smooth surfaces is achievable, yet there are certain limits when considering the achievable elongation of the material and the inability to produce sharp contours in the sheet metal. Present research using electrically assisted manufacturing (EAM) has shown that applying direct electrical current to the workpiece during the forming process can increase the formability and reduce springback of the material, while also lowering the required forming forces. Seeing the advantageous qualities of EAM, this study examines the use of EAM for a simple stretch forming process. Specifically, this research examines this stretch forming process with regard to how the location where the electrical current is applied to the material affects the process, the achievable forming depth without fracture, and the application direction of the current. Overall results displayed that the directional flow of electrical current and the application location did not affect the obtained forming forces or forming depths using EAM.
MSEC2010-34159
Micropin Extrusion of Metallic Materials Assisted by Ultrasonic Vibration Zhehe Yao Iowa State University Gap-Yong Kim Iowa State University LeAnn Faidley Iowa State University Qingze Zou Iowa State University Deqing Mei Zhejiang University Zichen Chen Zhejiang University
Micro extrusion is an economically competitive process to fabricate micrometallic parts. However, fabrication of extremely small geometric features leads to challenges in tool wear due to localized high stress and friction increase at the interface. This study focuses on micropin extrusion of aluminum with assistance of ultrasonic vibration. Experiments were conducted with and without ultrasound using magnetostrictive actuator. Load-displacement curves from the experiments showed a load reduction when ultrasonic vibration was applied. Experiments of ultrasonic micropin extrusion with two configurations were performed. The load reduction behaviors at off-resonance and inresonance conditions were compared. The reduction can be explained by stress superposition of ultrasonic vibration.
58
Abstracts
MSEC2010-34249
Tribological Aspects in Electrically Assisted Forming Cristina Bunget International Center for Automotive Research, Clemson University Wesley A. Salandro Clemson University Laine Mears Clemson University
The constantly increasing economical and ecological concerns in the automotive and aerospace industries have resulted in high demand for improved fuel economy and greater vehicle performance. Lightweight construction is critical for reducing inertial and rolling resistance losses to increase the product performance while maintaining safety and functional requirements. This will open a wide variety of opportunities to implement materials with high strength-toweight ratios, such as aluminum, magnesium, and titanium alloys. In large production scenarios, especially for automotive applications, metal forming provides many possibilities for cost-effective manufacture of lightweight components. However, when using conventional forming processes, these light materials bring about processing challenges: low formability, high yield strength and low strain hardening coefficients. Electrically assisted forming (EAF) is a method of overcoming these limitations. Specifically, EAF is a novel forming process where electricity, ac or dc, is applied to the metallic workpiece through the dies during deformation. Previous experimental investigations have shown that EAF can lead to reductions in flow stress and power consumption, increase in formability through larger achievable strains, the ability to reduce/eliminate spring back, and improved precision. The aim of this study is to investigate the influence of the presence of electricity on the different lubrication mechanisms and to evaluate lubricant performance in the EAF process. The tribological conditions have a significant influence on the frictional forces occurring at the tool/workpiece interface, thus on the forming load, part quality, and achievable form. When electricity is applied, besides the changes due to surface expansion at the interface occurring in conventional processes, the lubricant is also exposed to high, localized temperatures. To analyze this, electrically assisted ring compression tests are conducted and the performance of several lubricants is studied. By combining the experiments and finite element simulation result, friction coefficients and field effects on friction can be estimated. One goal of this study is to identify possible lubricant candidates to be used in EAF processes.
MSEC2010-34276
Effect of Severe Prior Deformation on ElectricalAssisted Compression of Copper Specimens Michael Siopis University of New Hampshire Brad Kinsey University of New Hampshire Nithyanand Kota Carnegie Mellon University O. Burak Ozdoganlar Carnegie Mellon University
In electrical-assisted forming (EAF), current is passed through the material during the deformation process, which results in a decrease in the required flow stress for the material. While resistive heating occurs, the flow stress reductions are beyond what can be explained by temperature effects alone. Hypotheses for this effect relate to the current affecting dislocation generation and aiding dislocation motion through the lattice structure. If the latter was the case, then materials with higher dislocation densities from severe deformation should have more pronounced benefits from EAF. In this research, equal channel angular extrusion (ECAE) was used to induce severe plastic deformation into the material. Subsequent EAF compression experiments with the ECAE specimens and as-received material with comparable grain sizes were conducted. As expected, the EAF process reduced the flow stress value substantially more, e.g., 224 MPa versus 115 MPa at a strain of 0.8 for the ECAE specimens compared to the as-received specimens, respectively. These flow stress reductions were from a case with no current applied to a 2 case where an initial current density of 250 A/mm was applied. EAF may be particularly beneficial at the microscale to address size effects because the current required to achieve an elevated current density is more viable.
9-4 FORMABILITY AND FRACTURE CRITERIA

MSEC2010-34062
The Effects of AHSS Shear Edge Conditions on Edge Fracture Hua-Chu Shih United States Steel Corporation Constantin Chiriac United States Steel Corporation Ming Shi United States Steel Corporation
Edge cracking is one of the major issues for stamping advanced high-strength steel (AHSS). This type of cracking is influenced by three major factors: the material property, the die condition, and the shearing/blanking process. The current shearing/blanking process has been applied to traditional mild steels for years and has not been modified for shearing AHSS. Other than the high-energy laser cutting process, the traditional die-cutting process would generate a rough edge (burr) with microcracks in shearing/blanking
59
Abstracts
edges for AHSS, which could serve as the crack initiation during forming. This study is to investigate the effects of shear edge conditions on edge cracking for AHSS. A special hole-shearing process has been developed on a laboratory hydraulic press. Different shearing parameters, including die clearance, cutting angle, and material orientations, were investigated in terms of shear edge conditions. The hole expansion test was conducted to evaluate the effects of shear edge conditions on the material edge stretchability. Results showed that an optimal selection of die clearance and shearing angle can greatly increase the edge stretchability for AHSS.
MSEC2010-34160
Ductility Enhancement in Pulsed Uniaxial Tension of Stainless Steel 304 Graham W. Cullen University of New Hampshire Yannis Korkolis University of New Hampshire
It was recently demonstrated that significant increases in formability in tube hydroforming (THF) can be achieved if the load is applied in a pulsed, as opposed to the monotonic, manner. The frequency of such loading is of the order of 1 Hz, and the benefits can be observed in the case of free inflation of a tube (i.e., without a die), as well. Hence, the mechanism of such improvements is not related to enhanced tribological conditions between the tube and the die, as is the case in the ultrasonic THF. In an effort to understand if and how the pulsed application of the load affects the material ductility, specimens from stainless steel 304 were subjected to uniaxial tension, with the load applied in a pulsed manner. The results of these experiments were compared to the corresponding monotonic cases under the same strain rates. Significant increases in ductility can be noted between the two types of loadings. Subsequently, further experiments described in the paper revealed that the deformation-induced heating of the stainless steel is often responsible for this behavior. However, if the loading is rather slow, then the ductility enhancement is still observed but cannot be attributed to the specimen heating.
device for application of axial force, cylindrical gypsum samples on which are fixed two strain gages, two bridges circuit type Switch & Balance Unit SB-10 with digital Strain Indicator-P3500, A/D board and PC. As the samples are used, two cylinders with differently gypsum compositions: gypsum of dressing and light orthopedic corsets, and from gypsum with sonic absorbent and thermal isolator properties. The acquisition and interpretation of data with the MATLAB program is realized, by using two original programs: Daquest-2m for acquisition data, and Evaluation-1m for calculation and plot diagram of shock wave time. By determination of shock propagation, time passing through the gypsum sample can be calculated the wave velocity and elasticity modulus of gypsum tested. For building materials on base of gypsum with special applications in medicine, and panels with sonic absorbent and thermal isolator properties are required to determine the elastic characteristics to enhance the manufacturing process, usefully.
MSEC2010-34284
In Pursuit of an Integrated Methodology for Accurate Elevated Temperature and Superplastic Tensile Testing Fadi Abu-Farha Penn State Erie, The Behrend College Joshua Sabo Penn State Erie, The Behrend College Craig Herring Penn State Erie, The Behrend College
Hydro and pneumatic sheet metalforming operations are commonly carried out at warm and elevated temperature; hence, for modeling, the behaviors of the formed materials, testing at such temperatures is necessary. The uniaxial tensile test is the most universally adopted mechanical testing procedure for material characterization purposes; yet in spite of its simplicity and standardization for roomtemperature testing, the test is problematic at higher-thanambient temperatures. Perhaps that explains the disagreements between different researchers in the field on some of the most detrimental aspects of the test. Crucially, any inaccuracies in warm and elevated temperature tensile testing have direct impact on the accuracy of the constitutive models and finite element simulations, which we rely on in running and optimizing hydro/pneumatic forming operations. This work presents a comprehensive testing methodology that aims at resolving the most critical of issues encountered in this unique type of testing. The methodology is centered about quick-mount grips that tackle the thermal issues by facilitating mounting the test specimen in a very short time. A testing procedure is devised accordingly, and preliminary testing results are presented to demonstrate the impact of the methodology on the accuracy of the results. In addition, the effect of the specimen geometry on the test outcome is investigated
MSEC2010-34167
Practical Methods Used for Determination of Elastic Characteristics of Gypsum Materials Petru A. Pop University of Oradea Patricia A. Ungur University of Oradea Liviu Lazar University of Oradea Florin M. Marcu University of Oradea
The paper is presented a dynamic installation used for determination of the elastic characteristics of gypsum materials, such as elasticity modulus-E, rigidity modulus-G, etc. This dynamic installation is composed from mechanical
60
Abstracts
using a wide variety of geometries; an optimized geometry is derived based on the obtained experimental results. The methodology is validated by testing AZ31B-H24 magnesium and 5083 aluminum alloy specimens at different temperatures and strain rates.
experiment with the learning algorithm, the error (eact) between Hobj and Hact was 0.26%. The effectiveness of the learning algorithm was thus confirmed, as well as the effectiveness of the combination of the fuzzy inference system and the learning algorithm.
9-5 EQUIPMENT AND CONTROL OF FORMING PROCESSES

MSEC2010-34020
Development of Fuzzy Inference System with Learning Algorithm and Database for Determining Press-Forming Conditions Shoichiro Yoshihara University of Yamanashi Atsushi Takahashi University of Yamanashi Masato Saito Topy Industries, Ltd. Bryan J. MacDonald Dublin City University Ken-ichi Manabe Tokyo Metropolitan University
A fuzzy inference system with an associated database was developed in order to determine the necessary forming conditions to obtain the objective height of a drawn cup using magnesium alloy sheet. The fuzzy inference system consists of four distinct modules: the input information, the database, the fuzzy inference algorithm, and the output information. The database, which contains information on the forming conditions used and the resultant height of the drawn cup, is constructed by the experimental results and the finite element analyses (FEA). As the input information, the objective height of the drawn cup (Hobj) and the initial thickness of the blank (tobj) are input in the input form. The data necessary to calculate the output information are extracted from the database on the basis of the input information. As the output information, the blank diameter (D0), the temperature (T), and the blank holding force (BHF) are calculated by the fuzzy inference system. Finally, the forming conditions are displayed in the output form. A case study utilizing circular-cup deep-drawing was used to test the inference system, whereby the experimental results for the height of the drawn cup using specific forming conditions (blank diameter, temperature, and blank holding force) agreed with those predicted using the inference system. For instance, the objective height of the drawn cup Hobj = 3.8 mm and thickness tobj = 0.5 mm were initially set as the input information. As the output information, the forming conditions of D0 = 19.3 mm, T = 300C, and BHF = 271 N were inferred by the fuzzy inference system. Under these conditions, the height of the drawn cup in the experiment (Hact) was 3.96 mm with fracture. The values of Hact and Hobj were almost the same. Furthermore, a learning method was developed for improving the system using the experimental results, the FEA results, and the fuzzy algorithm. In order to confirm the effect of the learning algorithm, the experiments are carried out. In the
MSEC2010-34033
Hot Forming Technique and Its Equipments for Ultrahigh-Strength Steel Ning Ma Dalian University of Technology Hu Ping Dalian University of Technology
Hot forming of ultrahigh-strength steel is an advanced forming technique that cannot only represent the best solution to increasing the strength-to-mass ratio of sheet components, but also meet the need of higher passive safety and weight reduction. Based on independently developed mass production line of hot forming, its key forming and quenching technique and relative equipment are proposed and described, including multistep and onestep methods, die manufacturing with a cooling system, a continuous heating furnace, and an integrated manufacturing system composed of the advanced interdisciplinary technology of machining, electronic control, material, and chemical engineering. Then the automobile body components are produced by the developed equipment of hot forming, and moreover, their mechanical properties are investigated. The typical tensile curve of the quenched components shows that the yield stress of the hot forming component is >1000 MPa, and the strength limitation is >1600 MPa. The three-point bending testing of the part is implemented. These experimental results indicate the validity of the developed technique and equipment.
MSEC2010-34196
The Development of a Complex Control Methodology for an Intelligent Stamp Forming Die William Emblom Univeristy of Louisiana at Lafayette Klaus J. Weinmann University of California
The quality of stamp formed parts has been shown to be improved by introducing active die elements and process sensing to the forming process. Further improvements in part quality through the reduction of part failure has been achieved by developing control methodologies utilizing feed back loops. Two approaches in implementing control have been successfully demonstrated. The first method demonstrated the use of segmented or flexible blank holders with independently controllable variable blankholder forces (BHF) as control elements. Researchers have demonstrated that both wrinkling and local punch forces may be controlled. Control using active variable BHF was
61
Abstracts
further advanced by combining both local force and wrinkling in a cascaded control system so that control of local forces is maintained until the onset of wrinkling, simultaneously, where upon the BHF are controlled based upon wrinkle criteria. The second approach for controlling the stamp-forming process is the use of active draw beads. These have been shown to improve the formability of a sheet by changing draw bead penetration into the sheet in order to follow the desired force trajectories. A drawback to the use of active draw beads for controlling local forces is that large draw-bead penetrations and low BHF can lead to the development of wrinkles in the sheet. However, the advantage of control based on draw-bead displacement is that because the restraining forces are due to friction and the flow of the sheet metal around the draw bead, it is easier to develop larger restraining forces than those from BHF. To take advantage of control based on both approaches, an intelligent die with active draw beads and variable BHF was designed and built. Active draw beads were located in regions where flow had to be slowed down significantly while BHF were used to control local forces where the use of draw beads is less appropriate and for the control of wrinkles throughout the die. This paper describes the development of the intelligent stamp-forming die with respect to the development and implementation of the controls used for the die. Included in this paper are descriptions of the hydraulic system used, instrumentation, control methodologies for both the draw beads and BHF including a simplified schematic of the controls system utilized, and sample results demonstrating both the ability to control active die elements and process parameters such as local forces and wrinkling.
temperature curves were used in FEA to determine heat transfer coefficients. Effect of the determined heat transfer coefficients on deep drawing was analyzed using FEA, and good agreement was obtained between FEA predictions and experimental measurements.
MSEC2010-34228
The Application of Horizontal Rotational Forming Process in Fabrication of Thermoplastic Sliding Bearings Petru A. Pop University of Oradea Juan Lopez Martinez Polytechnic University of Valencia Gheorghe Bejinaru-Mihoc Transilvania University Mircea Gordan University of Oradea
The paper presents an application of horizontal rotational forming in the fabrication of thermoplastic sliding bearings for machine tools. In addition, the general aspects regarding the flow process of thermoplastics by using rotational forming of revolution parts are described. The heat of plastic material at the melt-temperature point is realized by highfrequency current induction (HFCI) on a centrifugal molding installation of bimetallic bushes. From the experiment tests, we have observed that between the melt-temperature point of thermoplastic material, revolution speed, and size molding, a synchronism is required that depends on material density and whirl form of melting. The predictable revolution speed of a metallic mold has been achieved by technological attempts, as a function of workpiece size and type of material. The charge weight is experimentally determined depending on a parts wall thickness. This process leads to obtaining the workpieces at a high-quality level and constant wall thickness. The new bearings have been made from polyamide-PA.6, which changed with the success of the bronze bearings used at drilling machine tools.
MSEC2010-34208
Advantages of Servo Presses in Metal Forming with a Focus on Warm Forming Serhat Kaya RTI International Metals Inc. Taylan Altan The Ohio State University
Servo presses are recently introduced metal-forming machinery. They are, in many ways, a hybrid of mechanical and hydraulic presses. They are designed to combine the strengths of conventional mechanical and hydraulic presses and, at the same time, to minimize their constraints. The advantages of servo presses in metal-forming technology are discussed briefly. Advantages they offer in warm forming are discussed in more detail and demonstrated experimentally. By using the flexibility that the servo press offers, the effect of contact pressure on temperature change and surface roughness of aluminum and magnesium sheet is experimentally investigated. Nonisothermal warm forming is introduced and studied experimentally. Combined advantages of the nonisothermal approach and the servo motorcontrolled press are demonstrated by introducing a variable forming speed concept. As a result, 60% savings in cup drawing time is achieved experimentally. Measured
9-6 SHEET AND TUBE HYDROFORMING-II

MSEC2010-34113
Die Design and Axial Feeding in the TubeHydroforming Process Fuh-Kuo Chen National Taiwan University Sin-Liang Lin National Taiwan University
In the present study, the loading path with constant internal fluid pressure during axial feeding to hydroform an automotive structural part with higher expansion ratio was investigated. The axial feedings employed at various internal fluid pressures were simulated by the finite element method. It is found that the axial feeding applied at a
62
Abstracts
favorable internal fluid pressure, the production part with higher expansion ratio still could be made. Compared to other loading paths published in the literature, which are mainly linear paths, the proposed loading path provides a simple approach to achieve better performance in the hydroforming process. The factors causing wrinkling in the hydroforming process were also studied by analyzing the relationship between the die face shape and the material flow in the die cavity. An optimum die-face design that avoided pinching at the die closing process was then proposed. The actual hydroforming process for manufacturing the automotive structural part was conducted as well in the present study to validate the proposed loading path and the optimum die-face design. The consistent agreement between the production part and the finite element simulation results confirms not only the proposed loading path and die-face design, but also the effectiveness of the finite element analysis employed in the tubehydroforming process.
the dependence of the final Y shape from the lubricant and the unbalanced feeding condition. Finally, the model was used to simulate a Y-Joint hydroforming process using a full shaped die evaluating the improvement on the process (i.e. formability, forming forces, or thinning) when unbalanced conditions are adopted.
MSEC2010-34184
Experimental and Numerical Analysis of Titanium Microtube Elliptical Flaring Weichao Wu Northwestern University Ying Huang Wuhan University of Technology Rajiv Malhotra Northwestern University Yongjun Wang Northwestern Polytechnical University Jian Cao Northwestern University
Traditional tube-flaring processes focus on expanding one end of the tube without changing its cross-sectional shape. This paper presents a new two-step tube-flaring process for expanding one end of a titanium alloy microtube while simultaneously changing its cross-sectional shape from circular to elliptical. Experiments were performed to investigate and verify this process. Furthermore, an analytical model was developed to analyze the forming process and investigate the relationship between punch feed and maximum plastic strain during the flaring process. The analysis shows that the two-step flaring process used is effective in expanding the circular cross section to an elliptical cross section without failure. It is also shown that the developed analytical model can predict the fracture of the tube end during the flaring process, approximately. Finally, a FEM simulation was performed to further investigate the two-step flaring process.
MSEC2010-34147
Y-Joint THF Simulation Using Asymmetric Feeding Lengths Elisabetta Ceretti University of Brescia Antonio Fiorentino University of Brescia Roberto Marzi University of Brescia Claudio Giardini University of Bergamo
Tube hydroforming (THF) is a technology that guarantees a high final part quality and low manufacturing time and costs with respect to traditional manufacturing processes, in particular, it receives much interest in the shaped tubular components industries (bicycle, bike, or automotive). The process consists of a tube placed in a die and filled with a high-pressurized media that expands the tube until it reaches the desired geometry. The sealing and material feeding are guaranteed by two punches that plastically deform and then push the tube edges. Wrinkling and bursting are the most common defects, and even if they mainly depend on the right definition of the pressure and punch strokes curves, they are actually related to the amount of fed material (too much or few, respectively). In particular, the material feeding is influenced by the high friction acting on the pressurized tube, which does not allow the material to flow enough during the process. In a former study, it has been shown how it is possible to influence the final part geometry controlling the friction conditions during the process. In particular, a partial die was used and studied to find out how asymmetric friction conditions can lead to a spontaneous Y-joint forming whose shape (namely, bulge height and slope) can be controlled, increasing or not the friction asymmetry. In the present work, a FEM model of the previously conducted experiments was developed and validated and then it was used to study the process. In particular, it was used for the wide parameter range to collect further data on the friction phenomenon and to study
MSEC2010-34285
Reverse Bulging in Hydro/Pneumatic Sheet Metal Forming Operations: Is It Worth It? Fadi Abu-Farha Penn State Erie
The merits of warm and elevated temperature hydro/pneumatic sheet metal forming operations, most prominently superplastic and quick plastic forming, have been ever counteracted by two major drawbacks: slow forming rates and nonuniform thickness distribution with potentially severe thinning. Trying to resolve one of the two issues has generally led to escalating the other, so a compromise based on the nature of the part being formed is often targeted. To tackle the latter of the two issues, imposing a pre-thinning reverse bulging step has been shown to ease the problem with specific part geometries that involve large plastic strains and intricate details. The aerospace industry, however, is the prime sector that is able to afford the seemingly prolonged forming times
63
Abstracts
associated with this approach. Yet with the lack of adequate details on the implications of utilizing reverse bulging, this effort explores some of the hidden merits of the approach. A recently developed simple monitoring technique for providing direct feedback on the sheets advancement during pneumatic forming operations, coupled with an interrupted testing methodology, are utilized to have a closer look at the process. The results reveal significant time savings that can be achieved with the proper use of reverse bulging, for both simple and complex part geometries.

10-1 CASTING
MSEC2010-34063
Identification for Control of Low-Pressure Die Casting Xinmei Shi UBC Daan Maijer UBC Guy Dumont UBC
Controlling and eliminating defects, such as macroporosity, in die-casting processes is an ongoing challenge for manufacturers. Current strategies for eliminating defects focus on the execution of a preset casting cycle, diestructure design, or the combination of both. To respond to process variability and mitigate its negative effects, advanced process-control methodologies may be employed to dynamically adjust the operational parameters of the process. In this work, a finite element heat transfer model, validated by comparison to experimental data, has been developed to predict the evolution of temperatures and the volume of liquid encapsulation in an experimental casting process. A virtual process, made up of the heat transfer model and a wrapper script for communication, has been employed to continuously simulate the operation of the real process. A stochastic state-space model, based on data from measurements and the virtual process, has been developed to provide a reliable representation of this virtual process. The parameters of the deterministic portion result from system identification of the virtual process, whereas the parameters of the stochastic portion arise from the analysis and comparison of measurement data with virtual process data. The resulting state-space model, which can be extended to a multi-input, multioutput model, will facilitate the design of a model-based controller for this process.
MSEC2010-34298
Effects of Deformation Speed and Type of Alloy on Friction and Lubrication by Tip Test Joseph S. Ajiboye University of Lagos
The tribological conditions in cold-forging operations are extremely severe, especially with high ram speed, due to large surface expansion and normal pressure at the tool/workpiece interface. The effects of deformation velocity and type of alloy were determined in the two sets of experiments carried out in the present study. In the first set, two different deformation speeds of 0.1 and 1 mm/s were used for the aluminum alloys of 6061-O and 1050-O, and copper alloy tests. The results were further confirmed with the second sets of experiments using AA2024 and AA6061 and three deformation speeds of 0.1, 1, and 5 mm/s to evaluate the performance of each lubricant under increasing ram speed. Four lubricants, such as grease, corn oil, VG100, and VG32, were used. While all the lubricants show a reduction in maximum load with increasing deformation speed, grease shows a rise in the maximum load from zero to a maximum at a deformation speed of 1 mm/s and then descends gradually to a minimum load at a speed of 5 mm/s for AA2024-O and AA6061-O. Since the load reduction seen with grease as lubricant is probably due to thermal softening, it will not be considered a desirable lubricant under increasing deformation speed because of the adverse effects on the tooling. It is found that in choosing lubricant for cold-forging operations, the type of workpiece material and deformation speed should be properly considered. Of the liquid lubricants (corn oil, VG100, and VG32) considered, corn oil shows the best lubricant for cold-forging operations of copper, aluminum 6061-O, 1050-O, and 2024-0 under increasing speed magnitude.
MSEC2010-34103
Effects of Container Geometry on Energy Consumption during Hardening in Ice Cream Manufacturing William C. Cromer Kansas State University Mark Miller Kansas State University X. J. Xin Kansas State University Z. J. Pei Kansas State University Karen Schmidt Kansas State University
Energy consumption by the dairy food industry in the United States constitutes 10% of all energy consumed by the U.S.
64
Abstracts
food industry. Reducing energy consumption in cooling and refrigeration of foods plays an important role in meeting the challenge of the energy crisis. Hardening is an important and energy-intensive step in ice cream manufacturing. This work presents finite element method (FEM) investigation of the ice creamhardening process, aiming to provide insight and guidance for energy savings in ice cream manufacturing. Effects of container shape and dimensions, container layers, and heat transfer boundary conditions on energy consumption for hardening of ice cream were investigated.
MSEC2010-34238
A Variable Search Technique for Multiple Control Valves Used in Melt Modulation during Injection Molding John P. Coulter Lehigh University Akapot Tantrapiwat King Mongkut Institute Ladkrabang
A variable search technique was investigated for the use of a melt-modulation system with multiple control valves. The method was developed in order to obtain an optimum solution that locates the positions for all valves. It later showed that not all valve angles in the system had to be determined, but it was only a number of significant valves that needed to be fine-tuned during the search process. It also showed that the valve position and location were greatly dependent on the cavity and runner configurations. Once the valve control variable search method had been established, a series of family mold models was created and analyzed using the MoldFlow software. Instead of using the default runner from the software, a modification on the 3D models was made in order to embed melt-modulation valves. The simulation result showed that within a limited number of trials, an optimum solution can be obtained. The number of searching trials can also be reduced by applying different search gains and changing appropriate initial values.
MSEC2010-34152
Simulation of the Heat Treatment of an Automotive Cast Part Patrice Lasne Transvalor S.A. Mickael Barbelet Transvalor S.A. Olivier Jaouen Transvalor S.A. Frederic Coste Transvalor S.A. Harry Tempelman Hitachi Ihab Ragai Hitachi Construction Truck Manufacturing Ltd.
The in-use properties of an automotive part are linked to the final structure in the metal. In this paper, we study an automotive part obtained by casting and then, after reheating, the part is water quenched. The objectives are to present how the different operations can be simulated in order to predict the local phases in the different areas of the part. To reach these objectives, two software packages are used in sequence. The first one, Thercast, is used to simulate the casting operation. The second one, Forge, is applied to the water-quenching simulation. The general formulations used are briefly presented in this paper. The aim of casting simulation is to compute the metal behavior from the liquid state at the pouring stage to the solid state during cooling into the mold. Filling- and cooling-phase simulations, taking into account the air gap, ensure that no internal defects, such as shrinkage, porosity, microporosity, or hot tearing, are taking place in the part. Forge software allows the water-quenching stage simulation. A model is used to deduct the isothermal transformation (IT) diagram from the material composition. The initial grain size influences the transformation kinetics. Another main phenomenon is the efficiency of the cooling bath. The results of the simulation (phase distribution, distortion, residual stresses) strongly depend on these input conditions. Thus, the effect of input data variations on final results must be studied. The modeling approach is validated by comparisons to micrographic observations. Another solution to determine the reliability of the models is to observe the local properties in the quenched part. The prediction of the local microhardness can be used to evaluate the accuracy of the quenching models.
10-2 FORMING
MSEC2010-34044
A Straightening Method Investigation Based on Rolling Caused Stress Redistribution for Distorted Monolithic Components Jie Sun Shandong University Jianfeng Li Shandong University Zhongqiu Wang Shandong Academy of Science
Monolithic components, such as monolithic frames, beams, wainscots, ribs, etc., are being used widely in aviation to improve the performance of modern aircraft. However, due to the original complicated residual stress, complex figure, large dimension, and long machining period of the monolithic components, distortion after NC machining is almost ineluctable. To meet the final technical requirements, a straightening process is absolutely necessary for many components. A reverse-deformation method is commonly used to correct the distorted monolithic components. However, large correcting stress (usually >100 MPa) is introduced while the shape and dimension of the distorted part can meet the technical requirements after reverse deformation straightening. Moreover, microcracks may occur due to correcting loads that are too large. For the
65
Abstracts
complicated distortion, such as torsion deformation, bend combining torsion, buckling distortion, etc., the reversedeformation correcting method does not work well. Aiming at the difficulty of straightening the distorted monolithic components, a residual stress distribution and deformation compensation method based on the rolling process for straightening is put forward. The rolling-process finite element method is established. Based on FEM analysis, the relationship curve among the rolling position, component wall thickness, and the amount of deformation after rolling is established. The curve is used as a guideline for rollingparameter selection in the real manufacturing process. A scaled frame part-straightening experiment by the rolling method is designed. The validation of the rolling straightening method and rolling parameter selection based on the straightening curve is verified.
MSEC2010-34047
Investigation on Sheet Hydroforming Process of Titanium/Aluminum Clad Metal Housing Huang-Chi Tseng National Chiao Tung University Zong-Chun Wu National Chiao Tung University Chinghua Hung National Chiao Tung University Ming-Hu Lee Metal Industries Research & Development Centre
In this research, the sheet hydroforming process (SHF) was adopted to form a Ti/Al clad metal housing with complex shape. Nowadays, SHF has been widely accepted for the production of components characterized by high surface quality, precise dimensional accuracy, together with high drawing ratio. For investigating the formability of the Ti/Al clad metal housing through SHF, the concept of virtual film was developed with an explicit finite element method. First, the simulation model was verified by comparing the deformation of the blank obtained from experiments. Through finite element simulations, several significant process parameters, such as holding force, tooling geometry, blank dimensions, single stage (with prebulging effect), and multistages SHF, were analyzed for improving formability of the Ti/Al clad metal housing during SHF.
MSEC2010-34045
Spring Back in Sheet Metal Forming of Stainless Steel 410 Ihab Ragai Hitachi Construction Truck Manufacturing Ltd. James A. Nemes The Pennsylvania State University, Great Valley
This paper deals with the use of finite element simulation of sheet metal forming as a tool to evaluate geometrical defects caused by elastic spring back. The simulations aim to provide reliable information about the deviation of the real part geometry from that defined in the design phase in order to overcome the subsequent assembly problems. The material studied and presented in this paper is stainless steel 410. In order to determine the material properties and parameters needed for the simulations, a series of experiments, including uniaxial and cyclic tests, were carried out. Moreover, bending experiments were conducted so that simulation results can be verified against simple forming operations. To expand the use of the model to predict the effect of forming parameters on spring back, an aircraft engine component, namely, cone forming, was simulated and the results were compared to the actual formed part. Predictions of the final shape and thickness variation were successfully obtained and in agreement with the cone-forming experiments.
MSEC2010-34200
Process Control Model for Tube Hydroforming Obadiah Kilonzo North Carolina State University
Ongoing research has been done to develop control methods based on the simulated loading path input to the press machinery. This forms an open-loop system where the characteristics of the press hydraulic unit involved delivering the forming agents (i.e., the axial cylinders and valves), are neglected. This process approach leads to most experiments being done by simplifications, which is time consuming and expensive, curbs the ability to have feedback control, and restricts development of complex machinery response algorithms. Cylinder force control and controller design models have been researched widely, such as PID and H?, but less is known about their application to tube hydroforming (THF) process control which is relatively new. This paper focuses on modeling the THF process and developing a real-time PID controller to operate with a prototype model. The position of the cylinder is tracked and compared to the reference provided from a database via a dynamic data exchange link showing that control could be achieved with a prototype. Position control with the above approach results in efficient and concerted control merging the loading path design flexibility with machinery dynamic response.
66
Abstracts
10-3 MACHINING
MSEC2010-34091
Prediction the Effect of Vibration on Machining Distortion in High-Speed Milling Aeronautical Monolithic Components Qinghua Song Shandong University Xing Ai Shandong University Z. Q. Liu Shandong University
High-speed milling technology is being widely used in many different fields, such as aeronautics and astronautics, automobile, and die and mold; especially it is used in highspeed machining of aeronautical monolithic components. In the milling process of monolithic components, large machining distortions are often observed. With an increase of machining velocity, chatter vibration due to the dynamic interactions between tool and workpiece is one of the most common detrimental phenomena and a major obstruction toward achieving automation, higher productivity, and better surface finish; it also plays an important role in machining distortion. However, influences of vibration on machining distortion of monolithic components have not been previously reported. The main contribution of this submission is that, based on the stability lobe diagram of a two-degrees-of-freedom milling system obtained by using the numerical method, two kinds of cutting conditions (stable and unstable) are selected to perform the cutting tests of aeronautical monolithic components. Cutting distortion and secular distortion are measured and analyzed by using the MISTRAL 775 coordinate measuring machine (CMM), respectively. Influences of chatter on machining distortion are investigated. Machining-induced residual stresses are also simultaneously measured by using the XStress 3000. It is shown that both cutting distortion and secular distortion are smaller in the stable case; in the unstable case, cutting distortion is also smaller, while secular distortion is very large, and torsion occurs in the workpiece end with a larger box. Machined-induced residual stress is one of the most important factors yielding machined distortion. Therefore, the workpiece needs to be machined in stable conditions for subsequent assembly work, especially aeronautical monolithic components.
MSEC2010-34118
Study on the Influence of Different Tool Edge Radius on Milling Ti6Al4V Yueping Liu Shandong University Jianfeng Li Shandong University Jie Sun Shandong University Feng Jiang Shandong University
Ti6Al4V has been widely used in the aviation and space industries due to its excellent mechanical properties. However, Ti6Al4V is a typical difficult-to-cut material. Its low elastic modulus could cause a serious rebound phenomenon; its low thermal conductivity could lead to high cutting temperature; and chemical reaction with almost all tool materials at cutting condition may occur owing to its high chemical activity. Improving surface quality and raising tool life are the main purpose for the Ti6Al4V process study. A cutting tools structure, especially its tool edge preparation, has a great influence on cutting temperature, cutting force, and chip morphology during cutting of Ti6Al4V. Cutting-tool edge preparation is one of key factors that influence the cutting characteristics and tool life. The size of cutting edge radius directly influences the generation and diffusion of cutting temperature in the contact area of the tool chip and tool workpiece. During the process of cutting Ti6Al4V, the elastic deformation in the cutting area will enlarge with the increase of cutting edge radius; meanwhile, cutting heat rises around the cutting edge. Accordingly, the cutting temperature should rise; however, the larger the cutting edge radius is, the bigger the contact area of tool chip and tool workpiece is, and the more diffused heat is induced. So there will be a balance point between heat generation and diffusion where the cutting temperature is the lowest. The temperature plays an important role in machining Ti6Al4V. To obtain the lowest cutting temperatures during Ti6Al4V machining, FEM numerical analysis and experiment study are combined to optimize the edge preparation size. First, the FEM model of the round cutting edge is precisely built with AdvantEdge software to simulate and analyze the process of milling Ti6Al4V, dynamically. Then, the experiment corresponding to the simulation is designed to verify the accuracy of the FEM model. At last, based on the accurate FEM model, the influence of a different cutting edge radius on cutting temperature, cutting force, and chip appearance during cutting Ti6Al4V is investigated. Aimed at the lowest cutting temperature, the optimum size of round edge radius to cutting Ti6Al4V is obtained.
67
Abstracts
MSEC2010-34122
Experimental Investigation of Interactions between Abrasive Tool and Workpiece in Honing Qiang Feng Tianjin University C. Z. Ren Tianjin University Yong Zhao Tianjin University Z. J. Pei Kansas State University
Honing is a material-removal process with a fixed-grain abrasive tool that has surface contact with the workpiece. The honed surface has a profound effect on the tribological performance. The interactions between abrasive tool and workpiece in honing determine the honed surfaces. This paper reports an experimental investigation on tool workpiece interactions during honing. It studied the scratch number, scratch depth, real contact area, and honing force in honing of a steel cylindrical workpiece by constant pressure with vitrified-bonded alumina stones. The results showed that grain size and honing pressure have significant effects on the toolworkpiece interaction.
MSEC2010-34229
Dimension Error in the Presence of Process and Machine Error in End Milling Hao Ning Chiang National Cheng Kung University J. J. Wang National Cheng Kung University Fu-Chuan Hsu Metal Industries Research & Development Centre Yu Ju Li National Cheng Kung University
The contribution of process and machine errors to the dimension error of machined parts was investigated in this study. End milling was performed in two different types of machine configuration (XFYZ and XYFZ) in order to evaluate the dimension error caused by process and spatial errors of machine tools. The spatial machine errors were obtained by the sequential diagonal method with the Doppler laser displacement meter. For the process error, a simple average force model for a single cutting point and the identified structure stiffness is used to calculate the force-induced surface error along the tool axis direction. Surface error due to tool run-out effect is also considered as a contributing factor to the process error. Finally, the prediction model of dimension error for end milling was established by analyzing the machine positioning error and process error. The error-prediction model was confirmed by different milling conditions of radial depth of cut and cutting fluid supply parameters. The dimension error of machined parts was measured by the coordinate measuring machine (CMM). The experimental results reveal that the proposed model was useful to predict the dimension error of machined workpiece in end milling.
MSEC2010-34165
New Advances in the Machining of Hard Metals Using Physics-Based Modeling Troy Marusich Third Wave Systems
The machining of hard metals has historically been understood to be challenging and costly due to its material properties (such as titaniums low thermal conductivity and high hardness, and nickels rapid work-hardening and high strength at elevated temperatures) and limited industry understanding of the physics behind chip formation and material removal. The achievement of meaningful cycle time reductions while maintaining part quality depends on a capability to model the physics of hard metal machining operations. With the help of a validated tool-path analysis model that can predict forces at each cutter location, cycle times and scrap can be reduced, and machine breakdown can be avoided, all through off-line analysis. Productivity and process efficiency can be improved through simulation, drastically reducing testing setup and machining time. Physics-based modeling technology has been identified as a cost-effective solution for identifying optimum cutting speeds, enabling researchers and manufacturers to increase material removal rates, reduce machining costs, and enhance industry expertise in hard metal machining best practices. This paper presents new advances to physics-based modeling that have been validated using experimental tests and comparisons to finite element milling simulations, used to compare different process parameters and resulting material removal rates, and successfully advance hard metal machining processes.
10-4 NONTRADITIONAL PROCESSES

MSEC2010-34089
Virtual 3D Model Simulation for Design and Implementation of Automated Processes Richard Chiou Drexel University Yongjin Kwon Ajou University Sang C. Park Ajou University Robin Kizirian Drexel University Yueh-Ting Yang Drexel University Matthew Dordai Drexel University
This paper presents the integration and implementation of automated processes, based on the sequence control specifications and requirements of programmable logic controller (PLC) systems to create a virtual test environment using a software simulation tool, PLCStudio. In order to meet the demands of the new manufacturing paradigm, PLCStudio is being designed as a next-generation tool for digital production. This production solution set represents
68
Abstracts
an integrated suite that provides manufacturing process design, tool and fixture design, factory and production systems design, visualization, and automation through 3D virtual simulation tools. The significant effects and benefits for the manufacturer from such a suite of tools would be a substantial reduction to the manufacturing life cycle. This includes reduction of the assembly time and a cut down on the costs for a process development through the virtual validation and commissioning of production systems. In this paper, a process with quantifiable goals and efficiencies utilizing a robot and other devices is developed. PLCStudio is used to model the process. PLC logic control is developed to control the system and tested virtually using PLCStudio before it is used in a full-scale physical test.
the mechanisms exiting in the densification process play a key role to understanding the pelleting of cellulosic biomass. This paper presents an overview of the modeling about the densification process, particle size distribution, and reduction in milling process and effects of process variables.
MSEC2010-34264
Simulation of Diamond Disk Conditioning in Chemical Mechanical Polishing: Effects of Conditioning Parameters on Pad Surface Shape Emmanuel Baisie North Carolina Agricultural & Technical State University Zhichao (Zinc) Li North Carolina Agricultural & Technical State University Xiaohong (Tina) Zhang Seagate Technology LLC
Diamond disk conditioning is traditionally employed to restore pad planarity and surface roughness in chemical mechanical polishing (CMP). In this paper, a mathematic model is developed by using a surface element method to simulate and predict the pad surface shape resulting from diamond disk conditioning. The developed model is then validated by published experimental data. Three metrics [total thickness variation (TTV), bow, and nonuniformity (NU)] are defined and utilized to evaluate the pad surface shape. Based on the validated model, effects of conditioning parameters (including sweeping profile, pad rotating speed, conditioner rotating speed, and conditioner diameter) on the pad surface shape are further investigated and discussed.
MSEC2010-34104
Effects of Airflow, Draw Temperature, and Boundary Conditions on Hardening in Ice Cream Manufacturing Nicholas Rauth Kansas State University Mark Miller Kansas State University X. J. Xin Kansas State University Z. J. Pei Kansas State University Karen Schmidt Kansas State University
Energy consumption by the dairy food industry in the United States constitutes 10% of all energy consumed by the U.S. food industry, and reducing energy consumption in cooling and refrigeration of foods plays an important role in meeting the challenge of the energy crisis. Hardening is an important and energy-intensive step in ice cream manufacturing. This work presents a finite element method (FEM) investigation of the hardening process in ice cream manufacturing and assesses the accuracy and acceptability of the presented FEM methods. The FEM results are compared to experimental data from the literature, and sources of variation, including convection coefficient, bottom surface boundary condition, and draw temperature, are explored.
10-5 FORMING, MACHINING, AND NONTRADITIONAL PROCESSES

MSEC2010-34029
Self-Consistent Model of Laminated Composites Zhu Yiguo Dalian University of Technology Zhao Dan Dalian University of Technology Hu Ping Dalian University of Technology
A self-consistent model of laminated composites was constructed. In the model, macroscopic and microscopic stress and strain were divided into two parts, one was an inplane part and the other was an out-of-plane part. Then the stiffness and compliance matrices could be partitioned. By using the definitions of macroscopic stress and strain and perfect interface condition, one could get the analytical expressions of macroscopic stiffness and compliance of two-layer composites. Macroscopic stiffness and compliance of multilayer composites could be obtained based on the analytical expressions. The reciprocal
MSEC2010-34201
A Review of Modeling in Pelleting of Cellulosic Biomass Na Qin Kansas State University Z. J. Pei Kansas State University
Biomass materials derived from living plants, animal manures, waste products, and other biological sources are renewable source of energy and environmentally benign. They are used as one of the substitutes for fossil fuels. However, due to their heterogeneous nature, biomass materials possess inherently low bulk densities; thus, it is difficult to efficiently transport and store large quantities of feedstocks. In order to combat the negative handling aspects of bulk biomass, densification is often needed. And
69
Abstracts
property of the stiffness and compliance matrices could be proved by numerical tests and theoretical analysis.
MSEC2010-34162
Using an Airy Function to Predict Stresses in Wound Metal Strip Having Asymmetric Thickness Profile Jantzen Hinton Wright State University Paul Gross Wright State University Kevin Hoos Wright State University Arif Malik Saint Louis University Ramana Grandhi Wright State University
This work analyzes the evolution of stresses during the rewinding of flat-rolled steels having an asymmetric strip thickness profile (or wedge). When monitoring the stress distribution across the width of the sheet, control systems with strip flatness meters are unable to distinguish between rolled-in stresses and the stresses caused by winding. To avoid strip flatness defects, an efficient and accurate method was developed to separate the winding stress contribution from the overall stresses that are measured indirectly by a flatness control system. Commercial finite element software was first applied to determine in-plane evolution of stresses in a strip containing 2% wedge for various numbers of mandrel wraps during rewinding. The finite element analysis enabled a trend study that provided insight as to how the in-plane stresses in the rolled sheet evolve during the winding process. Coefficients of a fourthorder polynomial Airy stress function were then obtained to predict the stresses according to the mandrel wrap number and planar spatial position on the strip. With this approach, only a single function is needed to predict the entire inplane stress field. This paper illustrates development of the Airy stress function, characteristics of the in-plane stresses during winding of strip with asymmetric thickness profile, and an example in which the winding stresses are filtered out from the measured inputs to a flatness control system.
MSEC2010-34142
Forming Force Prediction in Two-Point Incremental Forming Using Backpropagation Neural Networks in Combination with Genetic Algorithms M. Luisa Garcia-Romeu University of Girona Elisabetta Ceretti University of Brescia Antonio Fiorentino Universita degli Studi di Brescia Claudio Giardini University of Bergamo
Process feasibility and material formability are two of the most concerning factors that are studied in the sheet incremental forming (SIF) process. They are two important matters under study of the scientific community with the final goal of improving the process performances and to make it reliable to allow its use for rapid prototyping and for small batch production. In recent years, the application of neural network techniques to forming processes has been a research topic for optimizing and predicting process parameters and the SIF process has not been an exception. Unfortunately, there are some drawbacks in using backpropagation (BP) neural networks, such as easily falling into the local minimum point. Because of that, recently, genetic algorithms (GAs) are applied to BP networks in order to optimize them. This paper describes the application of BP networks and GAs applied to BP networks for the prediction of the forming force in the SIF process. These models have been developed using experimental data from several tests. The two-point incremental forming (TPIF) tests were performed on a horizontal CNC milling machine, and DC04 deep-drawing sheets of steel 0.8 mm thick were worked. The reliability of the proposed approach has been evaluated by testing the trained networks with unseen experimental data, and the comparison between the two BP and GA-BP models are presented. All the details are accurately discussed in the paper.
70
Abstracts
10-6 MACHINING 2
MSEC2010-34137
Simulation of Facing Processes of Profiles with Hexagon Cross Section Rainer Britz Technischen Universitt Mnchen Heinz Ulbrich Technischen Universitt Mnchen
Interactions between machine structures and manufacturing processes, such as vibrations due to unsteady cutting, limit the process flow. With a detailed prediction of these interactions, it is possible to optimize operation charts, machine parameters, path parameters, and so on. The goal of the project Parametric modeling, prediction, and optimization of interaction between machining process and structure using multibody systems and implicit filtering, a part of the SPP1180, financed by the DFG (German Research Foundation), is to build a simulation model of an existing turning lathe and to optimize the manufacturing process with an appropriate optimization algorithm. The project is a collaboration with the Institute for Machine Tools and Industrial Management, Technische Universitt Mnchen (IWB). The major tasks are to build a model of the machine and to formulate the couplings between the machine model and the process model. In this paper, an overview of the mechanical model of the machine and the cutting model used is given as well as the coupling between the process and structure model. The simulated process starts at the point of the tool change and moves to the point where the cutting starts. At this point, the exact time of contact between the chisel and the workpiece is detected and an additional connection between chisel and workpiece is established. This process is modeled by a modified unilateral contact augmented by a cutting model. The mechanical model of the machine tool is built up using rigid bodies that are connected by spring damper elements. Chisel and workpiece are also modeled as rigid bodies. The drives of the slides are modeled by a kinetic excitation. The cutting edge of the chisel is modeled as one point and vectors that define the rake face. The shape of the workpiece is modeled by a contour path. This parametrization allows calculation of the cutting angles, depending on the orientation between chisel and workpiece. The goal of this work is to detect the transitions between open and closed cutting contact and to embed the cutting model in a way that allows the separation of chisel and tool during the work process. The face turning of a profile with a hexagon cross section is used as test case. Finally, results of the simulation are shown and compared to measurements.
MSEC2010-34141
Thermal Modeling of Workpiece Temperature in MQL Deep-Hole Drilling Bruce L. Tai University of Michigan David A. Stephenson University of Michigan Albert J. Shih University of Michigan
This study investigates the workpiece temperature in minimum-quantity lubrication (MQL) deep-hole drilling. An FEA-based inverse heat transfer model is developed to estimate the heat generation based on temperature inputs from embedded thermocouples. The temperature distribution in the workpiece is then calculated by the inverse solutions. The method is validated experimentally using a 10 mm carbide drill drilling a cylindrical iron workpiece under both dry and MQL conditions. The calculated temperature distribution shows good agreement with experimental temperature measurements. This study demonstrates that the heat generated on the hole wall surface is as significant in workpiece temperature as that on the hole bottom surface in deep-hole drilling.
MSEC2010-34309
A 3D Finite Element Study on Material Flow under the Cutting Edge in Hard Milling H. Singh University of Alabama Y. B. Guo University of Alabama
A 3D finite element model of hard milling has been created to have deeper insight into some key issues. The model illustrates the effects of milling insert geometry on ploughed depth, material flow, transition from ploughing to cutting, and stresses and temperatures in the subsurface. Different ploughing depths from 0.63.0 m are used to study the effects. The Johnson-Cook constitutive equation is used to model the plastic behavior of workpiece material AISI H13 steel (50 1 HRC). Surface and subsurface transient stresses and temperatures during ploughing show similar characteristics, except the magnitudes. A ploughing depth of 1.8 m corresponding to stagnation angle 35 is observed to be the threshold minimum uncut chip thickness at which transition from ploughing to cutting takes place. The material flow pattern with pileup characteristics in front of the tool rake face is presented.
71
Abstracts
MSEC2010-34325
Cutting Force Modeling When Milling Nickel-Base Superalloys Andrew Henderson Clemson University International Center for Automotive Research Cristina Bunget Clemson University Thomas R. Kurfess Clemson University International Center for Automotive Research
Superalloys are a relatively new class of materials that exhibit high mechanical strength, ductility, creep resistance at high operating temperatures, high fatigue strength, and typically superior resistance to corrosion and oxidation, even at elevated temperatures. These properties make superalloys ideal for applications in aircraft, cryogenic tanks, submarines, nuclear reactors, and petrochemical equipment. In the aerospace industry, the most commonly used superalloy is the nickel-base alloy, which accounts for 30 50% of the total material required in the manufacturing of the aircraft engine. It is used for rotating parts of gas turbines such as blades and disks, engine mounts, turbine casings, and components for rocket motors and pumps. To make full use of nickel-base superalloys, a machining process must be developed that is capable of controlling and identifying tool wear, and identifying the onset of subsurface damage and controlling its formation during processing. To accomplish this, a model relating process characteristics and cutting parameters needs to be developed. Due to high tool wear, the cutting forces increase drastically during machining, thus making it impossible to estimate the forces with existing models. This research proposes an update to the specific cutting forces model, taking into consideration rapid tool wear. As milling is the most common machining processes used to cut superalloys (e.g., turbine blades), it is specifically targeted by this research. Experiments were conducted under different cutting conditions to observe the cutting characteristics of nickel-base superalloys. Empirical observations were used to formulate updated coefficients. Later, this model will be applied for real-time control of the process results, such as geometry, tool wear, and subsurface damage, and also for estimation and control of other quantities, such as force, deflection, surface quality, and energy consumed. This will provide new insights into machining these advanced alloys.
10-7 MACHINING 3
MSEC2010-34186
Sensitivity of Steady State Intermittent Cutting Motion to Workpiece Characteristics Brandon Gegg Texas A&M University Steve Suh Texas A&M University
The tool and workpiece interactions will be modeled via discontinuous systems to study the effects of workpiece characteristics on the sensitivity of steady state motions. The general model will be presented through the domains of continuous dynamical systems for this machine tool. The periodic motions of intermittent cutting will be developed and implemented to describe the solution structure. The switching components at the chip/tool friction boundary will be discussed in regard to workpiece characteristics.
MSEC2010-34222
Utilizing Recurrence Quantification Analysis for Chatter Detection in Turning Rajesh Vazhayil Govindan KMEA Engineering College Narayanan Namboothiri V N Cochin University of Science and Technology
Recurrence quantification analysis (RQA) quantifies the number and duration of recurrences of the nonlinear dynamical system presented by its phase-space trajectory. The present work analyzes the dynamics of the cutting process in a lathe by studying the recurrent behavior of the system using RQA. It reports the capability of this analysis to detect the transition from chatter-free cutting to chatter cutting that occurs due to instability of the cutting process, during the turning operation. The study reveals that the RQA variable, percent determinism, is sensitive to this transition. It is found that the value of this variable increases when chatter occurs.
72
Abstracts
MSEC2010-34306
Case Studies of Diamond-Coated Tool-Cutting Simulations: Coating Thickness and Cutting Speed Effects Feng Qin University of Alabama Kevin Chou University of Alabama
Due to the interwoven effects in both diamond deposition and subsequent machining processes, the tool geometry and process parameters have compound effects on the thermal and mechanical states in diamond-coated cutting tools during machining. For example, increasing the coating thickness tends to increase deposition-induced residual stresses at the tool-edge interface. Furthermore, a thick coating will introduce a greater machining load due to an enlarged edge radius. However, it has not been investigated how the coating thickness affects the thermomechanical behaviors of diamond-coated tools during machining. In a previous study, finite elementbased simulations were developed to conduct systematic analyses of diamond-coated tool cutting. In this work, the developed 2D cutting simulations that incorporate deposition residual stresses were applied to evaluate the coating thickness and cutting speed effects on the tool stress contours, tool temperatures, as well as the interface stresses around a cutting edge. The major findings can be summarized as follows: (1) The coating thickness effect on the first principal stress is minor. A thicker coating can decrease cutting temperature effectively but increase the thrust force noticeably. Additionally, a thicker coating is also favorable for the reduction of interface radial normal stresses around the cutting edge. (2) For a constant coated tool edge radius, decreasing the substrate edge radius (while increasing the coating thickness) will elevate the maximum first principal stresses but significantly reduce tool temperatures and the interface radial normal stresses. (3) The cutting speed has little effect on the first principal stresses, but strongly affects the cutting-tool temperatures. Moreover, the interface radial normal stresses and circumferential stresses decrease with the increase of cutting speed, which is intuitive, since higher cutting temperatures associated with a high cutting speed are expected to relieve high-deposition stresses.

11-1 LASER MICRO/NANO PROCESSING
MSEC2010-34109
Nanosecond Laser Ablation of Titanium in Air and Water: The Time-Resolved Observation and Postprocess Characterizations Yun Zhou Illinois Institute of Technology Yibo Gao Illinois Institute of Technology Benxin Wu Illinois Institute of Technology
Titanium has lots of competitive applications in aerospace, biomedical, and many other areas due to its special properties. However, the machining of titanium using conventional mechanical approaches often has serious tool wear and low efficiency. Laser ablation can potentially provide a good solution for titanium micromachining. In this paper, nanosecond laser ablation of titanium in air and water has been studied. The laser ablation rate, laserinduced plasma, the ablated surface profile, and chemical composition change have been studied, and the results are discussed.
73
Abstracts
MSEC2010-34111
Laser Beam Propagation through ThreeDimensional High-Aspect-Ratio Microholes Sha Tao Illinois Institute of Technology Benxin Wu Illinois Institute of Technology Shuting Lei Kansas State University
The drilling of high-aspect-ratio microholes has very important applications in automotive, aerospace, electronics, and other areas. However, this is difficult to realize with conventional mechanical machining or electrical discharge machining approaches. Laser ablation can potentially provide a good solution to this, but it also involves many technical difficulties. One of these is that the hole structure may act like a waveguide and affect the laser beam propagation. However, previous investigations on this important issue are very limited. In this paper, laser beam propagation through high-aspect-ratio microholes has been studied by solving the three-dimensional transient Maxwells wave equation, and important discoveries from the calculations are discussed.
MSEC2010-34299
Study of Effect of Multiple Pulses on the Deformation Behavior of Ultrathin Metal Foils in 3D Microscale Laser Dynamic Forming Ji Li Purdue University
Laser dynamic forming (LDF) is a novel high-energy-rate microfabrication technique, which makes use of the shock pressure induced by laser to generate dynamic high-strainrate 3D forming of thin films. In the LDF process, a high shock pressure accelerates the workpiece to a high velocity and deforms it into complex 3D shapes. The forming velocity of the workpiece imparted by a single laser pulse with high energy may exceed the critical forming velocity of the material, thus causing it to fracture. This problem is more severe when the 3D structure of large aspect ratio needs to be formed. To overcome this problem, multipulse laser dynamic forming is investigated in this study. The total laser energy is evenly distributed in different laser pulses to keep the forming velocity below the critical forming velocity of the material. The effects of the multiple-pulse LDF on the deformation behavior of ultrathin foils are investigated. The deformation depth and thickness variation distribution of the formed 3D features are characterized to reveal these effects. In addition, the effects of vacuum conditions on multiple-pulse LDF process are carried out. It is found that the bounce off of the foil can be effectively reduced by multiple-pulse LDF, and the final shape could be controlled much more accurately. By extending single-pulse LDF to multipulse LDF, the forming capability of LDF is further enhanced and thus enlarges the applicable range of this technique.
MSEC2010-34271
Femtosecond Laser-Induced Surface Texturing and Crystallization of a-Si:H Thin Film Hongliang Wang Columbia University Panjawat Kongsuwan Columbia University Gen Satoh Columbia University Y. Lawrence Yao Columbia University
Hydrogenated amorphous silicon (a-Si:H) thin films have been considered for use in solar cell applications because of their significantly reduced cost; however, the overall efficiency and stability are less than that of their bulk crystalline counterparts. Limited work has been performed on solving the efficiency and stability issues of a-Si:H, simultaneously. In this study, both surface texturing and crystallization on a-Si:H thin film are achieved through onestep femtosecond laser processing in water. Light absorption is enhanced by light trapping based on surface geometry changes, and the formation of a mixture of hydrogenated microcrystalline silicon (c-Si:H) and a-Si:H after crystallization suggests that the overall stability may be increased. Furthermore, the formation mechanism for the surface spikes is discussed. A comparison of absorptance spectra for various surface morphologies and crystallinities shows that the combination of surface texturing and crystallization induced by femtosecond laser processing is very promising for a-Si:H thin-film solar cell applications.
11-2 LASER INDUCED PLASTIC

DEFORMATION
MSEC2010-34164
Finite Element Analysis of the Effect of Overlapping Impacts of Laser Shock Peening within Annealed AISI 1053 Steel Rohit Voothaluru Purdue University C. Richard Liu Purdue University
Laser shock peening is a surface-treatment technique similar to conventional shot peening. The laser-induced plasma causes plastic deformations and compressive residual stresses in materials that are useful for developing improved properties in the fields of fatigue, wear, or stress corrosion cracking. The finite element method is an efficient tool to predict the mechanical effects and deformations caused due to laser shock peening, which otherwise are difficult to calculate due to the severe pressure imparted in
74
Abstracts
a very short period of time. This paper presents the calculations performed using ABAQUS, for the simulation of multiple laser shock processing in order to evaluate the residual stress and the deformation of the material. A study of the effect of multiple laser shocks and their extent of overlap on the affected depths and the tensile and compressive residual stresses has been discussed. FEM calculations of residual stress fields and the extent of surface deformation in annealed AISI 1053 steel has been investigated along with a study of the distribution of tensile and compressive residual stresses due to the difference in the extent of overlap of the multiple shocks.
has been used by investigating the WLSP process with experiments and analytical modeling. An analytical model has been proposed to estimate the density of available nucleation sites in metallic materials after WLSP. The effects of processing temperature and high-strain-rate deformation on the activation energy of nucleation have been considered in this model. This model is based on the assumption that dynamic strain aging during WLSP can be assisted by the dense dislocation structures and warm temperature. This assumption is backed up by TEM study after WLSP, in which highly dense dislocations are surrounded by high density of precipitates.
MSEC2010-34282
Formability of Open-Cell Aluminum Foams by Laser Loredana Santo University of Rome Tor Vergata Alessandro Guglielmotti University of Rome Tor Vergata Fabrizio Quadrini University of Rome Tor Vergata
A new forming method for open-cell aluminum (Al) foams by laser was introduced. Laser forming is generally applied to sheet metals, but a good formability was observed also for Al alloy cellular structures. In this study, laser bending tests were performed on rectangular samples made of open-cell Al alloy foams by means of a diode laser. Laser scan velocity and power were changed in the experimentation so as to identify the best process conditions for three different Al foams. A finite element model was implemented to simulate the laser-material interaction during forming in dependence of the foam structure. At fixed values of laser velocity and power, higher bending angles were obtained for foams with smaller pores, but changing the process parameters, a better formability was observed for the foams with bigger pores.
MSEC2010-34301
Fatigue Performance Improvement by Dynamic Strain Aging and Dynamic Precipitation in Warm Laser Shock Peening of AISI 4140 Steel Chang Ye Purdue University Gary J. Cheng Purdue University
Warm laser shock peening (WLSP) integrates the advantages of laser shock peening and thermal-mechanical treatment (TMT) to improve material fatigue performance. Compared to traditional laser shock peening (LSP), warm laser shock peening, i.e., LSP at elevated temperature, leads to better performance in many aspects. WLSP can induce nanoscale precipitations by dynamic precipitation and high-density dislocation by dynamic strain aging (DSA), resulting in higher surface strength, which is beneficial for fatigue life improvement. Due to pinning of dislocation structure by nanoscale precipitates and the pinning of dislocation structure by Cottrell atmosphere, or the DSA effect, stability of the dislocation arrangement is significantly increased and the residual stress stability improved. In this study, AISI 4140 steel is used to evaluate WLSP process. It is concluded that the higher residual stress stability and higher surface strength caused by dynamic precipitation and DSA in WLSP leads to fatigue-life improvement.
MSEC2010-34297
Nucleation of Highly Dense Nanoscale Precipitates Based on an Innovative Process: Warm Laser Shock Peening Yiliang Liao Purdue University Chang Ye Purdue University Gary J. Cheng Purdue University
Warm laser shock peening (WLSP) is an innovative thermomechanical processing technique that combines the advantages of laser shock peening (LSP) and dynamic strain aging (DSA). It has been found that a unique microstructure with a high density of nanoscale precipitates surrounded by dense dislocation structures is generated by WLSP. In order to understand the nucleation mechanism of the highly dense precipitates during WLSP, Al 6061 alloy
11-3 LASER ENGINEERED FUNCTIONAL

SURFACES
MSEC2010-34250
Characterization and Prediction of Texture in Laser Annealed NiTi Shape Memory Thin Films Gen Satoh Columbia University Xu Huang Yale University Ainissa Ramirez Yale University Y. Lawrence Yao Columbia University
Thin-film shape memory alloys are a promising material for use in microscale devices for actuation and sensing due to
75
Abstracts
their strong actuating force, substantial displacements, and large surface-to-volume ratios. NiTi, in particular, has been of great interest due to its biocompatibility and corrosion resistance. Effort has been directed toward adjusting the microstructure of as-deposited films in order to modify their shape memory properties for specific applications. The anisotropy of the shape memory and superelastic effects suggests that inducing preferred orientations could allow for optimization of shape memory properties. Limited work, however, has been performed on adjusting the crystallographic texture of these films. In this study, thin-film NiTi samples are processed using excimer laser crystallization and the effect on the overall preferred orientation is analyzed through the use of electron backscatter diffraction and x-ray diffraction. A threedimensional Monte Carlo grain growth model is developed to characterize textures formed through surface-energy induced abnormal grain growth during solidification. Furthermore, a scaling factor between Monte Carlo steps and real time is determined to aid in the prediction of texture changes during laser crystallization in the partial melting regime.
MSEC2010-34295
Laser Coating of HAp/Ti Nanoparticles on Metal Implants: Interfacial Bonding Strength, Chemical Analysis, and Biocompatibility Martin Y. Zhang Purdue University Gary J. Cheng Purdue University
In this paper, laser coating of hydroxyapatite (HAp) and titanium (Ti) nanoparticles on Ti-6Al-4V implants was developed. An Nd:YAG laser was used to coat multilayers of HAp and titanium nanoparticles on implants. This coating process has the following advantages: (1) Low-temperature coating of nanoscale HAp is realized due to good sinterability of titanium nanoparticles; (2) high interfacial strength between layer and substrate because of the functional multilayer coating; (3) HAp nanoparticles provide better biocompability than microparticles; and (4) biphasic calcium phosphate (BCP) could be introduced, which has been reported to have excellent biocompatibility. In order to achieve these goals, careful selection of laser-processing parameters is required. A multiphysics model is built and validated with experiments. This model is employed to determine the appropriate laser-processing conditions. After laser processing, the features of the coated samples were characterized, including microstructures, chemical compositions, surface roughness, structure porosity, and interfacial bonding strength. Qualitative cell culture studies with osteoblast-like UMR-105 cells were carried out to reveal the biocompatibility of so-coated implants. It is found that multilayer laser-coated nanoHAp/Ti implants has beneficial biocompatibility, surface roughness, maintained chemical composition, porous microstructure, and strong coating/substrate interfacial strength.
MSEC2010-34283
Improving Biocompatibily of Laser Micromachined Silicon Wafer by Surface Coating with Poly(Ethylene Glycol) Diacrylate and Diamondlike Carbon for Biomedical Devices Yuan-Shin Lee North Carolina State University
This paper presents a study of laser micromachining and the effect of the micromachined regions on the biocompatibility in the protein adsorption for medical device applications. From the study, the surface roughness on the micromachined area promoted the protein adsorption; thus, it probably causes the thrombus formation for the application in the cardiovascular or blood related devices. In contrast, this incident can enhance the cell promotion that is helpful for the biomedical implant MEMS devices. To modify the surface property in biocompatibility, both diamondlike carbon (DLC) coating and polyethyleneglycol diacrylate (PEGDA), the protein-resistant and biocompatible materials, were proposed in this research. The UV lithography for coating PEGDA and pulse laser deposition for coating DLC on the laser micromachined substrates were applied while the coated substrates were biocompatibility tested with bovine serum albumin (BSA) to observe the protein adsorption. To image the quantity of adsorption, the fluorescein-labeled BSA was used for the fluorescent microscope to clearly image the reflective light. This study proposed a good opportunity for major novel techniques such as laser micromachining, PLD, and UV lithography in developing and prototyping biocompatible MEMS devices.
11-4 LASER MATERIAL INTERACTIONS

MSEC2010-34110
Nanosecond Laser Ablation of Silicon Carbide at Infrared Wavelength Yibo Gao Illinois Institute of Technology Yun Zhou Illinois Institute of Technology Benxin Wu Illinois Institute of Technology
Silicon carbide, due to its unique properties, has many promising applications in optics, electronics, and other areas. However, it is difficult to process using mechanical machining or electrical discharge machining due to its electrical insulation, high hardness, and brittleness. Laser ablation can potentially provide a good solution for silicon carbide micromachining. However, the study on silicon carbide ablation by nanosecond laser pulses at infrared wavelength is limited and will be presented in this paper. The laser ablation rate, laser-induced plasma, the ablated
76
Abstracts
surface morphology, and chemical composition change have been studied, and the results are discussed.
MSEC2010-34300
A Dislocation Dynamics-Based Constitutive Model and Experimental Validations by 3D Microscale Laser Dynamic Forming of Metallic Thin Films Huang Gao Purdue University Gary J. Cheng Purdue University
Microscale laser dynamic forming (LDF) shows great potential in fabricating the robust and high-aspect-ratio metallic microcomponents by the high-speed plasma shockwave. Experiments revealed that strain rate and sample size play important roles in determining the final results of LDF. To further understand the deformation behavior, we develop a constitutive model integrating size effects and ultrahigh-strain-rate effects to predict the ultimate plastic deformations. To derive this model, 3-D discrete dislocation dynamics (DDD) simulations are first set up to investigate the dislocation evolutions and the dynamic responses during shockwave propagation. It is observed that there exist three dynamic stages during the deformation process, and the initial strain-hardening rate in stage II increases with strain rate. The simulation also reveals that strain softening occurs only for the smaller cell size due to two competing mechanisms. In addition, the simulation predicts that the flow stress and yield strength increase with the strain rate and decrease with cell size. The modified mechanical threshold stress (MTS) model integrating these effects is implemented in Abaqus/Explicit and predicts the deformation depth and thickness variations in good agreement with the experimental results.
MSEC2010-34247
Investigation on Porosity Formation in AA6082 Hybrid Laser-GMAW Welding Alessandro Ascari University of Bologna Alessandro Fortunato University of Bologna Leonardo Orazi University of Modena and Reggio Emilia Giampaolo Campana University of Bologna Giovanni Tani University of Bologna
This paper refers to the results obtained in the investigation on bubbles formation in hybrid laser-GMAW welding. Bead on plate weldings were obtained on 8 mm thick AA6082 plates, and the process parameters investigated were: GMAW current, arc transfer mode, and mutual distance between arc and laser sources. Bubbles were observed by means of X-ray inspection techniques and measured exploiting an image analysis software. Finally, a correlation, based on analysis of variance, between process parameters and porosity formation is proposed.
MSEC2010-34252
Investigation of Fluid Flow and Heat Transfer in 3D Dual Beam Laser Welding Jun Zhou Penn State Erie, The Behrend College Hai-Lung Tsai Missouri University of Science and Technology
Dual-beam laser welding has become an emerging joining technique. Studies have demonstrated that it can provide benefits over conventional single-beam laser welding, such as increasing keyhole stability, slowing down cooling rate, and delaying the humping onset to a higher welding speed. It is also reported to be able to significantly improve weld quality. However, due to its complexity, the development of this promising technique has been limited to the trial-anderror procedure. In this study, mathematical models are developed to investigate the heat transfer, melt flow, and solidification process in both stationary and moving threedimensional dual-beam laser keyhole welding. Effects of key parameters, such as laser beam configuration on melt flow, weld shape, and keyhole dynamics, are studied. Some experimentally observed phenomena, such as the changes of the weld pool shape from oval to circle and from circle to oval during the welding process are analyzed in the current study.

12-1 MICRO/MESO MECHANICAL MANUFACTURING (I)
MSEC2010-34038
Effect of Grain Size and Specimen Size on Deformation during Microbending Sunal Parasiz Sakarya University Reid VanBenthysen University of New Hampshire Brad Kinsey University of New Hampshire
Sheet metal forming often consists of bending processes in which gradients of deformation exist through the thickness of the workpiece in a localized deformation area. In microscale bending, these deformation gradients become much steeper, as the changes in the deformation occur over short distances (on the order of microns). In addition, with miniaturization the number of grains that are present
77
Abstracts
through the thickness decreases significantly. In this research, the effect of grain size and specimen size on the deformation distribution through the thickness of microbent sheet specimens was investigated via microhardness evaluations. It was found that the deformation distribution, i.e., hardness profile, is not affected significantly by the grain size when the sheet thickness is large (for 1.625 mm specimens) or by miniaturization of the specimen size when the grain size is fine. However, the deformation distribution of the coarse-grained specimens deviates from the finegrained ones and from the 1.625 mm thick sheet specimens when the specimen size is miniaturized.
MSEC2010-34242
Laser-Induced Plasma Micromachining Kumar Pallav Northwestern University Kornel F. Ehmann Northwestern University
The paper introduces a new micromachining process that is motivated by the need to overcome the various limitations associated with the micro-EDM (-EDM) process. The limitations in -EDM are primarily due to the requirement of a conductive electrode and workpiece, tool wear, and complex wear compensation strategies. The new process, termed laser-induced plasma micromachining uses a laser beam to generate plasma in a dielectric near the workpiece surface whose explosive expansion results in material removal by mechanisms similar to those that occur in EDM.
MSEC2010-34227
Development of an Axisymmetric Pressure Application Method for Cylindrical Laminated Device Fabrication James H. Vlieg Oregon State University Brian K. Paul Oregon State University Richard B. Peterson Oregon State University
Microchannel arrays are being developed across a wide spectrum of applications, including blood processing, fuel cells, and thermal management, among many others. Typical arrays are based on a flat laminated architecture produced in a vacuum hot press (VHP) through uniaxial bonding pressure at elevated temperatures. Due to the cylindrical nature of certain microchannel applications, such as chemical processing within chemical facilities and heat rejection within Stirling cycle engines, the packaging of microchannel devices within cylindrical geometries would greatly simplify interconnect. This paper describes the development of a novel technique for an axisymmetric diffusion bonding pressure application with the use of a VHP capable of producing cylindrical laminated devices. Uniaxial bonding pressure is converted to axisymmetric pressure through the use of conical wedges. Pressure magnitude and distribution are controlled by the geometry of the pressure delivery platens, the design of which was aided by finite element analysis. Cylindrical test articles were produced by patterning thin metal foils by laser machining a single roll of metal shim stock, which was then coiled within an outer tube shell and axisymmetrically bonded with the VHP to produce a cylindrical laminated workpiece. Preliminary bonding results show quality bond lines with minimal void fractions. This new architecture is shown to be feasible for producing cylindrical laminated devices by microlamination using traditional VHP equipment.
78
Abstracts
12-2 MICRO/MESO MECHANICAL MANUFACTURING (II)

MSEC2010-34174
Ultrahigh-Speed Micromachining Said Jahanmir Mohawk Innovative Technology, Inc.
Product miniaturization has led to the development of micromanufacturing technology. Industries such as defense, medical, industrial packaging, and transportation require the manufacturing of small-sized precision components with miniaturized features. Currently these parts are being fabricated with silicon technology, with large-scale machines or with small desktop machines. For efficient material removal and fast production rates, the speed at the cutting point should be comparable to the speeds achieved in macromachining. While the present micromachining systems offer spindle speeds on the order of 100,000 rpm, the small cutting tools (50 m to 1 mm diameter) used in micromachining limit the surface speeds achieved at the cutting point. This causes a severe limitation on production rates, increases tool wear, and limits the degree of dimensional tolerances and precision that can be obtained. A new ultrahigh-speed microspindle has been developed for micromilling that can be used at rotational speeds as high TM as 500,000 rpm. The fully assembled MiTiUltra Spindle measures only 2 cm in diameter with a height of <4 cm. Since conventional ball bearings or fluid lubricated journal bearings cannot be used at speeds beyond 300,000 rpm for any extended period of time, the MiTiUltra uses a set of journal and thrust foil bearings. The cutting tool was then attached to the rotor using a shrink-fit approach. The microspindle was integrated with a two-axis micromilling machine. Cutting experiments were performed on an aluminum alloy and steel at speeds of >300,000 using 50 and 300 m end mills. The increase in rotational speed to 450,000 rpm in micromilling of aluminum alloy allowed an increase in feed rate to nearly 800 mm/min (the maximum feed rate available by the positioning stage), thus increasing the material removal rate by more than two orders of magnitude. The dimensional accuracy of several straight cuts made at different feed rates and depths of cut was measured. The developed spindle was also used for microgrinding of dental ceramics. In these studies, several ceramics used for preparation of dental restorations were cut with diamond tools. The propensity for generation of machining-related damage, such as surface and subsurface microcracks, were greatly reduced by machining at ultrahigh speeds and high feed rates. Micromachining at such high speeds, and in combination with high feed rates, has never been achieved before. The importance of tribology in the design of the spindle and in chip formation at such speeds is discussed.
MSEC2010-34221
Development of a Small Five-Axis Micromilling Center for Parts up to 100 mm in Diameter Deepkishore Mukhopadhyay Microlution Inc. Andrew Honegger Microlution Inc. Abhinandan Tulsian Microlution Inc. Andy Phillip Microlution Inc. Elizabeth Creighton Microlution Inc.
Over the last decade, there has been a tremendous increase in the use of microscale mechanical parts and devices in a variety of industries. Multiple machine tool builders are responding to this increase in demand by launching new products that are aimed toward machining of miniature parts. However, many of these machines tend to be built on the same design philosophy as their other products and thus reuse many components from existing product lines, leading to their awkward evolution from macroscale applications to address micromachining. Consequently, these machines generally tend to be unnecessarily expensive, large, inefficient, and complex when used for micromachining applications. In this paper, the development of a small five-axis machine tool (the Microlution 5100-S) for production-level micromachining applications is presented. This machine is based on the concept that small parts should be manufactured on specially designed small machines, a.k.a. micromachine tools (mMTs). The performance goals for this development effort were established as follows: 1 m linear positioning accuracy, capability to perform simultaneous five-axis machining on parts up to 100 mm in diameter, maximum acceleration of 2 g, and a high-speed spindle with a maximum speed between 50,000 and 70,000 rpm. Additionally, this development is directed at addressing the needs of high-volume micromachining applications. Hence, the machine required the development of a reliable, highcapacity tool changer and compatibility with many pieces of productivity-enhancing equipments viz. palette transfer robots and chip conveyors. The component selection and development processes for meeting and exceeding the above design goals are presented. The selection processes include the choice of motion-platform components, such as bearings and linear motors, the preference in choices for high-speed spindles, and material for the machine base. The machine structure and configuration are presented, along with results of finite element analysis with regard to the machines static and dynamic deformations. Design and implementation of a thermal control system for the 5100-S that restrict its thermally induced deformations is presented. The efficacy of the thermal system is proven in the form of results obtained from ASME B5.54 and ISO 230-3 tests conducted on the machine tool. The design of the highcapacity tool changer is described that demonstrates its quick tool-wheel change capability, bidirectional tool-access feature for both machine- and operator-level tool handling, and flexibility in accommodating either direct-shank tools or
79
Abstracts
miniature tool holders. The compatibility of the 5100-S with various productivity-enhancing equipment, such as machine-tending robots, chip conveyors, and the microfactory architecture is discussed. Finally, the 5100-S is compared to a select few traditional five-axis machining centers targeted toward micromachining applications with respect to energy usage, estimated productivity, and space utilization.
MSEC2010-34245
Experimental Investigation of Micromilling Accuracy Using on-Machine Measurement System Xinyu Liu Lamar University
In this paper, we proposed an error decomposition method in which some major error components can be experimentally estimated using an on-machine measurement (OMM) system. Unlike the conventional machining, the geometric error of a microtool, i.e., the deviation of the effective tool diameter from a nominal value, becomes a dominant factor affecting the machining accuracy. The error stems from both the tool fabrication error and the dynamic runout of the spindle system under high rpm. An on-machine measurement system based on a noncontact confocal laser sensor was developed that can accurately and efficiently acquire the effective tool diameter. To compensate the error due to the tool geometric error, the effective tool diameter was used to replace the nominal tool diameter to generate the tool path. The experimental results showed that the tool geometric error contributes over 50% to the total machining error. After compensation, the machining accuracy was significantly improved. The machine contour error has negligible influence on the dimension error of the machined feature, but it affects the form error, such as circularity of a machined hole. The process-induced surface location errors were estimated from both experiments and model simulation, and a good match was achieved.
microfeature production on curved surfaces. Tool stresses are shown to be highly dependent on the amount of fixture error. The scaling down of tool sizes is shown to result in an exponential increase in tool stresses. This paper proposes the use of a conductive touch-off method that utilizes the milling tool in its spindle to perform an in situ registration mapping of positional errors. The fixturing errors are characterized using the Denavit-Hartenberg robotic linkage convention. A forward kinematic solution uses homogeneous transformation matrices to investigate the effects of fixturing errors on milling tool path errors in fouraxis micromilling on curved surfaces. The touch-off registration measures the positional error in the tool axis direction allowing for axial tool position compensation. This results in decreased tool stresses and increased channel depth accuracy, which is necessary for successful milling. A preliminary implementation of the conductive touch-off registration approach has demonstrated the efficacy of the technique when applied to production of microfeatures on concave surfaces.
MSEC2010-34294
Machinability Study of SiC Nanoparticles Reinforced Magnesium Nanocomposites during Micromilling Processes Juan Li University of Central Florida Jian Liu University of Central Florida Chengying Xu University of Central Florida
This paper experimentally investigates the machinability of magnesium metal matrix composites (Mg-MMCs) with high volume fractions of SiC nanoparticles. Samples of MgMMCs with 5, 10, and 15 vol % reinforcements of SiC nanoparticles were studied and compared to pure magnesium. Different feed rates and spindle speeds were chosen as varied cutting parameters. Cutting forces, surface morphology, and roughness were measured to understand the machinability of the four different materials during the micromilling process. Based on the experimental results, it is observed that the cutting force increases with the increase of the spindle speed, the feed rate, and/or the volume fraction. A drastic increasing rate is observed when the nanoparticles volume fraction is increased from 5 to 10 vol %. The effect of the volume fraction is also studied in frequency domain, combined with the effect of the spindle speed and feed rate. More detailed theoretical analysis will be further studied to better understand the effect of the volume fraction on the machined surface quality and machining productivity.
MSEC2010-34273
An Investigation into Fixture Error Compensation in Micromilling Using Tool-Based Conductive Touch-Off Jacob Kunz Georgia Institute of Technology J. Rhett Mayor Georgia Institute of Technology Angela Sodemann Georgia Institute of Technology
In micromilling, decreased tool size leads to a need for tighter tolerances for fixture error in order to avoid excessive tool load and maintain machining accuracy. In four-axis machining on a curved surface, fixture errors propagate cumulatively leading to a significant error at the tool tip. As a result, a compensation approach is essential to successful
80
Abstracts
SYMP 13 Fabrication Process of Nanomaterials and Nanodevices

13-1 FABRICATION OF NANOMATERIALS
MSEC2010-34074
Fabrication of Al6061-CNT Composite by Mechanical Alloying Followed by Semi-Solid Powder Processing Yufeng Wu Iowa State University Gap-Yong Kim Iowa State University
Carbon nanotubes (CNTs) have been widely investigated as a reinforcement material to improve the mechanical, electrical, and thermal properties of composite materials. Various routes have been employed to fabricate aluminumcarbon nanotube (Al-CNT) composites in the past few years. However, uniform distribution of CNTs in the metal matrix is still challenging. In this paper, a novel semi-solid powder processing (SPP) was used to incorporate CNT uniformly into the Al6061-CNT composite. Al6061-CNT powders mechanically alloyed for different durations were also examined to understand how the CNTs were dispersed in the Al6061 powders. As-received CNT cluster balls were crushed into dense thin CNT layers during mechanical alloying. As mechanical alloying time increased, CNTs were dispersed in the Al6061 particles. Well-densified microstructures with severely deformed grains were observed in the Al6061-CNT composite.
coefficient is investigated. The material deformation and indentation geometry are extracted based on the final locations of the atoms, which have been displaced by the rigid tool. In addition to the modeling, an AFM was used to conduct actual indentation at the nanoscale and provide measurements to which the MD simulation predictions can be compared. The AFM provides resolution on the nanometer (lateral) and angstrom (vertical) scales. A threesided pyramid indenter (with a radius of curvature ~ 25 nm) is raster scanned on top of the surface and in contact with it. It can be observed from the MD simulation results that the indentation force increases as the depth of indentation increases, but decreases as the scratching speed increases. Moreover, the friction coefficient is found to be independent of scratching speed.
MSEC2010-34157
Layer-by-Layer Nanoassembly of CIS Nanoparticles Mangilal Agarwal Indiana UniversityPurdue University Indianapolis Sudhir Shrestha Indiana UniversityPurdue University Indianapolis Parvin Ghane Indiana UniversityPurdue University Indianapolis Kody Varahramyan Indiana UniversityPurdue University Indianapolis
Copper indium selenium (CIS), due to its tunable wide bandgap, has been widely studied for photovoltaic applications. In this work, CIS nanoparticles have been fabricated and functionalized with poly(sodium-4-styrene sulfonate) (PSS) and/or poly-allylamine hydrochloride (PAH), which allow them to disperse in aqueous solution. The resulting aqueous dispersion of CIS nanoparticles has subsequently been used to construct thin multilayer CIS films on flexible substrates using layer-by-layer (LbL) nanoassembly process. LbL nanoassembly is a costeffective process that allows construction of composite nanoscale multilayer coatings of oppositely charged polyelectrolytes, nanoparticles, and/or other nanomaterials. The results from quartz crystal microbalance (QCM) show that the CIS nanoparticles with other polyelectrolytes, such as PSS and PAH, can be used to deposit thin films of controlled nanometer-range thickness using the LbL process. The utilization of the developed LbL-based CIS films in solar cell fabrication is currently in progress.
MSEC2010-34115
AFM-Based Nanomachining for Nanofabrication Processes: MD Simulation and AFM Experimental Verification Rapeepan Promyoo IUPUI Hazim El-Mounayri IUPUI Ashlie Martini Purdue University
Recent developments in science and engineering have advanced the fabrication techniques for micro/nanodevices. Among them, the atomic force microscope (AFM) has already been used for nanomachining and nanofabrication, such as nanolithography, nanowriting, and nanopatterning. This paper describes the development and validation of computational models for AFM-based nanomachining (nanoindentation and nanoscratching). The molecular dynamics (MD) technique is used to model and simulate mechanical indentation and scratching at the nanoscale for the case of gold. The simulation allows for the prediction of indentation forces and the friction force at the interface between an indenter and a substrate. The effect of scratching speeds on indentation force and friction
81
Abstracts
MSEC2010-34226
Rationalizing Fabrication Conditions of Nanoporous Gold Shruti Baharani University of Toledo Yong Gan University of Toledo
Electrochemical dealloying has proven to be an efficient way of fabricating nanoporous gold, the morphology of which can be tailored by controlling factors such as the etching time, temperature of electrolyte, composition of the alloy, pre and/or post heat treatment and voltage; to suit applications such as fuel cell electrodes and sensors. This work aims at studying the effect of such factors as the electrolyte concentration on the dealloying processes, especially on the morphology. A model relating the factors including the processing parameters and pore size is established by statistical approaches using the Design Expert 7.1 software. An equation that fetches the individual as well as interaction effects on nanoporous gold is proposed. The validity of the equation is verified by existing research results and also by carrying out a series of tests.
SYMP 14 Sustainable Nanomanufacturing

14-1 SUSTAINABLE NANOMANUFACTURING
MSEC2010-34225
Fabrication of Nanoporous Ni-Zr Anode for Solid Oxide Fuel Cells by Electrochemical Method Surya Pothula University of Toledo Yong Gan University of Toledo
Solid oxide fuel cells are highly efficient energy conversion devices that electrochemically convert fuels to electricity with negligible pollution emissions. Anode of solid oxide fuel cell plays an important role in converting hydrogen into hydrogen ions and electrons. Many techniques, like plasma spraying, tap casting, screen printing, sintering process, etc., have been studied for the fabrication of anodesupported solid oxide fuel cells. In order to meet the high demand of energy in present days, a new technique is required for increasing the efficiency. Among the various methods, increasing surface area of anode is one. This can be achieved by fabricating the anode via the electrodeposition technique, which has been proved as an effective way of increasing surface area. In this work, we demonstrate that nanoporous Ni can be electroplated on a Zr substrate. Electrochemical dealloying of copper from a Ni-Cu alloy was carried out first to better understand the effect of voltage and run time on the process. As the potential increases, the amount of copper dealloyed into the solution was also increased. Passivation of nickel occurs as the time increases, allowing the formation of NiO. The preparation of nanoporous nickel films on zirconium by electrochemical deposition of Ni-Cu alloy followed by selective anodic etching of the more noble metal, copper, was studied in an aqueous solution containing Ni and Cu at room temperature. Potential varying electrodeposition produces crystalline or grain Ni-Cu alloys on Zr substrate, in which the Ni content increases as the deposition potential becomes more negative. Cyclic voltammetric data indicate that the anodic dissolution of nickel is retarded by passivation. By taking the advantage of nickel passivation, selective anodic etching of Cu is carried out. The multicyclic electrochemical alloying/dealloying process makes the film rich of nickel and complete dealloying of copper.
MSEC2010-34311
Fabrication and Characterization of Bulk Nanocrystalline Layer on Steel Components with Different Microstructures by Air-Blast Shot Peening Rahul Waikar University of Alabama Y. B. Guo University of Alabama
The fabrication of nanocrystalline (NC) layers in pearlitic and martensitic carbon steels viz. AISI 1018, 1045, and 1075 alloys using ABSP has been studied. The crosssectional microstructure of the samples showed that a gradual reduction of the grain size near the surface until a clearly demarcated NC layer was observed. The NC layers were characterized using optical, scanning electron microscopy (SEM), transmission electron microscopy (TEM), microhardness, and nanohardness measurements. 2D surface topography of the peened surface was also carried out to measured surface roughness. The roughnesses of the peened surfaces were dependent on the hardness of the sample. Samples with higher hardness had lower surface roughness value. NC layers varying from 5 to 15 m were observed using the optical and SEM images in the different types of steels. The SEM images clearly showed the dissolution of cementite phase in the NC layers. The nanohardness measurements of the steels showed that the NC layers had much higher hardness than the bulk material. The microhardness measurements also confirmed the mentioned phenomena. A TEM study was carried out on the NC layer and the grain size was confirmed to be 50 to 80 nm.
82
Abstracts
MSEC2010-34251
Addressing Uncertainty in the Environmental Analysis of Nickel Nanoparticle Production Malcolm O. Brown Oregon State University Karl R. Haapala Oregon State University Brian K. Paul Oregon State University Richard D. Glover University of Oregon James E. Hutchison University of Oregon
In spite of the many potential benefits and applications of nanoparticles, concerns have been raised regarding their production, use, and ultimate fate due to poor process yields and uncertain health and environmental impacts. Production of commercial nanoparticles is growing as they find increasing use in industrial and consumer products. Nickel nanoparticles (NiNPs) have shown promise as a single-element braze material, but the energy and material efficiencies of NiNP production remain uncertain. In this study, life cycle assessment (LCA) is employed to compare three different NiNP synthesis methods in terms of environmental impact. The study reveals challenges in using LCA to assess nanomanufacturing processes. Sensitivity analysis is performed across several process parameters to demonstrate an approach for addressing data uncertainties. The relative performance of the NiNP synthesis processes are discussed, and potential environmental implications for other NiNP synthesis processes are introduced. Policy change may be necessary to provide adequate transparency in assessing nanotechnologies for engineering applications.
blocking and subdued flux decline, finalizing in cake-layer development with steady state flow. This flow behavior is in agreement with experimental data from earlier studies. The inclusion of the wall-collision model and particle-trapping model enabled the revelation of cake-layer development as a fouling mechanism.
SYMP 15 Advances in Pervasive Sensing and Computing for Manufacturing Systems

15-1 SENSOR DATA ACQUISITION, ANALYSIS, AND WIRELESS COMMUNICATION
MSEC2010-34107
Spatial Blending Functions for Improved Estimation of Contact Pressure Distribution at the ToolWorkpiece Interface Sripati Sah University of Connecticut Timothy Kurp University of Connecticut Robert Gao University of Connecticut
On-line measurement of contact pressure distribution (CPD) at the toolworkpiece interface during sheet metal stamping processes plays a critical role in tool wear and product quality monitoring and control. Realizing such measurement poses a significant challenge, due to the severe operating conditions at the contact interface. Since the number of sensors that can be integrated into a tooling structure is limited by concerns of structural integrity, a mathematical framework is needed for estimating the contact pressure distribution measured by sparse sensors. This paper investigates a new technique termed the spatial blending functions (SBF), which provides an improved estimate of the contact pressure distribution by merging measurements from tooling-embedded sensors with simulation results from finite element modeling. The effectiveness of the SBFbased merging technique is demonstrated for the case of a panel stamping operation through finite element simulations and experiments performed on a stamping press with a tooling-integrated sensing system. Analysis of the results demonstrates that the SBF-based CPD estimation is more accurate than classic numeric surface interpolation methods and thus enhances contact pressure distribution estimation for stamping process monitoring.
MSEC2010-34269
Three-Dimensional Simulation of Cross-Flow Microfilter Fouling in Tortuous Pore Profiles with Semi-Synthetic Metalworking Fluids Bingyi Yu University of Illinois at UrbanaChampaign Shiv G. Kapoor University of Illinois at UrbanaChampaign Richard E. DeVor University of Illinois at UrbanaChampaign
Fluid flow and fouling mechanisms are examined with a three-dimensional simulation of the tortuous, verisimilar geometry of an -alumina microfilter. Reconstruction of the three-dimensional geometry was accomplished from twodimensional cross-sectional cuts, obtained from a focused ion beam. A wall-collision model and a particle-trapping model are developed for the investigation of fouling mechanisms. The reconstructed geometry and the two models were used in computational fluid dynamics to simulate metalworking colloidal particles traveling through and trapping in the tortuous pore paths of a microfilter. Results reveal sharp flux decline initiating from partial pore
83
Abstracts
MSEC2010-34177
Wireless Acquisition of Temperature Data from PCBN Embedded Thin-Film Sensors Anshuman Guha University of WisconsinMadison Xiaochun Li University of Wisconsin-Madison Dirk Werschmoeller University of WisconsinMadison
This paper presents the results of wireless data transmission experiments from micro-thin-film thermocouples (sensor) embedded into polycrystalline cubic boron nitride (PCBN) cutting inserts. A small wireless dataacquisition system (DAQ) is necessary for sufficiently fast acquisition of experimental data from the embedded microsensors in PCBN inserts, when mounted on a rotating cutting tool. For a wireless transfer of a low-amplitude and high-frequency thermal analog signal, a signal-conditioning circuit and wireless transmitting module are used. A transmitter module is used to establish Bluetooth communication with the receiver PC over the serial port profile (SPP). To characterize the wireless data-transfer system, heat signals are generated in stationary PCBN embedded thermocouples through laser pulses and CNC machining tests. During comparative tests, data were simultaneously acquired with a conventional wired DAQ board and the developed wireless DAQ system. The wireless DAQ capabilities and the overall dimensions of the devised wireless module greatly simplify its integration into various manufacturing applications.
heights. An exterior module receives the data from the enclosed unit, and the modules position is also varied in three-dimensional space. Bit error rate and received signal strength are measured, and the effects of spatial obstruction and multipath propagation are analyzed. An Agilent 8563E spectrum analyzer equipped with an Aaronia HyperLOG 7060 EMC antenna is also used to repeat the measurements at all of the points in order to provide EMI channel characterization and a redundant source of signal power data for comparison. Large-area transmissibility testing indicates that received signal strength is not dependent on equipment operation. The enclosure tests (perimeter, height, and proximity comparison) suggest that distance, both static and transient path obstructions, multipath propagation, and line of sight are factors that influence bit error rate and received signal strength. Spectrum analyzer measurements in our shop show no significant emissions in the 2.4 GHz range that cause interference. At no time during this study did the bit error rate reach 0.2% of the transmitted bits, and there were no failures in transmitting text between modules. Overall, the findings indicate that reliable data transmission with lowpower off-the-shelf Bluetooth modules is feasible.
SYMP 16 Data Driven Manufacturing

16-1 DATA DRIVEN MANUFACTURING
MSEC2010-34124
Reproduction of Lustrous Object and Cutter Location Using the Normal Vector-Generated by Photometric Stereo Method Seishi Nakamura Doshisha University Toshiki Hirogaki Doshisha University Eiichi Aoyama Doshisha University Hiromichi Nobe Mifuji Kikai Seisakusho, Ltd.
Diverse consumer demands, short product life cycles, and complicated product geometry have dramatically advanced the current product design and development process. In particular, short product life cycles require more rapid development of new products and the adoption of new production and management methods. Currently, geometric modeling using CAD/CAM software is widely used to develop new products. After modeling, a trial product is created using rapid prototyping (RP), followed by product evaluation and redesign, if necessary. There are two principal design methodologies associated with CAD: (1) Designing an entirely new product and (2) modifying an existing product. The present study focuses on modifying an existing product using reverse engineering (RE) to acquire measurement data from a pre-existing product. Using RE,
MSEC2010-34192
Transmissibility of 802.15.1Compliant Radio in Machining Enclosures in Industrial Environments Richard Sowles Heidenhain Corporation Derek A. Suen Penn State Erie, The Behrend College David Loker Penn State Erie, The Behrend College John T. Roth Penn State Erie, The Behrend College
Wireless sensors used in plant floor environments have been studied for obstruction and multipath propagation effects on signal quality. The trend toward wireless industrial data networks motivates this study, which explores the use of IEEE 802.15.1 radios in a machine shop at varying levels of operation. Previous studies have investigated the use of a wireless sensor embedded in a rotating tool holder to monitor tool life. In order to obtain information furthering the potential use of low-power radio in conjunction with machining enclosures, a Bluegiga WT12 Class 2 Bluetooth 2.1 module is placed within several CNC machining enclosures at varying table positions and
84
Abstracts
complex shapes can be designed more easily and design time can be shortened. An even more effective design system is possible by using RP in conjunction with RE. While the shape of the target object is less accurate, repeating the optimization process using RE decreases the labor associated with CAD data modification. In addition, using photographic images in the RE process is cheaper and easier than methods such as laser scanning, contact scanning, and CT scanning. In the present study, an object shape is first obtained from photographic images using the photometric stereo method, and then the target object is created using material that artificially gives character, like wood. It is proposed that a Gaussian filter be applied to improve the error margin by luster. Results showed that the maximum error margin of the reproduced object shape could be adjusted from 8.3 to 3.3%. In addition, we propose a new method to obtain cutting location (CL) data in ballend milling using the normal vector of object geometries generated by the photometric stereo method. As a result, the tool path was quickly and easily derived, without the use of CAD data.
length. We grouped it by using a k-means method, which was a nonhierarchical cluster analysis. We then decreased the variable by using the hierarchical cluster analysis. We also found an expression for deciding on the cutting condition and compared the catalog value to that of the theory. We did 15 min of cutting work using three cutting conditions, conditions recommended by the catalog, cutting conditions derived by data mining, and a proven cutting condition for die machining (rough processing).
MSEC2010-34254
Transient Analysis of Downtime Event in Manufacturing Systems Qing Chang New York Institute of Technology Jianbo Liu Michigan State University Stephan Biller General Motors Research and Development Center Guoxian Xiao General Motors Research and Development Center
In the manufacturing industry, downtimes have been considered as major impact factors of production performance. To improve the system performance in real time and properly allocate limited resources/efforts to different stations, it is necessary to quantify the impact of each station downtime event on the production throughput of the whole transfer line. Complete characterization of the impact requires a careful investigation of the transients of the line dynamics disturbed by the downtime event. We study in this paper, the impact of a single isolated downtime event on the performance of inhomogeneous serial transfer lines. Our mathematical analysis suggests that the impact of any isolated downtime event is only apparent in the relatively long run, when the duration exceeds a certain threshold called opportunity window. The size of the opportunity window not only depends on the initial buffer levels but also on the location and processing speed of the slowest station. Analytical solutions of the opportunity window and the loose upper bounds for the recovery time are also provided in the paper as two separate theorems. Despite the fact that the paper focuses on the transient analysis of a single isolated downtime event, the results are applicable to opportunistic maintenance scheduling, personnel staffing, and downtime cost estimation.
MSEC2010-34199
Cutting Condition Decision Methodology Based on Data-Mining of Tool Catalog Data Hiroyuki Kodama Doshisha University Toshiki Hirogaki Doshisha University Keiji Ogawa The University of Shiga Prefecture Eiichi Aoyama Doshisha University
In recent years, design and manufacturing have involved the use of CAD to draw, CAM to make tool passing data, and a machining center to cut metal molds. The CAM system can calculate specifications only for the tool passing that corresponded to the metal mold shape designed by using only the CAD system. However, the tool used and the cutting conditions usually needed to be decided by a skilled engineer with sufficient knowledge and experience. An engineer who is not highly skilled and experienced may find choosing the best cutting condition difficult. Therefore, a system that supports the engineer as he decides on the tool and cutting conditions is needed. The purpose of our research is to support the decision on the cutting conditions. We used the catalog of tool maker and to the end mill, in particular. We extracted tool-selection parameters by using catalog mining. We extracted data on the tool from the catalog and did catalog mining and examined the relation between the tool shape and the size of the tool by analyzing the cluster. We decided on the parameter used for catalog mining. Here, the target value is cutting speed, feed rate, axial depth of cut, and radius depth of cut. We made an expression for the decision on the cutting condition by using a multiple regression analysis. First, we grouped it by shape and the use of the tool. We assumed that the neck diameter, which is included in catalog, to be the same as the shank diameter and the effective length to be the overall
85
Abstracts
SYMP 17 Challenges in Adaptive Manufacturing Planning and Control

17-1 CHALLENGES IN ADAPTIVE MANUFACTURING PLANNING AND CONTROL
MSEC2010-34022
A Statistic Review of Computer-Aided Process Planning Research Jin Mao University of Auckland Xun Xu University of Auckland Lihui Wang University of Skvde Stephen T. Newman University of Bath
Since the late 1970s, computer-aided process planning (CAPP) has attracted a large amount of research interest, which has led to a huge volume of literature published on this subject. The literature encompasses both reviews and research articles. The review articles are mostly technologically oriented. This paper takes a different angle to look back the CAPP research, that is, a statistic approach. The paper analyses the journals that have been publishing CAPP research works. The concept of subject strength of a journal is introduced and used to gauge the level of focus of a journal on a particular research subject/domain, i.e., CAPP. Discussions about the recent CAPP research works are presented in different categories as they fall in, i.e., feature-based technologies, knowledgebased systems, artificial neural networks, genetic algorithms, fuzzy set theory and fuzzy logic, Petri nets, agent-based technology, Internet-based technology, STEPcompliant CAPP, and other emerging technologies. The term technology impact factor (TIF) is introduced to assess the level of impact of a particular technology, in terms of citation counts. All discussions and analyses are carried out based on the data gathered from Elseviers Scopus abstract and citation database. Finally, a discussion on the future development is presented. The literature suggests that this is the only review article of a similar nature in the first decade of the century.
that has inherent drawbacks, such as vendor-specific nature, incomplete data, irreversible data conversions, and lack of accuracy. These limitations hinder the development of a trustworthy simulation system. Hence, there is a need for higher-level input data that can assist with accurate simulation for machining processes. There is also a need to take into account true behavior and real-time data of a machine tool. The paper presents a near-real simulation solution for more accurate results. STEP-NC is used as the input data as it provides a more complete data model for machining simulations. Data from the machine tool is captured by means of sensors to provide true values for machining simulation purposes. The outcome of the research provides a smart and better informed simulation environment. The paper reviewed some of the current simulation approaches, discussed input data sources for a smart simulation system, and proposed near-real simulation system architecture.
MSEC2010-34049
An Integrated Approach to Spot-Welding Sequence Planning and Optimization Mohammad Givehchi Yazdi University of Skvde Amos Ng University of Skvde Lihui Wang University of Skvde
Almost in every discipline involved in product and production development (PPD), optimization problems arrive. These real-world problems are too complex to be solved by analytical models and classical optimization methods. The complexity increases dramatically when multiple objectives and disciplines are to be considered. CAx and Virtual Manufacturing (VM) tools are, on the other hand, being employed more and more to create virtual representation models of the products under development and their related production facilities, processes, and systems in a virtual environment before any physical realization is conducted. A seamless integration of these tools based on a well-formed integrated backbone of product data management (PDM) has been a main objective on the way of realization of strategic paradigm of product life cycle management (PLM). This paradigm addresses a variety of inter-related aspects during the life cycle of a product and helps in achieving a spectrum of objectives from high-level strategic ones to low-level functional ones. This achievement is possible by providing a framework consisting of necessary concepts, theories, methodologies, and infrastructure that supports all processes involved in the whole product life cycle. In this paradigm, the role of some theories, such as concurrent engineering (CE) and design for x (DFx), are essential. Based on the mentioned facts, and as the first step toward developing an Optimizica, a framework for addressing a vast variety of development and optimization problems in various disciplines of PPD, a project was defined to solve a limited process planning and optimization problem. In this
MSEC2010-34037
Smart Machining Simulation Based on High-Level Data Aini Z. Abdul K. The University of Auckland Xun Xu The University of Auckland
The main objective of any machining simulation system is to produce a model that can reveal or mimic the real machining process as accurately as possible. Current simulation systems often use G-code or CL data as input
86
Abstracts
problem, planning a process with the minimum cycle time for assembling a spot-welded sheet metal product was performed. The framework planned for this scope uses both third-party elements, such as Teamcenter, Process Designer, and Process Simulate, as well as new developed units, such as Optimizica for Process Simulate. Additionally, rule-based assembly planning methodology was proposed and implemented.
characteristics, such as different body types (small or medium), are applied and evaluated in terms of their conveyance efficiency. Results indicate that a combination of such multiple-load AGVs shows a good performance in terms of higher conveyance efficiency and lower environmental impact.
MSEC2010-34236
Development of Multiple Melt-Modulation Valves for Enhanced Injection Molding Akapot Tantrapiwat King Mongkut Inst. Ladkrabang John P. Coulter Lehigh University
A new melt-modulation system with multiple control valves was successfully developed to facilitate melt control in cold runner-based injection molding. The entire valve mechanism and port geometry were significantly improved. The new valve gave better control characteristic and can be made inexpensively. A valve-driving mechanism was also redesigned to be more compact and easy to be installed in a limited mold space. It allows four control valves to be placed in the same mold in which only two original valves were able to fit. The four-valve melt modulation performed on a runner system such that the effect of melt flow from each valve was influenced by all other valves. The interaction between four valves caused complicated behavior and also a difficulty to establish valve control parameters. A reciprocal search method was utilized and able to determine valve control variables within a reasonable number of trials. Experimentation was done on a potential case study that included both family molding and weld line positioning problems. As part of the outcome, a simple gain modification was developed and able to find an optimum solution. The technique was carried out in both traditional fixed angle and newly developed bang-bang control methods. The results shows that melt-modulation system with multiple control valves was able to effectively control melt behavior and enhanced filling process.
MSEC2010-34088
Autonomous Distributed AGV System Based on Taxi Transportation Strategy: Effect of MultipleLoad AGVS on Conveyance Efficiency Takahiro Kono Doshisha University Keiji Ogawa The University of Shiga Prefecture Toshiki Hirogaki Doshisha University Eiichi Aoyama Doshisha University
Manufacturing systems have recently been shifted from high-volume/low-mix manufacturing to high-mix/low-volume manufacturing and renamed flexible manufacturing systems (FMSs). However, problems have occurred, primarily the fact that such systems might not be able to cope with quick environment changes. It is not easy to change the layout and facilities of a factory once we build a big system because it controls the whole manufacturing system in FMS hierarchically. Therefore, new systems for variety-variable manufacturing with flexibility are proposed. A general idea of an autonomous and distributed manufacturing system has been suggested, and it seems feasible because each component part has original information-treatment and decision-making functions. The system gives the constituent elements of its manufacturing system an autonomous decision-making function. The role of an automated guided-vehicle (AGV) conveyance system, which controls the flow of parts in a factory, is becoming more important, but research on the conveyance system has been uneven. Examples include studies on AGV action decision-making theory, scheduling, and so on, whereas meanwhile, the use of autonomous decision-making controls in places where transportation is received and transported has hardly been researched. On the other hand, applications of knowledge from one field to a different field have recently drawing much attention. Such activity is known as a mimetic solution. We propose an application of knowledge hidden in traffic engineering to manufacture a trial mimetic solution. Manufacturing systems must withstand such uncertain factors as a sudden change of the manufacturing process, and we therefore propose applying the characteristics of taxi transportation with flexibility to an AGV conveyance system. A taxi is a transport unit in a traffic system with higher flexibility in traveling routes and arrival/departure points compared to railways and buses. Our proposed systems performance is shown based on conveyance efficiency and energy consumption. Additionally, the multiple-load taxis, which are based on taxi
87
Abstracts
SYMP 18 Advances in Biomanufacturing

18-1 ADVANCES IN BIOMANUFACTURING
MSEC2010-34127
Study of Double-Layered Microcapsule Formation in Compound Nozzle Jetting Wei Wang Clemson University C. Leigh Herran Clemson University Nicole Coutris Clemson University Yong Huang Clemson University Vladimir Mironov Medical University of South Carolina Roger R. Markwald Medical University of South Carolina
Double-layered microcapsules, which usually consist of a core (polymeric) matrix surrounded by a (polymeric) shell, have been used in many industrial and scientific applications, such as microencapsulation of drugs and living cells. Compound concentric nozzle-based jetting has been favored due to its efficiency and precise control of the coreshell compound structure. Thus far, little is known about the underlying formation mechanism of double-layered microcapsules in compound nozzle jetting. This study aims to understand the formability of double-layered microcapsules in compound nozzle jetting by coupling a theoretical analysis with numerical simulations. A linear temporal instability analysis is used to define the perturbation growth rate and its ratio as a function of the wavenumber, and a computational fluid dynamics (CFD) method is implemented to model the microcapsule formation process in order to determine the good microcapsule forming range based on the growth ratio curve. Using a pseudo-bisection method, the lower and upper bounds of the good formability range have been determined for a given materials-nozzle system. The proposed formability prediction methodology has been implemented and validated in modeling a water-poly(lactideco-glycolide) (PLGA), air compound jetting system with satisfactory prediction results.
types. By installing a power-driven tool on each of two sides of a workpiece, a synchronous polygon turning process is set up to complete the prescribed cutting in a single stroke. The tool on one side is to cut the planar faces using the conventional polygon turning process. Under the constraints of the above polygon turning, the tool on the other side demands special assignments for polygon turning of cylindrical faces. Assigned with a noninteger cutter-disk/spindle-speed ratio and a number of blades mounted on a cutter disk, an enormous number of line segments can be generated to approximate circular cuttings. The use of noninteger speed ratio enables the generation of an enormous number of sides with relatively low speed ratio and a few number of blades. This research also simulates the motion paths of blade tips and calculates the error between the approximate curve and true circular arc under the arbitrarily assigned parameters of blade numbers and speed ratios. For implementation, bars of titanium alloy Ti6Al-4V and stainless steel 316L were used to generate orthopedic implants and dynamic hip lag screws, on a Swiss lathe. This synchronous polygon turning has shown the efficacy and efficiency on the cutting of screw shanks.
MSEC2010-34326
A Perfused Two-Chamber System for Anticancer Drug Screening Liang Ma University of Washington Wei Li University of Washington Jeremy Barker University of Washington Changchun Zhou University of Washington Biaoyang Lin Swedish Neuroscience Institute
A cell culture microfluidic device has been developed to test the cytotoxicity of anticancer drugs while reproducing multiorgan interactions in vitro. Cells were cultured in separate chambers representing the liver and tumor. The two chambers were connected through a channel to mimick the blood flow. Glioblastoma (GBM) cancer cells (M059K) and hepatoma cells (HepG2) were cultured in the tumor and the liver chambers, respectively. The cytotoxic effect of cancer treatment drug Temolozomide (TMZ) was tested using this two-chamber system. The experimental results showed that, with the liver cells, the cancer cells showed much higher viability than those without the liver cells. This indicates that the liver metabolism has a strong effect on the toxicity of the anticancer drug. The results demonstrated that the perfused two-chamber cell culture system has the potential to be used as a platform for drug screening in a more physiologically realistic environment.
MSEC2010-34246
Synchronous Polygon Turning for Implant Manufacturing Frank Chuang National Chung-Hsing University Ko-Yu Lin National Chung-Hsing University Yuheng Chen National Chung-Hsing University
A complex machining process is proposed to generate a multifaceted column with both planar and cylindrical surface
88
Abstracts
SYMP 19 Manufacturing System Maintenance

19-1 METROLOGY, DIAGNOSIS, OPERATIONS, AND MAINTENANCE
MSEC2010-34116
Investigation of Contact Characteristics of LongFiber Reinforced Plastic Gears Based on Observation with a High-Speed Camera Tomoki Otawa Doshisha University Toshiki Hirogaki Doshisha University Eiichi Aoyama Doshisha University
Recently, the need for plastic gears under sanitary conditionsfor example, in business machines and acoustic equipmenthas increased because these gears have the advantage of being lightweight, low noise, and useable in oil-less conditions. Unlike metal gears, however, they can be used only in low-torque conditions. The problem here is that metal gears generate noise in driving. Therefore, plastic gears with a higher strength are required. Long fiber-reinforced plastic (FRP) gears, which contain the best characteristics of both plastic and metal gears, have been receiving attention lately. Although there has been much research on metal gears, there have been few reports on FRP gears, which means there are no clear criteria for design. Instead, FRP gears are designed on the basis of the scant plastic gear test data available and on the experiences reported by a few engineers. We researched the vibration, contact characteristics, and heat generation of FRP gears for use in power transmission from both a micro and macro viewpoint. We used three kinds of laminated materials for the gears: cotton-reinforced phenolic resin with good mechanical strength, workability, and impact resistance, cotton-carbon (3070%), cotton-aramid (70 30%) (4060%), and aramid fiber clothes. The gears were reinforced by setting the fiber cloth in radial and circumferential directions and were manufactured by hobbing. Therefore, the fibers at each tooth had the same direction and the same strength difference as each tooth decreased. We conducted a driving test to detect the vibration of the rotation direction dominant vibration of the gear by the acceleration pickup and also observed the dynamic contact state of gear meshing in operating conditions with a high-speed camera. The temperature distribution when driving was measured by thermography. Contact ratio is often used to show contact state, but there are currently no reports that describe the dynamic contact ratio of FRP gears, although there are some reports on plastic gears. We therefore considered a contact-ratio formula based on a new contact model that the dynamic real deflections of the gear tooth. The temperature distribution measurement was done from the side and the
upper surface of the gear. The characteristics of heat generation on the surface of each gear tooth were analyzed, and the temperature distribution was analyzed according to the time and each point of the tooth.
MSEC2010-34169
Adaptive Anomaly Detection Using a Hidden Markov Model Seungchul Lee University of Michigan Lin Li University of Michigan Jun Ni University of Michigan
Online condition monitoring and diagnosis systems are very important in the modern manufacturing industry. We present a new method to assess the degradation processes of multiple failure modes using the hidden Markov model (HMM). The HMM is combined with statistical process control (SPC) to detect the occurrence of unknown faults. This method allows an HMM to adjust and update the state space with the identification of new states. Hence, the online degradation assessment and adaptive fault diagnosis can be simultaneously obtained. The turning process are used to illustrate that previously unknown tool wear processes can be successfully detected at the early stages using the HMM.
MSEC2010-34312
The Development of a Novel On-Line Optical Inspection System for Tool Conditions In Machining Processes W. Li University of Alabama Y. B. Guo University of Alabama
Tool abrasion and material adhesion lead to tool flank wear and flank buildup, respectively, in machining magnesium alloys, which adversely affect surface integrity due to higher cutting forces and temperatures. In this paper, a novel online optical tool-monitoring system integrated with a CNC machining center is designed and applied to examining these two phenomena. Flank wear evolution on PVD-coated inserts in end milling of AISI H13 tool steel and material adhesion on flank face of PCD inserts in face milling of lightweight magnesium alloys were on-line inspected to assess the function of the designed optical measurement system. Tool wear failure criterion for the PVD milling inserts is set to be VB max = 250 m and flank wear evolution with cutting time is presented. Tool/work adhesion between the PCD inserts and magnesium alloy were observed under different combinations of cutting parameters including speed, feed, and depth-of-cut. The advantages of the on-line optical tool inspection system are discussed.
89
Abstracts

21-1 POSTER SESSION
MSEC2010-34335
Material Property Determination Meso- and Microscale Bulge Test Richard Jones, Jr. University of Louisiana at Lafayette William Emblom Univeristy of Louisiana at Lafayette
Fuel cells are an alternative to power generation; however, there are some manufacturing and performance limitations. The bipolar plate of the polymer electrolyte membrane fuel cell (PEMFC) requires the most attention in manufacturing research because of its cost and weight. In order to optimize the design, several factors must be examined such as formability and water buildup in the channels. This paper will address formability and size effects that influence material property behavior described in the literature. Research in material testing via bulge tests have been studied intensely, though few have investigated effects on the microlevel. Microproperty data are necessary to ensure a robust channel-design process. This poster and the research contained in it represent the development of a meso- and microscale bulge testing workbench for annealed SS304. The workbench is capable of measuring bulge height and pressure, data acquisition, and a data analysis program developed in Matlab. Data are validated by strain measurement in the bulging workpieces. Also, analytical calculations, including sheet thickness, radius of curvature of the deformed sheet, and microscopy measurement of millimeter and submillimeter grids, are etched on to the sheet surface.
constituent parts, components, subassemblies, or other groupings [4]. There are three types of disassembly: complete disassembly, incomplete disassembly, and selective disassembly. By designing products that are easy to disassemble, we can conserve natural resources and, if applied correctly, can cut costs. In this research, we aim to develop a generic method for creating plans of sustainable selective disassembly for a given product. Toward this aim, in this poster we present preliminary results for the use phase energy impacts of two toasters (a standard toaster and an ecotoaster).
MSEC2010-34337
Integrating Lightweight MaterialsComponent Manufacture in Titanium Mathew Kuttolamadom CU-ICAR Joshua J. Jones Clemson University International Center for Automotive Research Laine Mears Clemson University John Ziegert Clemson University Thomas R. Kurfess Clemson University International Center for Automotive Research
The purpose of this project is to explore the use of titanium as an automotive component material in order to reduce vehicle weight and energy consumption. Phase 1 (Identification): Working with a primary titanium manufacturer to identify cost-effective grades of titanium for automotive use and with an automotive OEM to identify potential components for replacement. Initial cost justifications will be developed for 12 candidate components, and a detailed cost analysis will be performed, including material costing and simulation of the manufacturing process for each component. Phase 2 (Process Planning): A cost-minimized process plan will be designed in conjunction with a major machine tool manufacturer, including incorporation of titanium strength/flow models, and prototypes will be manufactured. Material grade for testing will be selected based on component design requirements, and the process plan will be cost optimized within the functional constraints of the part design. Phase 3 (Validation): Prototype components will be tested and evaluated in the automotive application for functionality and performance. Prototypes will be evaluated for dimensional/surface quality and in fatigue. The poster provides snapshots of the above procedure on a sample component to develop the methodology and to identify potential problems in the process.
MSEC2010-34336
Use Phase Energy Impact of Two Toasters: Toward Sustainable Selective Disassembly Planning Raghunathan Srinivasan Washington State University Gaurav Ameta Washington State University
The four major processing options at the end of life of products are reuse, recycle, remanufacture, and disposal. Out of these reuse, recycle, and remanufacture of products or components are beneficial to the manufacturer, user, society, and the environment only if disposal can be possibly minimized. As of 2009, the U.S. produced 254 million tons of solid waste of which more than a third was recycled or recovered. Disassembly can be defined as a systematic method for separating a product into its
90
Abstracts
MSEC2010-34338
Manufacture of Aerospace Components with Pressure Welding Ho-Sung Lee Korea Aerospace Research Institute Jong-Hoon Yoon Korea Aerospace Research Institute Y. M. Yi Korea Aerospace Research Institute
Pressure welding technology is a solid state bonding process and generally involves heating the metal surfaces and then applying a suitable amount of axial pressure. In this state, the metal components being joined undergo only microscopic deformation, and the joining region is homogeneous and complete metallurgical bonding is possible without secondary materials or liquid phases. In the present work, pressure welding of titanium, steel, and copper alloys has been investigated to fabricate several aerospace components with various complex configure. The result shows that the pressure welding method has been successfully applied with blow forming for near net shape forming of aerospace components, including high-pressure tank for attitude control of spacecraft, combustion chamber with copper cooling channels, and other lightweight structural panels.
MSEC2010-34340
Sizing the Cryogenic Conditioning on the Young Modulus and CTE Properties in Case of Polymeric Multiphase Composites Dana Luca Motoc Transilvania University of Brasov Petru A. Pop University of Oradea Gheorghe Bejinaru Transilvania University of Brasov
The paper focuses on a theoretical-experimental comparative study with respect to the mechanical (e.g., E, Young modulus) and thermal property changes (e.g., CTE, coefficient of thermal expansion) in the case of selfmanufactured particle-fiber-type multiphase polymeric composite material samples subjected to various extreme environmental conditions, such as the cryogenic ones. The composite samples were made up from 65% E-glass random fibers and various particles (e.g., ceramic Al2O3, metalic - Fe) embedded in different volume fraction (e.g., 5 and 10%) into a polymeric matrix material. The experimental research was carried out using a LR5K Plus three-point bending configuration from Lloyd Instruments and a differential DIL 402 PC dilatometer from Netschz (Germany). The experimental data were subjected to a cross analysis for comparison to similar measures on the reference sample (two phase, random E-glass fibers and polymeric matrix). The results may aid manufactures/designers in managing their engineered materials and structures or to address thermal management issues.
MSEC2010-34339
Sinter Joining in Metal Injection Molding (MIM) Thomas Martens Clemson University Laine Mears Clemson University
In MIM, fine metal powders are mixed with a binder and injected into molds, similar to plastic injection molding. After molding, the binder is removed from the part and the compact is sintered to almost full density. The obstacle to sinter bonding a MIM part to a conventional (solid) substrate lies in the sinter shrinkage of the MIM part, which can be up to 20%, meaning that the MIM part shrinks during sintering, while the conventional substrate maintains its dimensions. This behavior would typically inhibit bonding and/or cause cracking and deformation of the MIM part. By applying a microstructure to the MIM part, the MIM part is given the ability to shrink while bonding to the substrate. On one hand, the friction between the MIM part and the substrate is reduced; on the other hand, the microstructure allows for certain deformation to follow the shrinkage without causing cracks.
MSEC2010-34341
The Design and Production of a Reusable Friction Stir Welding (FSW) Tool Christopher Murosky Penn State University Michael A. Ragen Penn State Erie, The Behrend College
Stir friction welding (SFW) tools are not standardized. They cannot be purchased off the shelf from an industrial supplier. SFW tools are quite often damaged or fractured during their use. It may take days if not weeks to have another SFW tool made or repaired. This research project will involve researching, designing, and building a prototype SFW tool that will allow the user to quickly change the welding tip so that it may take minutes instead of days to continue welding. The outcome of this project is to design a stir friction welding tool that can be reusable with minimal downtime.
91
Abstracts
MSEC2010-34342
Ultrasonic Vibration-Assisted Pelleting of Cellulosic Biomass for Bioethanol Manufacturing Pengfei Zhang Kansas State University Qiang Feng Kansas State University Eric Zinke Kansas State University Weilong Cong Kansas State University Meng Zhang Kansas State University Xiaoxu Song Kansas State University Qi Zhang Kansas State University Z. J. Pei Kansas State University Donghai Wang Kansas State University
Bioethanol produced from cellulosic biomass (the fibrous, woody, and generally inedible portions of plant matter) is an important alternative energy source to petroleum. It can significantly reduce the nations dependence on foreign oil, create new jobs, improve rural economies, and reduce greenhouse gas emissions. However, the high production cost has hindered the large-scale manufacturing of cellulosic bioethanol. The low density of cellulosic feedstocks causes high transportation and storage cost. Low efficiency of enzymatic hydrolysis leads to longer processing time and contributes to high production cost. Ultrasonic vibration-assisted (UV-A) pelleting of cellulosic biomass can increase the overall efficiency of biomass transportation by increasing the density and utilizing existing transportation infrastructure and storage systems for megaton quantities. UV-A pelleting is also proven to increase the sugar yield in hydrolysis. Experimental investigations have been conducted on ultrasonic vibrationassisted pelleting of cellulosic feedstocks with different variables, such as ultrasonic vibration power (controlling vibration amplitude), moisture content, and particle size.
orientation function distribution, and this can be checked manually, but is hardly automatable and exportable to the field work in a company. The quantitative description of the fiber orientation is explained by Advani, Tucker and Thomason, Nath, and Phelps. An example of fiber orientation identification is the work of Yasuda. In summary, although these are proposed methods for measuring the orientation, new applications continue to appear to improve the measurements, as in our casedesigning an operating procedure capable of performing many analyses applicable to the study of thermoplastics reinforced with long glass fibers.
MSEC2010-34344
A Thermally Activated Modular SPM Probe for Multifunctional Applications Bijoyraj Sahu University of Florida Curtis Taylor University of Florida Kam K. Leang University of Nevada Reno Robert Riddle University of Nevada Reno
The goal of this research is to address the critical issues of throughput, repeatability, scalability, and limited functionality of tip-based nanofabrication by designing, fabricating, and testing a novel active SPM cantilever probe with an automated ability to interchange probe tips (tools). The proposed unique nanoprobe system enables automated interchanging of probe tips. By simply switching tips, the probe can be used for nanodeposition, patterning, machining, metrology, and various other nanofabrication processes. Located at the distal end of an SPM cantilever is an electrically activated MEMS-based microgripper, which is designed to automatically load/unload tips from an array of modular probe tips (tools). Automation is achieved using a novel control scheme to determine the relative location between the microgripper and tool tip. This research will contribute new knowledge via feasibility studies of (1) active cantilevers for SPM probe-based fabrication and (2) thermal-proximity sensing.
MSEC2010-34343
Algorithms to Calculate Orientations of Fibers in LFRT Petru A. Pop University of Oradea Juan Lopez Martinez Polytechnic University of Valencia Flavius Ardelean University of Oradea Santiago Ferrandiz Bou Polytechnic University of Valencia
There are various techniques that can allow us to measure the fiber orientation. Some of it could not be described as automatic, because it would force us to make such an individual measurement, which would transform it into a rather tedious task. Other techniques can help us do this like the automatic way and therefore enable one to obtain the results of a fiber-distribution function. Wetherhold, Scout explains different methods that can allow the fiber
MSEC2010-34345
Multifuncitional Behavioral Analysis of Al-SiC Metal Matrix Composite Foam Produced by (TiH2 CaCO3) Dual Foaming Agent Joyjeet Ghose Birla Institute of Technology Vinay Sharma Birla Institute of Technology Surender Kumar Birla Institute of Technology
Aluminum alloy composite foams reinforced by 5% vol SiC particles were fabricated with a melt-foaming route using TiH2CaCO3 dual-foaming agent. The compressive modulus and strength of two different relative density aluminum foams were investigated experimentally. An empirical relationship was established between normalized
92
Abstracts
change in density and strain, using experimental data of compression tests up to different strain levels. Sound absorption property of the developed material was found out by impedance tube method. Acoustic test results indicate the potential of the material as a sound absorber.
MSEC2010-34346
An Electrically Activated Silver-Based Antibacterial Surface System Rohan Shirwaiker The Pennsylvania State University Richard Wysk The Pennsylvania State University Robert Voigt The Pennsylvania State University
Pathogenic infections are frequently transmitted in healthcare environments via fomite surfaces, such as door knobs and push plates, countertops, and medical instrument trays and storage boxes. Lower immunity of patients coupled with the emergence of antibiotic-resistant bacteria, such as methicillin-resistant Staphylococcus aureus (MRSA), makes the spread of such infections even more critical. This research presents the design and fabrication of an electrically activated silver-based antibacterial surface system to prevent such indirect contact transmission of nosocomial infections. The surface consists of a microscale grating pattern of alternate silver electrodes and SU-8 partitions with a minimum feature size of 20 m. Antibacterial action of the system relies on the flow of direct electric current on the order of a few microamperes through the media containing the bacteria, which results in the release of oligodynamic silver ions (Ag+). Preliminary testing results demonstrate significant antibacterial efficacy of the surface system, activated by a current of 15 A, against both Gram-positive (S. aureus) and Gram-negative (Escherichia coli) bacteria. Recent results also indicate a noticeable effect of feature sizes and magnitude of current on antibacterial efficacy of the system.
in order to estimate the heat partition value entering the cutting tool with the use of uncoated and coated tools. Therefore, it explains the differences in thermal behavior of uncoated and coated tools. In terms of coated tools, singlelayer and multilayer tool coatings were investigated to assess their effects on heat partition. The finite element method (FEM) was mainly used in combination with the previously generated experimental data [1]. Threedimensional uncoated and coated models [1] were modified and made compatible with ABAQUS to be able to perform thermal analyses of the cutting process. Finite element temperature values were matched with the reference values, and hence, the heat intensity value for the cutting tool was determined.
MSEC2010-34352
Fundamental Study on Size Reduction of Poplar for Biofuel Manufacturing Meng Zhang Kansas State University Xiaoxu Song Kansas State University Pengfei Zhang Kansas State University Qi Zhang Kansas State University Emily Jones Kansas State Univ. Timothy W. Deines Kansas State University Z. J. Pei Kansas State University Donghai Wang Kansas State University
Current situations are driving the U.S. to develop alternative liquid fuels that are domestically produced and environmental friendly. Biofuels produced from cellulosic biomass (such as forest products and residues, agricultural residues, and dedicated energy crops) can significantly reduce the nations dependence on foreign oil, create new jobs, improve rural economies, reduce greenhouse gas emissions, and improve national energy security. One of the leading cellulosic biomass candidates is poplar. Poplar has several characteristics that make it an attractive and promising biofuel feedstock: it can be grown in several temperate climates as a short-rotation woody crop; it has a very wide distribution in North America; it grows relatively fast. Poplar can produce 47 dry tons per acre annually over a 610 year rotation. From the bioconversion aspect, poplar also has many good properties: the wood of poplar species has diffuse porous structure with short fibers and small cells compared to many other hardwoods; the chemical composition of poplar wood is characterized by high cellulose content (about 5060%) and low lignin content (about 20% or less). These are beneficial factors for high biofuel yield. Manufacturing biofuels from cellulosic biomass requires reduction of the material size. Poplar wood has to be chipped and milled into small particles for further bioconversion. These mechanical size-reduction methods are regarded as an overall performance level. Few studies were conducted focusing on the size-reduction process of poplar wood and the interaction within the equipment. This poster presents an experimental
MSEC2010-34351
Investigation of the Effect of Cutting Tool Coatings on Temperature Distribution in Orthogonal Metal-Cutting Processes by Using Finite Element Modeling Kamuran Yesilkaya Tubitak Defense Industries Research and Development Institute
It is widely accepted that heat partition and temperature distribution for the metal cutting process have a significant effect on the morphological features of the cutting tool. Tool life and cutting accuracy are considerably affected by temperature distribution and heat transfer mechanisms. For orthogonal machining operations, finite element models can be accurately generated to gain an understanding of heat partition into the cutting tool. This study has been completed
93
Abstracts
investigation on the effects of milling on poplar-based biofuel manufacturing.
MSEC2010-34353
Manufacturing-Line Design with Product-ChangeDependent Intertask Times Jeonghan Ko University of Nebraska-Lincoln Ehsan Nazarian University of Nebraska-Lincoln
Traditional research work in manufacturing-line design assumes that the times between manufacturing tasks performed on a workstation are independent of the task sequence on that station. Furthermore, little attention has been paid to the sequence-dependent intertask times in multimodel production. Since the intertask times related to product model changeover have significant impact on manufacturing line performance, it is necessary to take into account the intertask times explicitly in multimodel manufacturing-line design. The need for this consideration is growing as product variety increases. This paper presents mathematical models of manufacturing-line design with the consideration of product-change-related intertask times in evaluating station times for multimodel production. The models aim to minimize capital investment of a manufacturing line by minimizing the number of stations. An optimization model is formulated using mixed-integer programming, and a heuristic solution procedure is developed for efficient calculation. This paper also investigates how manufacturing-line performance is affected by product-model build sequences and intertask times. The developed models will help enhance task-station assignment in multi- and mixed-model production by increasing line cost-effectiveness and reducing line changeover impact.
present a systematic optimization approach in order to improve the final adhesion of the diamond film and correlating the resulting machining performance with the delamination of the diamond coating. In this study, diverse surface pretreatments on WC-Co (6%) substrate were analyzed and compared, including different chemical etching processes, heat treatment in H2 and CH4 atmospheres, and the use of interlayer materials architectures (Cr, CrN) as diffusion barrier layers. The final performance of diamond films on WC-Co cutting inserts (SPG422) on A390 H3 aluminum alloys is compared for diamond films synthesized by hot-filament plasma-assisted CVD techniques, respectively. The quality of the film is analyzed using Raman spectroscopy, EDS, SEM, and AFM. Finally, correlations between the diamond-coating delamination, stresses on the film, and wear failure mode of the tool were analyzed using Rockwell hardness indentation, and machining performance tests.
MSEC2010-34355
Surface Generation of Hard Brittle Materials by Polishing with Closed Link Compact Machine Shinpei Okumura Doshisha University Toshiki Hirogaki Doshisha University Eiichi Aoyama Doshisha University Keiji Ogawa The University of Shiga Prefecture Yoshiaki Onchi Mizuho Co., Ltd. Sachiko Ogawa Doshisha University
In the manufacturing field, the need for sustainable development has become increasingly emphasized. In this study, we proposed fixed-abrasive polishing using a compact robot machine. The impact on the environment by using a compact machine was investigated by life cycle assessment for eco-friendly polishing processing. The actual polishing process was carried out with low pressure to determine the potential of the proposed polishing method. As a result, the following conclusions were obtained. Low-environmental-load processing was achieved by machine downsizing without affecting the processing results. The nanosurface could also be obtained with this method for glass material.
MSEC2010-34354
The Influence of Substrate Surface Pretreatments on the Adhesion of Diamond-Coated Cutting Tools Humberto Gomez University of South Florida Kevin Chou University of Alabama Xingcheng Xiao General Motors Corporation Robert Johnson Seki Technotron USA Ashok Kumar University of South Florida
The importance and interest of diamond films for machining applications is based on some of the unique diamond properties such as the highest thermal conductivity, extreme hardness, and low friction coefficient, making it very attractive to enhance the dry machining performance of magnesium and aluminum alloys in the automobile and aerospace industries. Different procedures have been reported in the literature about improving the adhesion of diamond films on carbide tools materials, but none of them
94
Abstracts
MSEC2010-34356
Development of Self-Adhesive Bamboo Fiber Composite with Three-Dimensional Shape Using Fibers Extracted with Machining Center Sachiko Ogawa Doshisha University Keiji Ogawa The University of Shiga Prefecture Toshiki Hirogaki Doshisha University Eiichi Aoyama Doshisha University Mitsuaki Taniguchi Doshisha University Hiromichi Nobe Mifuji Kikai Seisakusho, Ltd.
Bamboo is drawing attention as a sustainable and environmentally safe material because it is a renewable natural material and has a quick growth rate. Bamboo also has high specific strength and stiffness. Our research proposes a sustainable manufacturing system that focuses on the natural growth and properties of bamboo. One characteristic of this system is shape-controlled high-quality fibers. This can be achieved by in situ measurement and an end-milling extraction method with a machining center. Another characteristic is the potential to create a flexible composite shape thanks to controlled bamboo fiber shape and a press die. In this report, the fabrication of selfadhesive bamboo fiber composite is demonstrated by hot press forming. Proper forming temperature is investigated based on conditions and mechanical properties of the composites. A composite with three-dimensional shape is also fabricated using a press die with a three-dimensional curve. The forming was successful, and good transcription could be obtained.
95
Author Index
Last Name, First Name Page Last Name, First Name Page Last Name, First Name Page
Abbas, Ali .......................... 16, 48 Abdul K., Aini Z.................. 33, 86 Abell, Jeffrey.................19, 20, 53 Abu-Farha, Fadi .....24, 31, 60, 63 Agapiou, John ................... 27, 51 Agarwal, Mangilal .............. 32, 81 Ai, Xing .............................. 17, 67 Ajiboye, Joseph S.............. 32, 64 Altan, Taylan ..................... 30, 62 Ameta, Gaurav .................. 25, 90 Aoyama, Eiichi.......14, 20, 23, 25, 33, 36, 39, 84, 85, 87, 89, 94, 95 Ardelean, Flavius............... 26, 92 Arnold, Lee A..................... 12, 37 Ascari, Alessandro ............ 28, 77 Baharani, Shruti................. 32, 82 Baisie, Emmanuel ............. 24, 69 Barbelet, Mickael............... 13, 65 Barker, Jeremy .................. 22, 88 Barylski, Adam .................. 19, 46 Bejinaru, Gheorghe ........... 26, 91 Bejinaru-Mihoc, Gheorghe. 30, 62 Bengtsson, Nils ................. 16, 49 Bhatnagar, Samved........... 29, 43 Bihamta, Reza................... 15, 57 Biller, Stephan ................... 20, 85 Boggs, Taylor .................... 12, 38 Britz, Rainer....................... 31, 71 Brown, Malcolm O. ............ 20, 83 Bui, Quang-Hien................ 15, 57 Bunget, Cristina.....17, 30, 31, 45, 58, 59, 72 Cai, Wayne........................ 20, 53 Campana, Giampaolo ....... 28, 77 Cao, Jian ................13, 31, 55, 63 Castle, James.................... 23, 50 Ceretti, Elisabetta ...27, 31, 63, 70 Chang, Qing ...................... 20, 85 Chen, Fuh-Kuo .................. 31, 62 Chen, Maohua................... 13, 56 Chen, Shi-Qing.................. 15, 57 Chen, Shuping................... 13, 56 Chen, Yuheng ................... 22, 88 Chen, Zichen ..................... 17, 58 Cheng, Gary J. .. 18, 21, 28, 75, 76, 77 Chiang, Hao Ning .............. 17, 68 Chiou, Richard........24, 29, 45, 68 Chiriac, Constantin ............ 24, 59 Chou, Kevin...........26, 27, 32, 52, 73, 94 Chuang, Frank................... 22, 88 Collins, Schadrick.............. 27, 52 Cong, Weilong.......19, 22, 25, 30, 39, 46, 54, 92 Coste, Frederic.................. 13, 65 Coulter, John P.......13, 33, 65, 87 Coutris, Nicole ................... 22, 88 Creighton, Elizabeth .......... 28, 79 Cromer, William C. ............ 13, 64
Cui, Yan ............................. 30, 54 Cui, Zhen ................................. 55 Cullen, Graham W. ............ 24, 60 DAmours, Guillaume......... 15, 57 Dan, Zhao .......................... 27, 69 Deane, Erick ...................... 27, 52 Deines, Timothy................. 26, 40 Deines, Timothy W. .......... 25, 26, 41, 93 Deja, Mariusz..................... 19, 46 Delocki, Jacob ................... 29, 42 Deodhar, Sarang ............... 19, 34 DeVor, Richard E............... 20, 83 Dillon, Jr., O.W................... 29, 45 Dordai, Matthew................. 24, 68 Dumont, Guy...................... 13, 64 Ehmann, Kornel F.............. 16, 78 El-Mounayri, Hazim ........... 32, 81 Emblom, William .... 26, 30, 61, 90 Endres, William J. .............. 29, 43 Ezoe, Yuichiro.................... 12, 38 Fafard, Mario ..................... 15, 57 Faidley, LeAnn................... 17, 58 Feng, Qiang .... 17, 19, 22, 25, 30, 39, 46, 54, 68, 92 Ferrandiz Bou, Santiago .... 26, 92 Fiorentino, Antonio............ 27, 31, 63, 70 Fonda, James .................... 23, 50 Fortunato, Alessandro ....... 28, 77 Frank, Matthew .................. 16, 49 Gan, Yong.................... 20, 32, 82 Gao, Huang ....................... 28, 77 Gao, L. ............................... 13, 55 Gao, Robert ....................... 21, 83 Gao, Yibo............... 14, 28, 73, 76 Garcia-Romeu, M. Luisa .... 27, 70 Gegg, Brandon .................. 32, 72 Geisler, Chris G. ................ 19, 34 Ghane, Parvin.................... 32, 81 Ghose, Joyjeet....... 21, 26, 35, 92 Ghosh, Angshuman ........... 15, 56 Giardini, Claudio .... 27, 31, 63, 70 Glover, Richard D. ............. 20, 83 Goldsmith, Jason ............... 29, 42 Gomez, Humberto ............. 26, 94 Gong, Haibo....................... 21, 35 Gordan, Mircea .................. 30, 62 Grandhi, Ramana .............. 27, 70 Gross, Paul ........................ 27, 70 Guglielmotti, Alessandro .... 18, 75 Guha, Anshuman............... 21, 84 Guillot, Michel .................... 15, 57 Guo, Changsheng.............. 23, 44 Guo, D.M. .......................... 22, 39 Guo, Y.B. ........ 30, 31, 32, 33, 45, 71, 82, 89 Haapala, Karl R. ................ 20, 83 Heigel, Jarred .................... 24, 50 Henderson, Andrew ........... 31, 72 Hernandez, Manuel ........... 27, 52
Herran, C. Leigh.................22, 88 Herring, Craig.....................24, 60 Hidalgo, Miguel A. ..............14, 36 Hinton, Jantzen ..................27, 70 Hirogaki, Toshiki....14, 20, 23, 25, 33, 36, 39, 84, 85, 87, 89, 94, 95 Hitchiner, Mike P. ...............12, 48 Hoffman, Casey .................14, 35 Honegger, Andrew .............28, 79 Hoos, Kevin........................27, 70 Hsu, Fu-Chuan...................17, 68 Hu, Jack .......................19, 20, 53 Huang, Xu ..........................21, 75 Huang, Ying .......................31, 63 Huang, Yong ..........22, 26, 40, 88 Hung, Chinghua .................15, 66 Hutchison, James E. ..........20, 83 Ishizu, Kensuke..................12, 38 Iverson, Jon........................12, 48 Jahanmir, Said ...................28, 79 James, Sagil.......................12, 37 Jaouen, Olivier ...................13, 65 Jawahir, I.S. .......................29, 45 Jia, Jun...............................20, 35 Jiang, Feng ........................17, 67 Johns, Garret .....................29, 42 Johnson, Robert.................26, 94 Jones, Emily.......................25, 93 Jones, Joshua J. ....17, 25, 58, 90 Jones Jr., Richard ..............26, 90 Joslin, Andrew....................27, 52 Kapoor, Shiv G...................20, 83 Karandikar, Jaydeep .........12, 16, 47, 48 Kaya, Serhat ......................30, 62 Kilonzo, Obadiah................15, 66 Kim, Gap-Yong.......17, 32, 58, 81 Kim, Tae Hyung .................20, 53 Kinsey, Brad...........16, 17, 59, 77 Kizirian, Robin ........24, 29, 45, 68 Ko, Jeonghan .....................25, 94 Kodama, Hiroyuki...............20, 85 Komatsu, Takafumi ............23, 38 Kongsuwan, Panjawat........14, 74 Konno, Tsuyoshi ................23, 38 Kono, Takahiro...................33, 87 Korkolis, Yannis .................24, 60 Kota, Nithyanand................17, 59 Kruger, Grant .....................12, 37 Kumar, A. Senthil ...............23, 40 Kumar, Ashok.....................26, 94 Kumar, Surender....21, 26, 35, 92 Kunz, Jacob .......................28, 80 Kuppers, Jaron...................14, 35 Kurfess, Thomas R. ....25, 30, 31, 45, 72, 90 Kurp, Timothy.....................21, 83 Kuttolamadom, Mathew .....25, 90 Kwon, Patrick .........12, 16, 47, 49 Kwon, Yongjin ........24, 29, 45, 68
96
Author Index
Lasne, Patrice ....................13, 65 Lazar, Liviu.........................24, 60 Leang, Kam K. ...................25, 92 Lee, Ho-Sung .........15, 26, 56, 91 Lee, Ming-Hsing .................27, 51 Lee, Ming-Hu......................15, 66 Lee, S. Shawn ....................20, 53 Lee, Seungchul ..................33, 89 Lee, Yuan-Shin ..................21, 76 Lei, Shuting ............14, 29, 41, 74 Lei, Yang ............................13, 47 Lelkes, Peter I. .......19, 21, 34, 35 Li, Dichen ...........................21, 35 Li, Ho-Lung.........................19, 34 Li, Ji....................................14, 74 Li, Jianfeng.............15, 17, 65, 67 Li, Juan...............................28, 80 Li, Lin..................................33, 89 Li, Min.................................19, 34 Li, Sha ................................19, 53 Li, W. ..................................33, 89 Li, Wei ................................22, 88 Li, Xiaochun ...........21, 23, 50, 84 Li, Yu Ju .............................17, 68 Li, Zhichao (Zinc)................24, 60 Liao, Yiliang........................18, 75 Lin, Biaoyang .....................22, 88 Lin, Ko-Yu ..........................22, 88 Lin, Sin-Liang .....................31, 62 Lin, Yafu .............................26, 40 Lin, Yhu-tin .........................19, 53 Littlefair, Guy ......................29, 44 Liu, C. Richard ............18, 23, 43, 44, 74 Liu, Hai ...............................15, 57 Liu, Jian..............................28, 80 Liu, Jianbo..........................20, 85 Liu, Kui ...............................23, 40 Liu, Xinyu ...........................28, 80 Liu, Yueping .......................17, 67 Liu, Z.Q. .................17, 24, 50, 67 Loker, David .......................21, 84 Long, Yu.............................23, 44 Lopez Martinez, Juan ........26, 30, 62, 92 Lu, Ming-Chyuan ................27, 51 Lu, Ping ..............................27, 52 Ma, Lei ...............................23, 50 Ma, Liang ...........................22, 88 Ma, Ning.............................30, 61 MacDonald, Bryan J. ..........30, 61 Maijer, Daan.......................13, 64 Malhotra, Rajiv .......13, 31, 55, 63 Malik, Arif ...........................27, 70 Manabe, Ken-ichi ...............30, 61 Mao, Jin..............................33, 86 Marcu, Florin M. .................24, 60 Markwald, Roger R.............22, 88 Martens, Thomas ...............25, 91 Martini, Ashlie.....................32, 81 Marusich, Troy ...................17, 68
Marzi, Roberto ................... 31, 63 Mathew, Ronnie................. 12, 37 Matsumura, Takashi .......... 23, 38 Mayor, J. Rhett .................. 80, 28 Mears, Laine......... 17, 25, 58, 59, 90, 91 Mei, Deqing ....................... 17, 58 Melkote, Shreyes N. .......... 23, 50 Michaloski, John ................ 16, 49 Miller, Mark ........... 13, 24, 29, 42, 64, 69 Miller, Scott............ 12, 13, 37, 47 Milner, Justin L. ..... 27, 29, 42, 51 Min, Rong .......................... 15, 36 Mironov, Vladimir............... 22, 88 Mitsuda, Kazuhisa ............. 12, 38 Mitsuishi, Ikuyuki ............... 12, 38 Morehouse, John............... 23, 50 Moriyama, Teppei .............. 12, 38 Motoc, Dana Luca ............. 26, 91 Mukhopadhyay, Deepkishore ...... 28, 79 Murosky, Christopher......... 26, 91 Nakamura, Seishi .............. 20, 84 Namboothiri V N, Narayanan....... 32, 72 Nath, Chandra ................... 23, 40 Nazarian, Ehsan ................ 25, 94 Nemes, James A. .............. 15, 66 Newman, Stephen T. ......... 33, 86 Ng, Amos........................... 33, 86 Ngaile, Gracious ................ 15, 56 Ni, Jun ............................... 33, 89 Nobe, Hiromichi .... 14, 20, 25, 36, 84, 95 Nottingham, Daniel ............ 26, 41 Ogawa, Keiji ......... 14, 20, 23, 25, 33, 36, 39, 85, 87, 94, 95 Ogawa, Sachiko ......... 14, 25, 36, 94, 95 Okubo, Kazuya .................. 23, 39 Okumura, Shinpei .............. 25, 94 Onchi, Yoshiaki.................. 25, 94 Orazi, Leonardo................. 28, 77 Otawa, Tomoki .................. 33, 89 Ozdoganlar, O. Burak ........ 17, 59 Pallav, Kumar .................... 16, 78 Pan, Bing (Bill)................... 29, 44 Parasiz, Sunal ................... 16, 77 Park, Kyunghee ................. 16, 49 Park, Sang C. .................... 24, 68 Pasang, Timotius............... 29, 44 Paul, Brian K.......... 16, 20, 78, 83 Pei, Z.J. .... 13, 17, 19, 20, 22, 24, 25, 26, 29, 30, 39, 40, 41, 42, 46, 53, 54, 64, 68, 69, 92, 93 Perveen, Asma .................. 12, 38 Peterson, Richard B. ......... 16, 78 Petrzelka, Joseph .............. 16, 49 Phillip, Andy....................... 28, 79 Ping, Hu................. 27, 30, 61, 69
Pitschman, Matthew........... 29, 42 Polishetty, Ashwin.............. 29, 44 Pop, Petru A.......... 24, 26, 30, 60, 62, 91, 92 Pothula, Surya ................... 20, 82 Pritchett, Graham............... 26, 41 Proctor, Frederick .............. 16, 49 Promyoo, Rapeepan .......... 32, 81 Pu, Z. .................................29, 45 Puleo, D.A.......................... 29, 45 Qin, Feng ........................... 32, 73 Qin, Na................... 22, 24, 39, 69 Quadrini, Fabrizio............... 18, 75 Ragai, Ihab............. 13, 15, 65, 66 Ragen, Michael A............... 26, 91 Rahem, Ahmed .................. 15, 57 Rahman, Mustafizur .......... 12, 23, 38, 40 Ramirez, Ainissa ................ 21, 75 Ranganath, Santosh .......... 23, 44 Rauth, Nicholas.................. 24, 69 Ren, C.Z................. 17, 30, 54, 68 Ren, Feng .......................... 13, 55 Richardson, B.J.................. 30, 45 Riddle, Robert .................... 25, 92 Riveros, Raul ..................... 12, 38 Roth, John T. .............. 21, 27, 29, 42, 51, 84 Sabo, Joshua ..................... 24, 60 Sah, Sripati ........................ 21, 83 Sahu, Bijoyraj..................... 25, 92 Saito, Masato ..................... 30, 61 Salahshoor, M.................... 30, 45 Salandro, Wesley A. .... 17, 58, 59 Sangwan, K.S. ................... 20, 52 Santo, Loredana ................ 18, 75 Satoh, Gen............. 14, 21, 74, 75 Sawa, Kazuya .................... 23, 39 Schmidt, Karen ........... 13, 24, 29, 42, 64, 69 Schmitz, Tony ........ 12, 16, 47, 48 Shao, Guodong.................. 16, 49 Sharma, Vinay ....... 21, 26, 35, 92 Shi, Ming ............................ 24, 59 Shi, Xinmei......................... 13, 64 Shih, Albert J...................... 31, 71 Shih, Hua-Chu ................... 24, 59 Shirwaiker, Rohan.............. 25, 93 Shrestha, Sudhir ................ 32, 81 Singh, H. ............................ 31, 71 Singh, Perminderjit............. 20, 52 Siopis, Michael...................17, 59 Sodemann, Angela ............ 28, 80 Song, Qinghua ................... 17, 67 Song, Xiaoxu......... 25, 26, 30, 40, 54, 92, 93 Sowles, Richard ................. 21, 84 Srinivasan, Raghunathan... 25, 90 Srivastava, Anil .................. 12, 48 Stephenson, David A. ........ 31, 71 Strano, Matteo ................... 15, 57
97
Author Index
Suen, Derek A. .................. 21, 84 Suh, Steve......................... 32, 72 Sun, Jie ..................15, 17, 65, 67 Sundaram, Murali .............. 12, 37 Tai, Bruce L. ...................... 31, 71 Takagi, Utako .................... 12, 38 Takahashi, Atsushi ............ 30, 61 Talarico, Ronald ................ 23, 44 Tani, Giovanni ................... 28, 77 Taniguchi, Mitsuaki........... 14, 25, 36, 95 Tantrapiwat, Akapot ......... 13, 33, 65, 87 Tao, Sha.................14, 29, 41, 74 Taylor, Curtis ..................... 25, 92 Tempelman, Harry............. 13, 65 Thompson, Raymond ........ 27, 52 Tobe, Shouta..................... 23, 38 Traverso, Mike................... 16, 48 Tsai, Hai-Lung ................... 28, 77 Tsai, Jhy-Cherng ............... 27, 51 Tseng, Bill.......................... 29, 45 Tseng, Huang-Chi ............. 15, 66 Tulsian, Abhinandan.......... 28, 79 Ulbrich, Heinz .................... 31, 71 Ungur, Patricia A. .............. 24, 60 VanBenthysen, Reid.......... 16, 77 Varahramyan, Kody........... 32, 81 Vazhayil Govindan, Rajesh ......... 32, 72 Venkatesh, Sid .................. 16, 49 Vlieg, James H. ................. 16, 78 Voigt, Robert ..................... 25, 93 Voothaluru, Rohit............... 18, 74 Waikar, Rahul.................... 32, 82 Walczyk, Daniel................. 14, 35 Wang, Donghai............25, 26, 41, 92, 93 Wang, Heping...............23, 43, 44
Wang, Hongliang ............... 14, 74 Wang, Hui .......................... 19, 53 Wang, J.J........................... 17, 68 Wang, Junbiao................... 15, 36 Wang, Lihui........................ 33, 86 Wang, Wei ......................... 22, 88 Wang, Xin .......................... 12, 47 Wang, Yang ....................... 13, 56 Wang, Yongjun ........... 13, 15, 31, 36, 55, 63 Wang, Youjiang ................. 20, 35 Wang, Zhongqiu ................ 15, 65 Weinmann, Klaus J............ 30, 61 Werschmoeller, Dirk ......... 21, 23, 50, 84 Whitenton, Eric .................. 24, 50 Wilson, Don F. ................... 27, 52 Wong, Y.S.......................... 12, 38 Wootton, David M. ............. 19, 34 Wu, Benxin14, 28, 29, 41, 73, 74, 76 Wu, Shenfeng .................... 23, 43 Wu, Weichao ........ 13, 15, 31, 36, 55, 63 Wu, Xiaorong ..................... 26, 41 Wu, Yufeng ........................ 32, 81 Wu, Zong-Chun ................. 15, 66 Wyatt, Tom ........................ 19, 34 Wysk, Richard.................... 25, 93 Xia, Cedric ......................... 13, 55 Xiao, Guoxian .................... 20, 85 Xiao, Han ........................... 15, 57 Xiao, Xingcheng................. 26, 94 Xiao, Xudong ..................... 13, 55 Xin, X.J. ..... 13, 24, 29, 42, 64, 69 Xu, Changxue .................... 26, 40 Xu, Chengying ....... 27, 28, 52, 80 Xu, Xun .............................. 33, 86 Xue, Liang.......................... 13, 55
Yamaguchi, Hitomi .............12, 38 Yang, Yueh-Ting ....24, 29, 45, 68 Yao, Donggang ......19, 20, 34, 35 Yao, Y. Lawrence...14, 21, 74, 75 Yao, Zhehe ........................17, 58 Yazdi, Mohammad Givehchi ...33, 86 Ye, Chang ..........................18, 75 Yesilkaya, Kamuran ...........25, 93 Yi, Y.M. ..................15, 26, 56, 91 Yiguo, Zhu..........................27, 69 Yoon, Jong-Hoon ...15, 26, 56, 91 Yoshihara, Shoichiro ..........30, 61 Yu, Bingyi ...........................20, 83 Yuan, Wenqiao...................30, 54 Yuan, Zhenyi ......................13, 55 Zapata, Raul...........12, 16, 47, 48 Zhang, Martin Y..................21, 76 Zhang, Meng .........25, 26, 30, 40, 54, 92, 93 Zhang, Pengfei......20, 25, 26, 30, 41, 53, 54, 92, 93 Zhang, Qi ........25, 26, 30, 41, 54, 92, 93 Zhang, Qingwei ......19, 21, 34, 35 Zhang, Shi-Hong ................15, 57 Zhang, Shijun .....................24, 50 Zhang, Wei.........................19, 34 Zhang, Xiaohong (Tina) .....24, 69 Zhang, Xinquan..................23, 40 Zhang, Xueping............23, 43, 44 Zhao, Yong ........................17, 68 Zhou, Changchun...............22, 88 Zhou, Jack G..........19, 21, 34, 35 Zhou, Jun ...............28, 29, 42, 77 Zhou, Yun ..............14, 28, 73, 76 Ziegert, John ......................25, 90 Zinke, Eric ..........................25, 92 Zou, Qingze........................17, 58
98
E X P E R T I S E I N A D H E S I V E S , C O AT I N G S , V I B R AT I O N A N D M O T I O N C O N T R O L
Providing value to our customers, coworkers, and communities.
Built on a foundation of trust and integrity more than 85 years ago, we continue to increase the value of our customers products, encourage chemistry and engineering innovations from our employees and support the communities in which we work ... Ask Us How. For more information or employment opportunities, visit us at www.lord.com.
SA8139 2010 LORD Corporation
I am Cummins... You can depend on me.

Global Community Global Company Global Opportunity
Global Community; Our work community is based on collaborating with teammates from around the globe. Cummins also strives to make a positive difference in the communities where we live and work. Global Company; As a global company, we are active in more than 190 countries. We are committed to acting with integrity and embrace the diverse perspectives of all people with dignity and respect. Global Opportunity; We provide a variety of diverse work locations and opportunities. Our technical innovation drives our global leadership and creates future opportunities.
Our differences are what strengthen us as a company.
F o r e m p l o y m e n t i n f o r m a t i o n , p l e a s e v i s i t w w w. c u m m i n s . c o m
Join us at Oregon State University in Corvallis, Oregon June 13-17, 2011 for the first ever MSEC/NAMRC/ICMP Conference combining the flagship manufacturing conferences from the American Society of Mechanical Engineers (ASME), the Society of Manufacturing Engineers (SME) and the Japan Society of Mechanical Engineers (JSME). Oregon State University is adjacent to Portlands Silicon Forest with over 1,000 high technology companies and is situated between the Pacific Ocean and the Cascade Mountain Range. Area wineries and hikes provide attendees a multitude of pre or post conference activities. Come mingle with your manufacturing colleagues and explore the beauty of the Pacific Northwest! Sixth Annual ASME International Manufacturing Science & Engineering ConferConfer ence (MSEC) MSEC is the foremost annual forum sponsored by the Manufacturing Engineering Division (MED) of ASME to disseminate the most recent results in manufacturing research and development through both technical papers and panel sessions. 39th Annual SME North American Manufacturing Research Conference (NAMRC) NAMRC is the premier international forum for applied research and industrial applications in manufacturing and design. Sponsored by the North American Manufacturing Research Institution of SME, global academic and industrial leaders in manufacturing attend this conference to interact with each other and advance the field. 2011 JSME/ASME International Conference on Materials and Processing (ICM&P) ICM&P 2011 is an international conference co-sponsored by the Materials and Processing (M&P) Division of the JSME and ASME MED to promote international collaboration in advancing manufacturing science and technology. In 2011, ICM&P coincides with the 19th JSME Materials and Processing Conference (M&P 2011). The conference is recognized as the premier meeting on materials and processing technology in Japan.
Registration will be open soon! Visit MSEC-NAMRC-ICMP.org for more details.
Visit http://msec-namrc-icmp.org for more information about the MSEC/NAMRC/ICMP Conference.

MSEC2010 Final Program

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

MSEC2010 Final Program

Загружено:

Авторское право:

Доступные форматы

ASME 2010 International Manufacturing Science and Engineering Conference

Erie, Pennsylvania, USA October 12-15, 2010

Sponsored by The ASME Manufacturing Engineering Division

Los Alamos National Laboratory

General Electric Company

Komatsu America Corporation Lord Corporation

National Science Foundation

Ben Franklin Technology Partners

The ASME OldGuard

Manufacturer & Business Association

WELCOME BY THE HOST

ASME 2010 International Manufacturing Science and Engineering Conference

WELCOME FROM THE PROGRAM CHAIRS

ASME 2010 International Manufacturing Science and Engineering Conference

WELCOME FROM THE ASME/MED CHAIR

ASME 2010 International Manufacturing Science and Engineering Conference

ASME 2010 International Manufacturing Science and Engineering Conference

ASME 2010 International Manufacturing Science and Engineering Conference

ASME 2010 International Manufacturing Science and Engineering Conference

Committees / Student Manufacturing Design Competition

STUDENT MANUFACTURING DESIGN COMPETITION

ASME 2010 International Manufacturing Science and Engineering Conference

ASME 2010 International Manufacturing Science and Engineering Conference

ASME 2010 International Manufacturing Science and Engineering Conference

Early Research Career Forum

EARLY RESEARCH CAREER FORUM

ASME 2010 International Manufacturing Science and Engineering Conference

1:30pm 3:00pm 3:30pm 5:15pm 5:15pm 6:15pm 7:15pm

3:00pm 3:30pm 5:00pm 6:15pm 6:15pm 7:15pm 10:00pm

ASME 2010 International Manufacturing Science and Engineering Conference

9:00am 9:15am 10:15am 10:30am 11:45am 12:30pm

9:15am 10:15am 10:30am 11:30am 12:30pm 1:30pm

1:30pm 1:45pm 3:15pm 3:30pm 5:15pm

1:45pm 3:15pm 3:30pm 5:00pm 8:00pm

10:00am 10:30am 12:00pm 1:00pm 2:00pm 3:30pm

10:30am 12:00pm 1:00pm 2:00pm 3:30pm 6:00pm

ASME 2010 International Manufacturing Science and Engineering Conference

Conference Venue Map

CONFERENCE VENUE MAP

ASME 2010 International Manufacturing Science and Engineering Conference

TUESDAY, OCTOBER, 12 SYMP 21 Conference Events

SYMP 21 Conference Events

21-7 NAMRI BOARD MEETING Room 150

21-4 EARLY RESEARCH CAREER FORUM Penn State Behrend 12:00pm5:00pm

WEDNESDAY, OCTOBER, 13 SYMP 21 Conference Events

SYMP 21 Conference Events

21-15 HERO BX TOUR 1 21-16 HERO BX TOUR 2

21-23 WELCOMING REMARKS West Ballroom

SYMP 21 Conference Events

SYMP 21 Conference Events

21-17 PENN STATE BEHREND TOURS 1 4:00pm6:00pm

SYMP 21 Conference Events

SYMP 21 Conference Events

21-31 WELCOME RECEPTION

21-5 MED EXECUTIVE COMMITTEE MEETING Room 150 10:30am11:30am

ASME 2010 International Manufacturing Science and Engineering Conference

SYMP 3 Advances in Nontraditional Manufacturing

SYMP 7 Smart Machining

3-1 ADVANCES IN NONTRADITIONAL MANUFACTURING 1 Room 170B 10:30am12:00pm

7-1 MACHINING AND GRINDING 1 Room 160A 10:30am12:00pm

ASME 2010 International Manufacturing Science and Engineering Conference

SYMP 9 Advances in Materials Forming