Abstract of Papers

Submitted to

2017 MSEC‐NAMRC‐ICMP

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Paper Number Page Paper Number Page Paper Number Page Paper Number Page MSEC2017‐2603 5 MSEC2017‐2702 18 MSEC2017‐2771 29 MSEC2017‐2835 41 MSEC2017‐2604 5 MSEC2017‐2703 18 MSEC2017‐2773 30 MSEC2017‐2839 42 MSEC2017‐2605 5 MSEC2017‐2704 19 MSEC2017‐2774 30 MSEC2017‐2840 42 MSEC2017‐2611 6 MSEC2017‐2705 19 MSEC2017‐2775 30 MSEC2017‐2841 42 MSEC2017‐2614 6 MSEC2017‐2708 19 MSEC2017‐2776 31 MSEC2017‐2843 42 MSEC2017‐2615 7 MSEC2017‐2710 19 MSEC2017‐2777 31 MSEC2017‐2847 43 MSEC2017‐2619 7 MSEC2017‐2711 20 MSEC2017‐2778 31 MSEC2017‐2850 43 MSEC2017‐2621 7 MSEC2017‐2712 20 MSEC2017‐2779 32 MSEC2017‐2853 43 MSEC2017‐2624 8 MSEC2017‐2715 20 MSEC2017‐2780 32 MSEC2017‐2854 44 MSEC2017‐2626 8 MSEC2017‐2719 21 MSEC2017‐2781 32 MSEC2017‐2856 44 MSEC2017‐2630 8 MSEC2017‐2720 21 MSEC2017‐2782 33 MSEC2017‐2858 44 MSEC2017‐2638 9 MSEC2017‐2721 21 MSEC2017‐2783 33 MSEC2017‐2860 45 MSEC2017‐2639 9 MSEC2017‐2723 22 MSEC2017‐2786 33 MSEC2017‐2863 45 MSEC2017‐2641 10 MSEC2017‐2725 22 MSEC2017‐2787 34 MSEC2017‐2864 45 MSEC2017‐2643 10 MSEC2017‐2726 22 MSEC2017‐2788 34 MSEC2017‐2871 46 MSEC2017‐2644 10 MSEC2017‐2731 22 MSEC2017‐2789 34 MSEC2017‐2872 46 MSEC2017‐2654 11 MSEC2017‐2733 23 MSEC2017‐2790 35 MSEC2017‐2873 46 MSEC2017‐2656 11 MSEC2017‐2734 23 MSEC2017‐2792 35 MSEC2017‐2874 47 MSEC2017‐2657 12 MSEC2017‐2735 23 MSEC2017‐2794 34 MSEC2017‐2877 47 MSEC2017‐2659 12 MSEC2017‐2736 24 MSEC2017‐2796 36 MSEC2017‐2878 47 MSEC2017‐2665 12 MSEC2017‐2737 24 MSEC2017‐2797 36 MSEC2017‐2879 48 MSEC2017‐2666 13 MSEC2017‐2739 24 MSEC2017‐2798 36 MSEC2017‐2880 48 MSEC2017‐2673 13 MSEC2017‐2741 24 MSEC2017‐2803 36 MSEC2017‐2882 48 MSEC2017‐2674 13 MSEC2017‐2742 25 MSEC2017‐2807 37 MSEC2017‐2886 48 MSEC2017‐2678 14 MSEC2017‐2746 25 MSEC2017‐2809 37 MSEC2017‐2887 49 MSEC2017‐2679 14 MSEC2017‐2747 25 MSEC2017‐2811 37 MSEC2017‐2888 49 MSEC2017‐2680 15 MSEC2017‐2749 26 MSEC2017‐2814 38 MSEC2017‐2889 49 MSEC2017‐2681 15 MSEC2017‐2752 26 MSEC2017‐2815 38 MSEC2017‐2891 50 MSEC2017‐2684 15 MSEC2017‐2753 26 MSEC2017‐2817 38 MSEC2017‐2892 50 MSEC2017‐2687 15 MSEC2017‐2755 26 MSEC2017‐2818 39 MSEC2017‐2893 50 MSEC2017‐2689 16 MSEC2017‐2756 27 MSEC2017‐2823 39 MSEC2017‐2894 51 MSEC2017‐2690 16 MSEC2017‐2758 27 MSEC2017‐2825 39 MSEC2017‐2895 51 MSEC2017‐2691 16 MSEC2017‐2759 27 MSEC2017‐2826 40 MSEC2017‐2896 51 MSEC2017‐2692 16 MSEC2017‐2760 28 MSEC2017‐2827 40 MSEC2017‐2898 51 MSEC2017‐2694 17 MSEC2017‐2763 28 MSEC2017‐2829 40 MSEC2017‐2900 52 MSEC2017‐2695 17 MSEC2017‐2765 28 MSEC2017‐2830 41 MSEC2017‐2904 52 MSEC2017‐2699 17 MSEC2017‐2766 29 MSEC2017‐2833 41 MSEC2017‐2906 52 MSEC2017‐2700 18 MSEC2017‐2769 29 MSEC2017‐2834 41 MSEC2017‐2907 52

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Paper Number Page Paper Number Page Paper Number Page Paper Number Page MSEC2017‐2909 53 MSEC2017‐2974 65 MSEC2017‐3029 77 MSEC2017‐3119 89 MSEC2017‐2911 53 MSEC2017‐2975 65 MSEC2017‐3030 77 MSEC2017‐3147 89 MSEC2017‐2913 53 MSEC2017‐2978 65 MSEC2017‐3031 77 MSEC2017‐3162 89 MSEC2017‐2915 54 MSEC2017‐2979 65 MSEC2017‐3032 78 MSEC2017‐3163 89 MSEC2017‐2918 54 MSEC2017‐2980 66 MSEC2017‐3034 78 MSEC2017‐3164 90 MSEC2017‐2921 54 MSEC2017‐2981 66 MSEC2017‐3035 78 MSEC2017‐3165 90 MSEC2017‐2924 55 MSEC2017‐2982 66 MSEC2017‐3036 78 MSEC2017‐3166 90 MSEC2017‐2926 55 MSEC2017‐2983 67 MSEC2017‐3037 79 MSEC2017‐3167 90 MSEC2017‐2927 55 MSEC2017‐2985 67 MSEC2017‐3038 79 MSEC2017‐3168 91 MSEC2017‐2928 56 MSEC2017‐2987 67 MSEC2017‐3039 79 MSEC2017‐3169 91 MSEC2017‐2930 56 MSEC2017‐2989 68 MSEC2017‐3043 80 MSEC2017‐3170 91 MSEC2017‐2932 56 MSEC2017‐2991 68 MSEC2017‐3045 80 MSEC2017‐3171 91 MSEC2017‐2934 57 MSEC2017‐2992 68 MSEC2017‐3046 80 MSEC2017‐3172 92 MSEC2017‐2935 57 MSEC2017‐2993 68 MSEC2017‐3047 81 MSEC2017‐3174 92 MSEC2017‐2936 57 MSEC2017‐2994 69 MSEC2017‐3048 81 MSEC2017‐3175 92 MSEC2017‐2937 58 MSEC2017‐2997 69 MSEC2017‐3049 81 MSEC2017‐3177 92 MSEC2017‐2938 58 MSEC2017‐2999 69 MSEC2017‐3050 81 MSEC2017‐3178 93 MSEC2017‐2939 58 MSEC2017‐3000 70 MSEC2017‐3051 82 MSEC2017‐3179 93 MSEC2017‐2940 59 MSEC2017‐3001 70 MSEC2017‐3052 82 MSEC2017‐3180 93 MSEC2017‐2941 59 MSEC2017‐3002 70 MSEC2017‐3054 82 MSEC2017‐3181 93 MSEC2017‐2942 59 MSEC2017‐3003 71 MSEC2017‐3058 83 MSEC2017‐3182 94 MSEC2017‐2944 59 MSEC2017‐3006 71 MSEC2017‐3059 83 MSEC2017‐2947 60 MSEC2017‐3007 71 MSEC2017‐3060 83 MSEC2017‐2949 60 MSEC2017‐3008 72 MSEC2017‐3061 84 MSEC2017‐2951 60 MSEC2017‐3009 72 MSEC2017‐3062 84 MSEC2017‐2952 61 MSEC2017‐3012 72 MSEC2017‐3065 84 MSEC2017‐2954 61 MSEC2017‐3014 73 MSEC2017‐3069 84 MSEC2017‐2955 61 MSEC2017‐3015 73 MSEC2017‐3072 85 MSEC2017‐2956 62 MSEC2017‐3016 73 MSEC2017‐3074 85 MSEC2017‐2957 62 MSEC2017‐3018 74 MSEC2017‐3075 85 MSEC2017‐2958 62 MSEC2017‐3019 74 MSEC2017‐3080 86 MSEC2017‐2960 62 MSEC2017‐3020 74 MSEC2017‐3084 86 MSEC2017‐2962 63 MSEC2017‐3021 75 MSEC2017‐3090 87 MSEC2017‐2965 63 MSEC2017‐3022 75 MSEC2017‐3091 87 MSEC2017‐2966 63 MSEC2017‐3024 75 MSEC2017‐3092 87 MSEC2017‐2970 63 MSEC2017‐3026 76 MSEC2017‐3093 87 MSEC2017‐2972 64 MSEC2017‐3027 76 MSEC2017‐3098 88 MSEC2017‐2973 64 MSEC2017‐3028 76 MSEC2017‐3104 88

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The Effects of and Mechanical Forming on the Hardness and Microstructural Layout of Commercially Pure Grade 2 Alloy Plates Technical Publication. MSEC2017‐2603 Kadephi V Mjali, Cape Peninsula University of Technology, Cape Town, Western Cape, South Africa, Peter Madindwa Mashinini, University of Johannesburg, Johannesburg, South Africa, Annelize Els‐Botes, CSIR, Pretoria, Gauteng, South Africa This paper illustrates the effects of the laser and mechanical forming on the hardness and microstructural distribution in commercially pure grade 2 titanium alloy plates. The two processes were used to bend commercially pure grade 2 titanium alloy plates to a similar radius also investigate if the laser forming process could replace the mechanical forming process in the future. The results from both processes are discussed in relation to the mechanical properties of the material. Observations from hardness testing indicate that the laser forming pro‐ cess results in increased hardness in all the samples evaluated, and on the other hand, the mechanical forming process did not influence hardness on the samples evaluated. There was no change in microstructure as a result of the mechanical forming process while the laser forming process had a major influence on the overall microstructure in samples evaluated. The size of the grains became larger with in‐ creases in thermal gradient and heat flux, causing changes to the overall mechanical properties of the material. The thermal heat generated has a profound influence on the grain structure and the hardness of titanium. It is evident that the higher the thermal energy the higher is the hardness, but this only applies up to a power of 2,5kW. Afterwards, there is a reduction in hardness and an increase in grain size. The cooling rate of the plates has been proved to play a significant role in the resulting microstructure of titanium alloys. The scanning speed plays a role in maintaining the surface temperatures of laser formed titanium plates resulting in changes to both hardness and the micro‐ structure. An increase in heat results in grain growth affecting the hardness of titanium.

Residual Stress Distribution and the Concept of Total Stress in Laser and Mechanically Formed Commercially Pure Grade 2 Titanium Alloy Plates Technical Publication. MSEC2017‐2604 Kadephi V Mjali, Cape Peninsula University of Technology, Cape Town, Western Cape, South Africa, Peter Madindwa Mashinini, University of Johannesburg, Johannesburg, South Africa, Annelize Els‐Botes, CSIR, Pretoria, Gauteng, South Africa This paper discusses the investigation of residual stresses developed as a result of mechanical and laser forming processes in commercially pure grade 2 titanium alloy plates as well as the concept of total fatigue stress. The intention of the study was to bend the plates using the respective processes to a final radius of 120mm using both processes. The hole drilling method was used to measure residual strains in all the plates. High stress gradients were witnessed in the current research and possible cases analyzed and investigated. The effects of pro‐ cessing speeds and powers used also played a significant role in the residual stress distribution in all the formed plates. A change in laser power resulted in changes to residual stress distribution in the plates evaluated. This study also dwells into how the loads that are not normally incorporated in fatigue testing influence fatigue life of commercially pure grade 2 titanium alloy plates. Also, the parent material was used to benchmark the performance of the two forming processes in terms of stresses developed. Residual stresses developed from the two forming processes and the parent material used together with the mean stress was incorporated into the alternating stress from the fatigue machine to develop the concept of total fatigue stress. This exercise indicated the effect of these stresses on the fatigue life of the parent material, laser and mechanically formed plate samples. A strong link between these stresses was obtained and formulae ex‐ plaining the relationship formulated. A comparison between theory and practical application shown by test results is found to be satisfac‐ tory in explaining concerns that may arise. The laser forming process is more influential in the development of residual stress, compared to the mechanical forming process. With each parameter change in laser forming there is a change in residual stress arrangement. Under the influence of laser forming the stress is more tensile in nature making the laser formed more susceptible to early fatigue failure. The laser and mechanical forming processes involve bending of the plate samples and most of these samples experienced a two‐dimensional defect which is a dislocation. The dislocation is the defect responsible for the phenomenon of slip by which most deform plastically. Also the high temperatures experienced in laser forming were one of the major driving factors in bending.

Optimization of Friction Stir Welding Process Parameters to Join Al 5052 and Al 6061 Alloy Plates Using Grey‐Taguchi Tech‐ nique Technical Publication. MSEC2017‐2605 SANDEEP RENANGI, SUDHAKARA DARA, Siddartha Institute of Science and Technology, Tirupathi, India, Prasanthi G, JNTUA College of Engineering, Ananthapuramu, India Friction stir welding (FSW) is a solid state welding process used for welding similar and dissimilar materials. The process is widely used be‐ cause it does not have common problems such as solidification and liquefaction cracking associated with the fusion welding techniques. The objective of the present research is to find the best combination of friction stir welding process parameters to join aluminum 5052 and

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6061 alloy materials. The combination of process parameters is helpful to improve ultimate tensile strength, yield strength, percentage of elongation and hardness of welded joint. To achieve the research objective taguchi based grey analysis was used. The optimum process parameters was found be at rotational speed is 1400 rpm, transverse speed of 100 mm/min and axial force is at 11 KN.

Adapting Warehouse Management Systems to the Requirements of the Evolving Era of Industry 4.0 Technical Publication. MSEC2017‐2611 Cyril Alias, University of Duisburg‐Essen, Duisburg, Germany, Udo Salewski, w3logistics AG, Dortmund, NRW, Germany, Vivi‐ ana Elizabeth Ortiz Ruiz, University of Duisburg‐Essen, Duisburg, NRW, Germany, Frank Eduardo Alarcón Olalla, Universidad San Francisco de Quito, Quito, Ecuador, José do Egypto Neirão Reymão, Universidade Federal do Rio de Janeiro, Rio de Janei‐ ro, Rio de Janeiro, Brazil, Bernd Noche, University of Duisburg‐Essen, Duisburg, NRW, Germany With global megatrends like automation and digitization changing societies, economies, and ultimately businesses, change is underway. In the light of fueled technological change disrupting current business plans and entire industries, business actors have accordingly developed an instinctive fear of economic decline and realized the necessity of taking adequate measures to keep up with the times. Increasingly, organizations find themselves in an evolve‐or‐die race with their success depending on their capability of recognizing the requirements for serving a specific market and adopting those requirements accurately into their own structure. In the transportation and logistics sector, emerging technological and information challenges are reflected in fierce competition from within and outside. Especially, processes and supporting information systems are put to the test when technological innovation start to spread among an increasing number of actors and promise higher performance or lower cost. As to warehousing, technological innovation continuously finds its way into the premises of the highly heterogeneous warehouse operators, leading to modifications and improvements of the processes. Such innovation can be at the side of the hardware equipment or in the form of new software solutions. Particularly, the fourth industrial revolution is under way in industrialized countries, and partly even in industrializing economies. Same applies to Future Internet technologies, a European term for innovative software technologies and the research upon them. On the one hand, new hardware solutions using robotics, cyber‐physical systems and sensors, and advanced materials are constantly put to widespread use. On the other one, software solutions based on intensi‐ fied digitization including new and more heterogeneous sources of information, higher volumes of data, and increasing processing speed are also becoming an integral part of popular information systems for warehouses, particularly for warehouse management systems. With a rapidly and dynamically changing environment and new legal and business requirements towards processes and supporting infor‐ mation systems in the warehouses, new performance levels in terms of quality and cost of service are to be obtained. For this purpose, new requirements towards the functionality of warehouse management systems need to be derived in order to safeguard the new performance goals. While introducing wholly new solutions is one option, retrofitting and adapting existing systems to the new requirements is another one. The warehouse management systems will need to deal with more types of data from new and heterogeneous data sources as well as to connect to innovative machines and represent their respective operating principles. In both scenarios, systems need to satisfy the de‐ mand for new system features in order to remain capable of acting and able to process information to optimize logistics processes in real time. By taking a closer look at an industrial use case of a real warehouse management system, opportunities of incorporating such new requirements into their existing system architecture and setup are presented as the system adapts to new types of data, increased speed of information processing, and new kinds of machines and equipment used in the warehouse. Eventually, the present paper proves the adaptability of existing warehouse management systems to the requirements of the new digital world, and viable methods to adopt the necessary renovation processes.

Fatigue Behavior of Two Notched Cutting Tool Materials: M42 HSS and WC‐10Cobalt Technical Publication. MSEC2017‐2614 Zainul Huda, King Abdulaziz University, Jeddah, Saudi Arabia, Muhammad H. Ajani, Muhammad S. Ahmed, University of New South Wales, Kensington, NSW 2052, Australia Fatigue testing experiments have been conducted for notched specimens of two cutting‐tool materials: high speed (M42 HSS) and cemented carbide composite (WC‐10Co). The effects of varying loads and notch on the fatigue lives of M42 HSS and WC‐10Co, including a comparative study of the fatigue behaviors of the two cutting‐tool materials, have been reported. The notched specimens, having R=0.1mm, of HSS and WC‐Co were subjected to bending stresses by using a WP‐140 fatigue testing machine. The fatigue behaviors of the two cutting‐tool materials have been investigated by developing their S‐N curves as well as examinations of the fracture surfaces of the materials. A distinct endurance limit for M42 HSS was observed while WC‐Co did not show any endurance limit. A fatigue life of 10000000 cycles corresponding to a fatigue limit of 430 MPa was determined for M42 HSS. It has been found that a reduction of stress amplitude by 6

60 MPa results in an increase of fatigue life by around 175% for the notched specimens of cemented carbide. The research findings would enable manufacturing engineers to select a suitable cutting tool material having a notch for application under cyclic stressed .

“Combined Extrusion‐Forging: Simulation, Experimental and Microscopic Investigation of Axisymmetric Single Collar Collet Holder” Technical Publication. MSEC2017‐2615 SRIKAR POTNURU, NIT Rourkela, Visakhapatnam, Odisha, India, Susanta Kumar Sahoo, Santosh Kumar Sahoo, NIT Rourkela, Rourkela, Odisha, India Combined Extrusion‐forging is a renowned forming process which is a pathway for manufacturing complex components. In that con‐ text providing a component with higher metallurgical & mechanical properties can be enhanced by severe plastic deformation that pro‐ cesses the fine‐grained materials formation in the product. These fine‐grained materials presence makes the component with higher quali‐ ty. The novelty of the concept is to validate the presence of ultra‐fine grained materials at lower ram displacement. This paper presents the estimated forming load, metal flow pattern and alike, along with microstructural validation with experimental and simulation data for manufacturing a collet chuck holder by combined forward backward extrusion and forging. The design of experimental die‐punch setup and simulation of the process using modelling software DEFORM3D has presented for estimation of forming load and metal flow patterns. Enough number of experiments has been carried out at various punch movements to find out forming load and metal flow pattern. Micro‐ scopically analyses have been performed to validate the data with the results obtained from the experimentation and simulation processes, and they are found to be in good agreement. Mathematical analysis was also performed in application with UBET to obtain the forming load at different reduction percentages; it was found that the numerical data was well validated with the experimental results. Further, micro‐hardness analysis was performed. As the component was manufactured under heavy loads residual stress was found to check the load carrying capacity of the component.

Design and Development of Novel Lubricant Free Transmission System for Manual Bone Drilling Machine Technical Publication. MSEC2017‐2619 Mehdi Salehi, Karlsruhe University of Applied Science, Karlsruhe, Germany, David Sternkopf, Karlsruhe University of Applied Science, Karlsrue, Germany, Eric Schilling, SMT Schilling Metalltechnik GmbH, Muehlheim, Germany, Ruediger Haas, Karls‐ ruhe University of Applied Science, Karlsruhe, Germany This paper describes design and development of novel lubricant free transmission system for manual bone drilling machine. In order to design the transmission system, applied forces and torques on the gears has to be achieved. In this regard, bone drilling forces and torques were detected, preforming experimental tests of the drilling operation by CNC milling machine. At this point, various drill diameters and machining parameters were considered. After achieving the bone drilling forces, they were utilized for gears design process. The design process including gear geometry, material and detailed design analysis were done according to German norm VDI 2736‐ Part 3. In this context, the mating worm gears materials were selected out of stainless steel 316 and Polyether Ether Ketone (PEEK), which can reduce weight, noise, moment of inertia, and necessity of lubrication, etc. In order to evaluate the gears performance, numerically and experi‐ mentally were performed. The static stress and deflection of the PEEK gear tooth were investigated numerically by finite element analy‐ sis. According to the numerical results, each tooth force carrying capacity (until yield stress) were estimated until 302 N. Surface tempera‐ ture and wear rate for two types of PEEK gears were examined, experimentally, while applying two resistance torque values, 0.75 and 0.5 Nm, to the manufactured transmission system. The selected torques were three and five times bigger than drilling torque values, enabling us to simulate the bone drilling operation considering unexpected loaded in the extreme case, misuse, emergence situation, and degrada‐ tion. The maximum temperatures of the tooth contour of the transmission system raised to 127 °C. According to the results, the maximum achieved PEEK gear life was 200 minutes for the Natural PEEK polymer at the 0.5 Nm torque.

Geometry‐Driven Finite Element for Four‐Dimensional Printing Technical Publication. MSEC2017‐2621 Tsz Ho Kwok, Concordia University, Montreal, QC, Canada Four‐dimensional (4D) printing is a new category of printing that expands the fabrication process to include time as the fourth dimension, and its process planning and simulation have to take time into consideration as well. The common tool to estimating the behavior of a de‐ 7 formable object is the finite element method (FEM). Although FEM is powerful, there are various sources of deformation from hardware, environment, and process, just to name a few, which are too complex to model by FEM. This paper introduces Geometry‐Driven Finite El‐ ement (GDFE) as a solution to this problem. Based on the study on geometry changes, the deformation principles can be drawn to predict the relationship between the 4D‐printing process and the shape transformation. Similar to FEM, the design domain is subdivided into a set of GDFEs, and the principles are applied on each GDFE, which are then assembled to a larger system that describes the overall shape. The proposed method converts the complex sources of deformation to a geometric optimization problem, which is intuitive and effective. The usages and applications of the GDFE framework have also been presented in this paper, including freeform design, reserve design, and design validation.

Additive Manufacturing Thermo‐Mechanical Processing Influence on Tensile Mechanical Behavior Technical Publication. MSEC2017‐2624 Omar Fergani, NTNU‐ Norwegian University of Science and Technology, Trondheim, Norway, Steven Liang, Georgia Institute Of Technology, Atlanta, GA, United States, Torgeir Welo, NTNU‐ Norwegian University of Science and Technology, Trondheim, Norway, Norway, Mohamed Elmansori, Arts et Metier Paristech, Aix en Provence, France This study describes a new analysis framework for additive manufacturing. The basic concepts of processes mechanics and ther‐ mo‐mechanical processing are introduced in order to understand the material’s behavior and the mechanical properties under tension. A semi‐analytical approach based on the solution of a moving heat source and the thermal stresses is established. The study provides an analysis of the state of stresses induced by the laser and their influence on occurrence defects and potentially residual stresses. Finally, tensile and fracture morphology experiments on 316L are performed to investigate thermo‐mechanical processing generated by a set of preselected process parameters

Non‐Contact Ultrasonic Abrasive Machining of Wire‐Electrical Discharge Machined SUS304 Steel Technical Publication. MSEC2017‐2626 Kai Liang Tan, Swee Hock Yeo, Nanyang Technological University, Singapore, OTHERS, Singapore Non‐contact ultrasonic abrasive machining (NUAM) is a variant of ultrasonic machining (USM). In NUAM, material is removed predomi‐ nantly by cavitation erosion in the abrasive slurry. Due to a significantly lower material removal rate than the traditional USM, NUAM is investigated for its applicability on surface finishing in this study. Experiments were conducted on SUS304 steel samples machined by wire electrical discharged machining (WEDM). Due to the thermal spark phenomenon during WEDM, a thermal recast layer, of thickness approximately 15 µm, is often left over on the specimen’s surface after the process. The undesired thermal recast layer contributes to the high surface roughness values and poor surface integrity of speci‐ mens. Poor surface integrity could lead to deteriorated fatigue and tribological performances of a component, significantly reducing the component’s lifecycle. The objective of this paper is to develop a non‐traditional finishing process suitable for the efficient removal of re‐ cast layers, thereby improving the surface integrity of WEDM surfaces. In this experiment, a NUAM system was configured using a 40 kHz ultrasonic system for surface finishing purposes. Ultrasonic wave was generated and transmitted over a transducer; then amplified over a booster and horn assembly to result in vibration amplitude of 70 µm at the horn tip. The high‐power ultrasound was used to generate cavitation bubbles in the abrasive slurry, consisting of deionized water and aluminum oxide at various sizes and concentrations. NUAM was found to be effective in removing the unstable thermal recast layers by a combined cavitation erosion and micro‐abrasive im‐ pingement mechanism. Due to the removal of the unstable recast layer, the average surface roughness, Ra, of the specimens improved from approximately 2.5m to ~1.7m after 20 minutes of processing time. The addition of abrasive particles was observed to aid in more efficient removal of thermal recast layers than a pure cavitation condition. In pure cavitation condition, the non‐uniform removal of recast layer resulted in more surface undulations and higher surface roughness. An optimal abrasive size of 15 µm was found to result in the most significant roughness improvement; whereas the abrasive concentration was discovered to have little effect on the process outcome.

Flexible Job‐Shop Scheduling for Reduced Manufacturing Carbon Footprint Technical Publication. MSEC2017‐2630 QIONG LIU, Youquan Tian, Huazhong University of Science and Technology, Wuhan, China, John Sutherland, Purdue

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University, West Lafayette, IN, United States, Chao Wang, Beijing Jiaotong University, Beijing, China, Freddy O. Chekem, Huazhong University of Science and Technology, Wuhan, China In order to help manufacturing companies quantify and reduce product carbon footprints in a mixed‐model manufacturing system, a prod‐ uct carbon footprint oriented multi‐objective flexible job‐shop scheduling optimization model is proposed. The production portion of the product carbon footprint, based on the mapping relations between products and the carbon emissions within the manufacturing system is proposed to calculate the product carbon footprint in the mixed‐model manufacturing system. Non‐Dominated Sorting Genetic Algorithm‐II (NSGA‐II) is adopted to solve the proposed model. In order to help decision makers to choose the most suitable solution from the Pareto set as its execution solution, a method based on grades of product carbon footprints is proposed. Finally, the efficacy of the proposed model and algorithm are examined via a case study.

Electrospun Sodium‐Cobalt Oxide Ceramic Nanofiber and the Electromagnetic Responses Technical Publication. MSEC2017‐2638 Arturo Bautista, Juan Aguado, Cal Poly Pomona, Pomona, CA, United States, Yong Gan, California State Polytechnic Universi‐ ty, Pomona, Pomona, CA, United States In this work, a sodium‐cobalt oxide (NaxCo2O4) ceramic composite nanofiber was manufactured through electrospinning. The response of the fiber to external electromagnetic field was characterized to observe the heat generation in the fiber. In addition, we also measured the current passing through the fiber under the polarization of DC potential. It is found that the fiber has intensive heating behavior when it is exposed to the electromagnetic field. The temperature increases more than 5 degrees in Celsius scale only after 5 s exposure. The current potential curve of the fiber reveals its dielectric behavior. It is concluded that this ceramic fiber has the potential to be used for hyperther‐ mia treatment in biomedical engineering or for energy conversions.

A Personalized Attribute Determination Process in a Cloud‐Based Adaptable Product Configurator Technical Publication. MSEC2017‐2639 PAI ZHENG, The University of Auckland, Auckland, New Zealand, Shiqiang Yu, Xun Xu, University of Auckland, Auckland, New Zealand Product configurator, as an effective tool in mapping customer requirements with the company’s existing product attributes, enables indi‐ vidual customer’s satisfaction and the company’s competitiveness in a cost‐efficiency way. However, with the tendency towards mass cus‐ tomization and personalization, customers are no longer just select from the available options in a configure‐to‐order mode, but more ac‐ tively involved in the product development process to create their own individualized products in an engineer‐to‐order mode by co‐design or even design by themselves. Also, most existing product configurators are developed by a single company with its own product family in a centralized manner, which is not abundant for the ever increasing personalized requirements and companies sometimes cannot reach the specific niche market. Moreover, they generally apply the matching procedures to all the customers in the same sequential way, which is always tedious and time consuming, especially for the case of configuring a complicated product.

Aiming to solve these problems, this paper proposed a cloud‐based adaptable product configurator for personalized attribute determina‐ tion process. It has two assumptions: 1. product needs to be adaptable enough for configuration so that it can be easily changed, i.e.: each attribute of it is almost independent; 2. customers prefer to improve the design from an existing tangible or visualized product other than design from scratch, which is the fundamental of utilizing product configurator. Based on the two assumptions, the proposed conceptual framework of a cloud‐based adaptable product configurator is developed in the paper based on a two‐stage process, i.e. modular design of product functions and scalable design of product attributes. Moreover, a personalized attribute determination process is established by considering each customer’s individual preferences. It can effectively deal with incomplete or personalized information from customers by matching with the most appropriate existing design first. The incomplete information stands for the uncertainty or vagueness of customers’ choice, e.g.: customer might not sure what dimension of the shaft she needs. The personalized information stands for the requirements beyond the existing attribute selection, which needs to be considered for product design improvement. And then, the additional infor‐ mation is processed and recorded to map into new design knowledge. Also, the proposed method utilizes customer’s previous selection information in the matching process to shorten the procedure time and provide the product option with the highest probability. Thus, it facilitates the multi attribute decision making process in a personalized way.

An example of a local curtain retail company is described. The company, acts as the platform provider, provides a cloud‐based adaptable 9 product configurator for service providers to add their own modules, and for customers to configure and quote in an ETO‐based manner. The statistical analysis of the quoting times in past six months (09/2015‐03/2016) are counted by utilizing a WordPress plugin in this work, and several typical types of curtains with its attribute selection process is described. The result shows that it can effectively reduce custom‐ er’s input effort and it has many potential advantages in assisting customer‐centric product design for mass customization and personaliza‐ tion.

Design of Hardware TCP/IP Stack for Sensing Systems Intended for Monitoring of Mechanical Equipment Technical Publication. MSEC2017‐2641 Zhengying Li, Zhiqiang Xu, Quan Liu, Wuhan University of Technology, Wuhan, Hubei, China Fiber Bragg grating (FBG) sensors have been widely used in monitoring of the mechanic equipment. However, for measuring high‐speed dynamic signal of a large mechanical equipment, the demodulation rate of the interrogator should be very high, while the number of sen‐ sors could be tens or hundreds, thus, a large amount of sensing data could be generated. Nonetheless, a network throughput of the inter‐ rogator based on the software stack is relatively low and a large amount of data cannot be transmitted simultaneously, which becomes the bottleneck of the sensing system. In order to promote the network throughput, a hardware TCP/IP stack based on the field programmable gate array (FPGA) is proposed. In contrast to the existing hardware stacks, this stack is designed with a new module structure that is divided according to functions instead of protocol types. It can realize both UDP and TCP transmissions with less logic elements than similar de‐ signs. Unlike ASIC TCP/IP stack, the entire system can be realized on a single FPGA chip and upgraded without changing of the original hardware circuit. The proposed design has two key features. Firstly, the hardware stack can be connected directly to the data acquisition logic part without software operations thus the data throughput from the signal acquisition to the network transmission can maintain a relatively high speed. Therefore, the system can demodulate data from hundreds of sensors at high speed and transmit them in real time. Secondly, the module structure is clear and independent of specific FPGA platform. Consequently, it can be transplanted or upgraded easily in order to meet different practical demands. The proposed design embodies the characteristics and advantages of the system on a pro‐ grammable chip (SOPC). In order to validate the proposed design, all logic modules were simulated and the design was tested on the circuit board. Performance test results have shown that UDP and TCP throughputs of the proposed hardware stack are up to 80Mbps in the case of 100Mbps Ethernet controller chip, which is about eight times higher than throughput of software design. Finally the design was verified by monitoring of the oil pipeline platform. The obtained results have shown that proposed design can detect the vibration frequencies of the oil pipeline that are around 600Hz and it can sample 288 FBG sensors and transmit sensor data correctly. Thus the proposed design is suitable for a large sensing system intended for the dynamic monitoring of the mechanical equipment.

Feature Selection for Helicopter Swashplate Bearing Fault Diagnosis Technical Publication. MSEC2017‐2643 Yong Wang, Binghamton University, Binghamton, NY, United States, Lin Li, University of Illinois at Chicago, Chicago, IL, United States This paper provides a case study of diagnosing helicopter swashplate ball bearing faults using vibration signals. We develop and apply fea‐ ture extraction and selection techniques in the time, frequency, and joint time‐frequency domains to differentiate six types of swashplate bearing conditions: low‐time, to‐be‐overhauled, corroded, cage‐popping, spalled, and case‐overlapping. With proper selection of the fea‐ tures, it is shown that even the simple k‐nearest neighbor (k‐NN) algorithm is able to correctly identify these six types of conditions on the tested data. The developed method is useful for helicopter swashplate condition monitoring and maintenance scheduling. It is also helpful for testing the manufactured swashplate ball bearings for quality control purposes.

Ball Burnishing Under High Velocities Using a New Rolling Tool Concept Technical Publication. MSEC2017‐2644 Lars Hiegemann, A. Erman Tekkaya, Institute of Forming Technology and Lightweight Construction / TU Dortmund University, Dortmund, Germany Ball burnishing is a process used to smooth rough surfaces. For not rotational symmetric parts, the process is typically conducted on milling machines. Since it is an incremental process, it is relatively time consuming. Therefore, a rolling tool is developed, which superposes the rotation of the milling spindle with the feed of the machine to increase the rolling velocity. In order to achieve constant rolling forces, hy‐ drostatic ball burnishing tools are used. Within this work, the influence of this tool concept on the processing time as well as on the leveling 10 of surface irregularities is investigated. This is achieved by a comparison with a conventional ball burnishing process. Finally, the rotating tool is used to investigate the influence of high rolling speeds on the leveling of the surface. All experiments were carried out with thermal‐ ly coated specimens. A model for calculating the strain rates at the roughness peaks during ball burnishing is derived. For the experiments carried out with the rotating rolling tool, rolling velocities of 50,000 mm/min were realized. Calculations with the developed model showed that this results in local strain rates at the roughness peaks of up to 1,384 s‐1. In addition, the flow stresses at the roughness peaks were calculated. Compared with quasi static experiments, the flow stress drops to less than the half under high velocities. This results in a better leveling of the surface for rolling velocities between 10,000 mm/min and 25,000 mm/min. A further rise of the rolling speed increases the flow stress again and thereby reduces the possible leveling.

Investigations on the Application of Minimum Quantity Solid Lubrication in Technical Publication. MSEC2017‐2654 Mayurkumar Makhesana, Kaushik Patel, Nirma University, Ahmedabad, Gujarat, India Machining is the manufacturing process, capable of producing required shape and size by material removal. In recent times industries are striving to enhance the performance of machining processes. One of the problems associated with machining is the amount of heat gener‐ ation as a result of friction between tool and workpiece. Heat generated may affect the quality of machined surface and tool wear. In order to control it, cutting fluid is applied in large quantity. The problem arises with the use of cutting fluid is its effect on workers’ health and environment. The present investigation is an attempt to explore the use the solid lubricants in machining as an alternative to cutting fluid. The work involves development of minimum quantity solid lubrication set up. Turning experiments has been performed by applying solid lubricants mixed with cutting fluid in minimum quantity. The performance of minimum quantity solid lubrication has been assessed in form of obtained surface finish, power consumption and tool wear during turning. Experimental findings discovered the superiority of minimum quantity solid lubrication over conventional cutting fluid and can be considered as cost effective and sustainable lubrication method.

Software Defined Manufacturing Extends Cloud‐Based Control Technical Publication. MSEC2017‐2656 Armin Lechler, University Stuttgart, Stuttgart, Germany, Alexander Verl, Institute for Control Engineering of Machine Tools and Manufacturing Units, ISW, Stuttgart, Germany Nowadays, the key goal in manufacturing is being very efficient within changing markets and under turbulent conditions. Therefore, pro‐ duction plants with their machines logistics and all the other involved components have to be adaptable to changing conditions. For this reason, reconfigurable manufacturing systems are needed, which allow a fast adaption to new requirements of the product to be manufactured. Today, reconfiguration in manufacturing is mostly limited due to missing reconfigurability of the control software in combi‐ nation with the underlying hardware. The coupling is that strong that in manufacturing control software is always bound to special hard‐ ware. Until now, flexibility is only possible by changing application or part programs that are interpreted by a fixed control kernel. The adaption of any core functionality is impossible, and any other changes require high manual effort for redesigning software systems and parametrizing their functionalities. For better adaptability in manufacturing this coupling has to be dissolved. Other disciplines and industries have similar requirements like the information and communication technology (ICT). In the area of ICT, there are more and more concepts of Software Defined Anything (SDX) like Software Defined Networking (SDN) or Software Defined Radio (SDR). Flexible, adaptive and really reconfigurable manufacturing should be improved by a new concept of Software Defined Manufacturing (SDM). SDM allows freely defined functionalities within the physical limitations of the mechanical and electrical components of a machine. But current manufacturing equipment with its control architecture does not offer the technical basis for such a concept. Existing concepts of cloud‐based control architectures show indeed a virtualization of the control algorithms. Due to the fact that the soft‐ ware is running remotely, the software is decoupled from its hardware. However, the local control algorithms with hard real‐time require‐ ments still have a very strong coupling with the hardware. The local control software could not be defined freely according to the require‐ ments of the product to be manufactured. In this paper, a new control architecture for manufacturing that combines cloud‐based control as a service (CaaS) and Software Defined Manufacturing is presented. As a result, an architecture of an operating system for manufacturing equipment is shown, which is freely programmable. This paper deals with Software Defined Manufacturing for local control software, communication and cloud‐based control systems. SDM allows defining the behavior of the entire manufacturing process based on design description of a product to be manufactured. In addition, methods are described, which allow the automatic configuration and optimiza‐ tion of such an architecture by using simulation technics and collected process data.

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Monitoring of Molten Pool Thermal History and its Significance in Laser Cladding Process Technical Publication. MSEC2017‐2657 GOPINATH MUVVALA, Debapriya Patra Karmakar, Indian Institute of Technology Kharagpur, Kharagpur, West Bengal, India, Ashish Kumar Nath, Indian Institute of Technology, Kharagpur, Kharagpur, West Bengal, India The current study focuses on the process monitoring of thermal history and its significance in laser cladding technology. Thermal history of the molten pool during laser cladding was monitored using an IR‐pyrometer and the molten pool life time, solidification shelf duration and cooling rates were calculated. Effect of these on three different cases was studied in brief: (a) Elemental segregation in based super alloy, (b) Wettability between metal matrix and WC particles and (c) Decomposition of TiC particles in metal matrix. It was found that with slow cooling rate, formation of Laves phases in Inconel 718 became dominant which is detrimental to the mechanical properties. Also, slow cooling resulted in the decomposition of TiC particles resulting in poor wear properties of the coating. In contrast to the above two cases where slow cooling was found to be detrimental for mechanical properties of the coating, it increased wettability as well as bonding through diffusion between the WC particles and the metal matrix. Also the effect of presence of TiC and WC in metal matrix on molten pool thermal history was studied. The microstructures, elemental segregations and fractured surfaces were characterized using SEM and EDS analyses.

Development of Hybrid Composites (Al‐SiC‐C) Through Stir Casting: Machinability Studies Technical Publication. MSEC2017‐2659 Satyanarayana Kosaraju, Gokaraju Rangaraju Institute of Engineering and Technology, HYDERABAD, India, Venu Gopal Anne, National Institute of Technology Warangal, waranagal, — Please Select —, India, swapnil gosavi, Progressive Educa‐ tion Society’s Modern College of Engineering, Maharashtra, India Composite materials are important engineering materials due to their outstanding mechanical properties. Composite materials offer supe‐ rior properties to conventional alloys for various applications as they have high stiffness, strength and wear resistance. The high cost and difficulty of processing these composites restricted their application and led to the development of reinforced composites. In the last two decades, wear performances of Particulate Metal Matrix Composites (PMMCs) reinforced with various reinforcements ranging from very soft materials like graphite, talc etc., to high hardened ceramic particulates like SiCp, Al2O3 etc., have been reported to be superior to their respective unreinforced alloys. Therefore, present work focused on the study of machinability of Al based binary composites reinforced with 8.5% SiC and Al based Hybrid composite reinforced with 8.5% SiC, 2% and 4% Graphite powder (Solid lubricant) have been studied by considering the effect of process parameters such as speed, feed, depth of cut and composition of material. Binary and hybrid composite materials have been casted by stir casting methodology. Hardness of all the workpiece casted is tested to evaluate and compare the me‐ chanical strength of binary and hybrid composites. Experiments have been conducted using Design of Experiments approach. The cutting force and surface roughness in turning of both the binary and hybrid materials have been measured using cutting force dyna‐ mometer (4 component kistler dynamometer) whereas the roughness has been measured using surface roughness tester (Marsurf M400) simultaneously in order to find the effect of graphite powder as hybrid composite during machining. The results reveal that cutting forces are lower for hybrid composite than that of binary composite because of increase in percentage by volume of graphite. Depth of cut is the most influencing factor on cutting forces and in case of surface roughness; feed is the most influencing factor. The multi objective optimiza‐ tion has been carried out using Grey relational based Taguchi method. It is also shown that the performance characteristics of the turning operations, such as the cutting force and the surface roughness are greatly enhanced by using Grey Relational Analysis

Development of Post‐Processing System for Three Types of Five‐Axis Machine Tools Based on Solid Model Technical Publication. MSEC2017‐2665 Jiangang li, HIT SZ, Shenzhen, China, Yangpeng Song, HITSZ, Shenzhen, China, Ye Liu, HIT SZ, Shenzhen, China Although machine control data can be obtained by means of converting cutter location (CL) data comprised of the tool tip coordinate and the tool ax‐ is orientation vector in the workpiece coordinate frame with postprocessor, its uncertain whether they can be used for 5‐axis machining. Owing to the fact that most postprocessors focus on the method to derive solution‐ s for the equations of NC data by the form‐shaping function matrix and the inverse kinematics model with‐ out taking the manufacturing scene into consideration, this study has presented a new post‐processing system to generate and optimize NC data more effectively by correcting and selecting optimum solution intelligently for machining based on the solid model of machine tool in simulation environment. In general, the post‐ processing system consists of user interface layer, data access layer and data processing layer to give expression to the characteristics of universality, practi‐

12 cality and adaptability. User interface layer is mainly about loading the machine model and setting the relevant parameters. Data access layer includes model library of generalized five‐axis machine tool configurations, rules library of cutter location data and NC data. Data processing layer is the major research in the paper, which illustrates how to correct the inverse solutions set and select the optimization solution for actual machining. The visual interface for post‐processing system written by C++ was successfully applied in the experiment on a five‐axis machine tool with a C‐axis behind a B‐axis rotary table, which demonstrated the effectiveness of the proposed post‐processing methodology in the field of manufacturing.

Efficient Process Planning Strategies for Additive Manufacturing Technical Publication. MSEC2017‐2666 Uppili Srinivasan Venkatesan, Indian Institute of Technology, Bombay, Mumbai, Maharashtra, India, Sanjay S. Pande, Indian Institute of Technology Bombay, Mumbai, Maharashtra, India This work reports the development of robust and efficient algorithms for optimum process planning of Additive Manufacturing (AM) pro‐ cesses needing support structures during fabrication. In particular, it addresses issues like part hollowing, support structure generation and optimum part orientation. Input to the system is a CAD model in STL format which is voxelized and hollowed using the 2D Hollowing strat‐ egy. A novel approach to design external as well as internal support structures for the hollowed model is developed considering the wall thickness and material properties. Optimum orientation of the hollowed part model is computed using Genetic Algorithm (GA). The Fitness Function for optimization is the weighted average of process performance parameters like build time, part quality and material utilization. A new performance measure has been proposed to choose the weightages for performance parameters to obtain overall optimum performance. The paper presents, in detail, the design and development of algorithms with results for typical case studies. The proposed methodology will significantly contribute to improving part quality, productivity and material utilization for AM processes.

Predicting Multi‐Scale Dimensional Accuracy of Engine Cylinder by Honing Technical Publication. MSEC2017‐2673 Zaoyang Zhou, Xueping Zhang, Shanghai Jiao Tong University, Shanghai, China, Zhenqiang Yao, Shanghai Jiao Tong Univer‐ sity, China, Select State/Province, China, Lifeng Xi, Shanghai Jiao Tong University, Shanghai, Select State/Province, China The deviations of cylinder bore dimensional accuracy have tremendous influence on engine performances including friction power loss, vibration, leak tightness between piston ring and cylinder wall, and abrasive resistance. Many researches were devoted to capturing cylin‐ der dimensional accuracies by honing using analytical, experimental and simulation methods. These researches investigated the topogra‐ phy and roughness of the honed surface, the relationship between the process parameters and the dimensional accuracies. However, most researches focused on macro‐scale dimensional accuracy and micro‐scale surface texture respectively. To overcome the limitation, a mul‐ ti‐scale model for cylinder bore honing is proposed to predict the dimensional accuracy and surface texture of cylinder bore at macro‐scale and micro‐scale simultaneously. The model integrates the microscale factors of the honing stone abrasives distribution characteristics, abrasive wear process, previous cylinder surface topography, and macro‐scale factors of cylinder geometry and honing head motion tra‐ jectory. A Force matching method is adopted to determine the feed depth of cylinder honing process. Thus the model can predict the roundness, cylindricity, roughness and Abbott‐Firestone curve of the honed cylinder bore at multi‐scale levels. Simulation results show that material removal distribution is closely related to cylinder bore initial shape deviations. The deviations with long wavelengths cannot be eliminated by the sequential honing.

Controlling Topography of Machined Surface for Adhesive‐Sealing Technical Publication. MSEC2017‐2674 Shun Liu, Sun Jin, Xueping Zhang, Shanghai Jiao Tong University, Shanghai, China, Lixin Wang, benfu Mei, Bin Hu, Pan Asia Technical Automotive Center Co.,Ltd, Shanghai, China Adhesive is widely used in engine, airplane and other industry parts to bond and seal machined joint surfaces. Adhesive performance is important and mechanically complex, closely related to the adhesive material property, bonding process and topography of machined sur‐ faces. The effects of material properties, bonding process, and the geometry and dimensions of adhesive layer on adhesive performance have been well studied in adhesive research field. However, the effect of the topography of machined surface on sealing performance was 13 somehow neglected in literature. On the other hand, the texture of machined surface, especially at micro‐level of surface roughness, usu‐ ally used as the objective to determine process parameters in machining and also regarded as indicators of machining productivity, has been systemically and sufficiently studied. However sealing performance has not been widely investigated to relate to topography of ma‐ chined surface generated from machining operation. Actually, the surface topography plays an important role in the both fields as an index for machining process and also a factor for functional performance. Desired surface should be determined firstly and then machining pa‐ rameters are designed properly to achieve the desired surface, in order to improve the functional behavior such as the applied adhesive sealing performance of machined components. This research has objectives: 1) the desired surface topography is determined based on the relationship between machining operation and surface texture; 2) The effects of machined surface topography on the reliability of adhesive joint surfaces are analytically investigated. Thus, the research provides a systematic thinking for the selection of surface topography and parameters of face milling operation to improve the performance of adhesive bonding and sealing for its industry implementation.

Study on Oil Adsorption and Polishing Characteristics by Novel Nanofiber Pad for Ultra‐Precision Abrasive Machining Technical Publication. MSEC2017‐2678 Wei Wu, Doshisha University, Kyoto, Japan, Lei MA, Doshisha University, Kyotanabe‐shi, Kyoto‐fu, Japan, Toshiki Hirogaki, Eiichi Aoyama, Doshisha Univ, Kyoto, Japan, Morihiko Ikegaya, Takatsugu Echizenya, Hiroyoshi Sota, M‐TechX Inc., Kana‐ gawa, Japan The nano fiber which can be used in many fields such applications as medical care, protection of the environment, apparel and agriculture. We also suspect this will become the fastest growing field over the next few years. This time, we focused on its one of the applications as abrasive machining used its oil adsorbing performance and polishing performance which realized polymeric nano fiber mass production by melt blowing method. In the present report, we proposed its oil adsorption physical model and compared with experiment results to de‐ velop a nano fiber polishing pad. We also used this model calculated the mass ratio of oil to abrasive grain and the abrasive size in abrasive machining when the fiber mass and bulk density were constant. On the other hand, for realizing the free‐form nano surface, such as mold‐ ing die surface, we conducted base experiment with different diameter fiber and different size grain and investigated its base polishing characteristics with commercial felt buff. As a result, it was demonstrated that the polished surface roughness of workpiece became small‐ er and polishing processes on the workpiece were more stable completely using this low cost new abrasive material on abrasive machining. We also considered that the nano fiber abrasive pad can sufficiently be used in abrasive machining with oil slurry as next generation abra‐ sive material.

Data‐Driven Prognostics Using Random Forests: Prediction of Tool Wear Technical Publication. MSEC2017‐2679 Dazhong Wu, Connor Jennings, Pennsylvania State University, University Park, PA, United States, Janis Terpenny, Penn State, University Park, PA, United States, Robert Gao, Case Western Reserve University, Cleveland, OH, United States, Soundar Kumara, Pennsylvania State University, State College, PA, United States Manufacturers have faced an increasing need for the development of predictive models that help predict mechanical failures and remain‐ ing useful life of a manufacturing system or its system components. Model‐based or physics‐based prognostics develops mathematical models based on physical laws or probability distributions, while an in‐depth physical understanding of system behaviors is required. In practice, however, some of the distributional assumptions do not hold true. To overcome the limitations of model‐based prognostics, da‐ ta‐driven methods have been increasingly applied to machinery prognostics and maintenance management, transforming legacy manufac‐ turing systems into smart manufacturing systems with artificial intelligence. While earlier work demonstrated the effectiveness of da‐ ta‐driven approaches, most of these methods applied to prognostics and health management (PHM) in manufacturing are based on artifi‐ cial neural networks (ANNs) and support vector regression (SVR). With the rapid advancement in artificial intelligence, various machine learning algorithms have been developed and widely applied in many engineering fields. The objective of this research is to explore the ability of random forests (RFs) to predict tool wear in milling operations. The performance of ANNs, SVR, and RFs are compared using an experimental dataset. The experimental results have shown that RFs can generate more accurate predictions than ANNs and SVR in this experiment.

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Plasmonic Nanofocusing in Deep and Extreme Sub‐Wavelength Scale for Scalable Nanolithography Technical Publication. MSEC2017‐2680 Zhidong Du, Chen Chen, Liang Pan, , West Lafayette, IN, United States Maskless nanolithography is an agile and cost effective approach if their throughputs can be scaled for mass production purposes. Using plasmonic nanolithography approach, direct pattern writing was successfully demonstrated with 22 nm half‐pitch at high speed. Plasmonic nanolithography uses an array of plasmonic lenses to directly pattern features on a rotating substrate. Taking the advantage of air bearing surface techniques, the system can expose the wafer pixel by pixel with a speed of ~10 m/s, much faster than any conventional scanning based lithography system. It is a low‐cost, high‐throughput maskless approach for the next generation lithography and also for the emerg‐ ing nanotechnology applications, such as nanoscale metrology and imaging. A critical part of the PNL is to use plasmonic lens to deliver highly concentrated optical power at nanoscale. We have demonstrated such nanoscale process and achieved 22 nm resolution. Here, we report our recent efforts of designing new plasmonic nanofocusing structures that is capable of achieving optical confinement below 20 nm which can potentially support direct patterning at sub‐10nm resolution

Design and Fabrication of Electrostatic Microcolumn With Varying Apertures in Massively Parallel Electron Beam Lithography Technical Publication. MSEC2017‐2681 Zhidong Du, Ye Wen, Liang Pan, Purdue University, West Lafayette, IN, United States Massively parallel electron beam lithography may be an alternative manufacturing method in semiconductor industry if the issues of the multi electron beam source are addressed. The microcolumns are suitable for the massively parallel electron beam lithography because of their compactness and the ability to achieve high spatial resolution. A new design with varying apertures for our recent nanoscale photoe‐ mission source is presented here. Given the easiness of the fabrication of the microcolumn, we optimized the parameters of the design and found that the resolution can be improved by changing the ratio between the diameters of the focus and extractor electrodes.

Tool Path Planning for Directional Freezing Based 3D Nano Printing Process Technical Publication. MSEC2017‐2684 Guanglei Zhao, Suny/Buffalo, Amherst, NY, United States, Chi Zhou, University At Buffalo, Amherst, NY, United States, Dong Lin, Kansas State University, Manhattan, KS, United States As an emerging and effective nano‐manufacturing technology, the directional freezing based 3D printing can form 3‐Dimensional (3D) nano‐structures with complex shapes and superior functionalities, and thus has received ever increasing publicity in the past years. One of the key challenges in this process is the proper heat management, since the heat induced melting and solidification process significantly affects the functional integrity and structural integrity of the 3D printed nano‐structures. To address this challenge, this paper proposes a novel path planning modeling and optimization framework to intelligently control the internal and external heat transfer process and ulti‐ mately optimize both the macro‐ and micro‐structure of the printed part. Specifically, a heuristic tool path planning model was formulated and optimized based on thermal analysis process. The simulation results demonstrate that the tool path planning highly affects the spatial and temporal temperature distribution of the being printed part and the optimized tool path planning can effectively improve the uni‐ formity of the temperature distribution which will consequently enhance the performance of the fabricated nano‐structures.

“Phase Transformations During High‐Speed, High‐Temperature Scratching of ” Technical Publication. MSEC2017‐2687 Chirag Alreja, Indian Institute of Technology Madras, Chennai, India, Sathyan Subbiah, Indian Institution of Technology Madras, Chennai, India Higher temperature assisted processing of silicon, such as in heat‐assisted turning, is often being considered to improve surface integrity. At higher temperatures and under mechanical loading and unloading, caused by the moving tool, silicon deforms plastically often in association with occurrence of phase transformations. This paper investigates such phase transformations in rotational scratching of single crystal (100) p‐type silicon with a conical diamond tool under various furnace‐controlled temperatures ranging from room tempera‐ ture to 500°C and at scratching speeds comparable to that used in the diamond turning process (1 m/s). Phase transformation study, using Raman , at various crystal orientations, show differences in phases formed at various temperatures when compared to that

15 reported in indentation. The tendency to form phases is compared between scratched and diamond turned surfaces at room temperature, and also with that reported at low scratching speeds in the literature. Analysis of depths of the scratched groove indicates that that at temperatures beyond a certain threshold, plastic deformation and significant elastic recovery may be causing shallow grooves. This study is expected to help tune heat‐assisted diamond turning conditions to improve surface formation.

Characterization Modelling and Analysis of Light Reflectance During In‐Process Surface Measurements Using White Light Based 3D Optical Gauge Technical Publication. MSEC2017‐2689 Ankit Barde, Indian Institute of Technology , Kharagpur, Kharagpur, West Bengal, India, Pasquale Franciosa, WMG, University of Warwick, Coventry, United Kingdom, Darek Ceglarek, WMG, University of Warwick, Coventry, Coventry, United Kingdom, Manoj Kumar Tiwari, Indian Institute of Technology,Kharagpur, Kharagpur, India The quality of light reflectance model mainly depends upon the correctness of cloud of points generated by the high‐resolution charge coupled‐device (CCD) camera. We have performed an experiment to capture the dimension of an object using Optigo 200 robot which pro‐ vides an innovative way for solving dimensional control related challenges. The integrated system collects highly accurate and dense cloud of points for measuring an object at different design of experiment (DOE) levels. It also performs immediate analysis of collected data and calculates the deviations from the given specifications. Thus we tried to visualize the object using its key parameters. In this paper, we de‐ scribe the functional relationship of real‐world surfaces with the dependence of light exposure and camera direction. Seven step wedge (as a measurement object) is used in our case study to carry out the stereovision based experiment. Finally, a comparative analysis shows model accuracy over conventional measurement techniques.

Influence of Dislocation Density and Solute Atoms Concentration on the Electroplastic Effect of Al‐Cu Alloy Technical Publication. MSEC2017‐2690 Weichao Wu, Beijing Institute of Technology, Beijing, China, Chun Xu, Shanghai Institute of Technology, Shanghai, China, Chaorun Si, Beijing Institute of Technology, Beijing, China, Tian Xue, Northwest University, Xian, China A mechanism of the electroplastic effect based on interaction of dislocation and solute atoms is proposed and investigated. It is found that the dislocation magnification duo to plastic deformation will enhance the electroplastic effect, and the current density threshold of Al‐Cu alloy during electroplastic deformation is studied. Moreover, the solute atoms concentration has a great effect on the electroplastic effect. The influence of electrical current pulses to Portevin Le Chatelier (PLC) effect of Al‐Cu alloy is also reported

Assessment of Optical Performance of Aspheric Lens Manufactured Using Single Point Diamond Turning Technical Publication. MSEC2017‐2691 Shivam Yadav, Dr. Babasaheb Ambedkar Technological University, Thane, Maharashtra, India, Raju S. Pawade, Dr. Ba‐ basaheb Ambedkar Technological University, Mangaon, India, India, Haseen Shaikh, Sardar Patel Institute of Technology, mumbai, India, India Manufacturing of aspheric profile of lens at nanometric level is difficult but the measurement and evaluation of metrology parameters is still a bigger challenge. For successful results of the lens systems, precise and defect free lenses are required. The manufacturing conditions have direct effect on the metrological parameters. For appropriate evaluation of metrology parameters, proper interpretation of aspheric surface parameters must be known. . In this study, the mechanical parameters, such as radius of curvature, slope error, tilt, centre thickness, and sag value of lens, were measured by using contact type form talysurf, non‐contact type fizeau interferometers, and other instruments. The experimental results reveal that an increase in the spherical aberration is caused by in‐ creasing the lens thickness beyond 4.995mm or by increasing the radius of curvature beyond ‐13.8396mm or by increasing the aspheric higher order coefficients. Also its dependencies on the diameter of least confusion is studied.

On‐Line Detection of Friction Stir Welded Joints by High Temperature Phased Array Ultrasonic Inspection and Control of Weld Process Parameters Technical Publication. MSEC2017‐2692 16

Daniel Huggett, LSU, Ponchatoula, LA, United States, Muhammad Wahab, Louisiana State University, Baton Rouge, LA, United States, Ayman Okeil, LSU‐BR, Baton Rouge, LA, United States, T. W. Liao, MIE, LSU, 3261 PFT Hall, Baton Rouge, LA, United States Non‐Destructive Evaluation (NDE) of welded structures is essential in industry and manufacturing sectors. However, NDE techniques are limited when applied at high temperatures, which prevents usefulness for on‐line real time inspection of welded joints. In this work, a high temperature (HT) inspection system was created utilizing Phased Array Ultrasonic Testing (PAUT), and tested on Friction Stir (FS) welded aluminum alloy joints. The system created in this work proves HT‐PAUT is capable of determining defects during the welding process. Sup‐ plementing this work, a custom defect detection software was created to analyze S‐Scan data to interpret when and where a defect occurs to provide defect indicator signals. These defect signals can be utilized for controlling the FSW process parameters to automatically correct if a defect is observed. The technology developed can be utilized as a platform for future automated welding processes and control for creating the next generation weld‐NDE systems

Studying the Mechanisms of High Rates of Tool Wear in the Machining of Aramid Honeycomb Composites Technical Publication. MSEC2017‐2694 David Gill, Derek Yip‐Hoi, Western Washington University, Bellingham, WA, United States, Max Meaker, Western Washing‐ ton University, Renton, WA, United States, Taryn Boni, Alex Brennen, Erica Eggeman, Western Washington University, Bel‐ lingham, WA, United States, Aidan Anderson, Western Washington University, Anacortes, WA, United States Aramid honeycomb composite structures have revolutionized the aerospace industry by providing high strength, light weight, energy ab‐ sorbing structures for many applications. To finder wider utilization, the costs of producing honeycomb structures must be reduced and one important area of focus is to reduce tool wear and increase tool life. This study began with the hypothesis that the high rate of tool wear was due to excessive tool rubbing because of the lower stiffness of this material when compared to solid materials. Tool wear measurements were taken over the life of a tool and high speed video was utilized to study the machining process. The results of the tool wear test showed a standard tool wear timeline. The video analyses showed the tool experiencing rubbing far beyond expectations due to the collapse of honeycomb cells induced by twisting far in advance of the arrival of the tool.

Dynamic Sampling Design for Characterizing Spatiotemporal Processes in Manufacturing Technical Publication. MSEC2017‐2695 Chenhui Shao, University of Illinois At Urbana‐Champaign, Urbana, IL, United States, Jionghua (Judy) Jin, S. Jack Hu, Univer‐ sity of Michigan, Ann Arbor, MI, United States Fine‐scale characterization and monitoring of spatiotemporal processes are crucial for high‐performance quality control of manufacturing processes, such as ultrasonic metal welding and high‐precision machining. However, it is generally expensive to acquire high‐resolution spatiotemporal data in manufacturing due to the high cost of the 3D measurement system or the time‐consuming measurement process. In this paper, we develop a novel dynamic sampling design algorithm to cost‐effectively characterize spatiotemporal processes in manufac‐ turing. A spatiotemporal state‐space model and Kalman filter are used to predictively determine the measurement locations using a crite‐ rion considering both the prediction performance and the measurement cost. The determination of measurement locations is formulated as a binary integer programming problem, and genetic algorithm is applied for searching the optimal design. In addition, a new test statistic is proposed to monitor and update the surface progression rate. Both simulated and real‐world spatiotemporal data are used to demon‐ strate the effectiveness of the proposed method.

The Pressure Straightening Technology of Linear Guide Rails Using Dual Indenter‐Dual Clamp System Technical Publication. MSEC2017‐2699 Zhang Yongquan, Lu Hong, Wei Fan, Wuhan University of Technology, Wuhan, China, Wang Shaojun, Southeast Missouri State University, Cape Girardeau, MO, United States, Wei Qinyu, Ling He, Wuhan University of Technology, Wuhan, China To improve the compressive capacity and straightening efficiency of straightening process, the stroke‐deflection model (SDM) using dual indenter and dual clamp system (DIDCS) for linear guide rails is developed in this paper. The DIDCS is actually simplified as a symmetrically supported beam with two symmetrical concentrated forces on the top surface of workpiece, so the straightening process is regarded as pure bending process. To explore the deflection variation during the whole process with DIDCS, the curvature‐deflection model (CDM) con‐ sidering the span control of dual indenter and dual clamp is firstly analyzed based on elastic‐plastic deformation theory and small defor‐ mation principle. The geometrical features and material properties of linear guide rails, which are the main factors influencing bending 17 characteristics, are then mathematically modeled for the further analysis of stress and strain distributions in straightening process. Besides, to obtain the actual bending moment model (BMM) of different model parameters, the distribution regulations of elastic and plastic re‐ gions are analyzed followed by pure bending assumptions. The bending rebound model (BRM) is established with bending moment, geo‐ metrical features and material properties, and the SDM is finally calculated by initial deflection, rebound deflection and span parameters of the DIDCS. On basis of the DIDCS, the straightening process is simulated with the established finite element analysis model (FEM) to demonstrate the longitudinal stress distribution and the reflection of different straightening stages. The proposed SDM is also experimen‐ tally validated on the ROSE‐JZ50 straightening machine with different materials.

Analysis of Friction Stir Riveting Processes: A Review Technical Publication. MSEC2017‐2700 Haris Khan, Jingjing Li, The Pennsylvania State University, University Park, PA, United States, Chenhui Shao, University of Illi‐ nois At Urbana‐Champaign, Urbana, IL, United States This study presents a detailed analysis of friction stir riveting (FSR) processes that are used for joining similar as well as dissimilar materials. It covers the operating principle of FSR methods along with the insight into various process parameters responsible for successful joints formation. The paper further evaluates the research in friction stir‐based riveting processes which unearth the improved metallurgical and mechanical properties such as microstructure modification, local mechanical properties and improved strength, corrosion and fatigue re‐ sistance. The results of the study show that use of FSR process yields refined microstructures and improved mechanical properties in mate‐ rials, which will entail a substantial increase in the use of friction stir‐based riveting processes.

An Effective Spiral Trajectory Generation Approach for the Turning of Piston Skirt With Middle‐Bulged Varying Ellipse Technical Publication. MSEC2017‐2702 Lu Hong, Su Xiangang, Wuhan University of Technology, Wuhan, China, Zhang Xinbao, Huazhong University of Science and Technology, Wuhan, China, Zhang Yongquan, Wei Fan, Wuhan University of Technology, Wuhan, China, Wang Shaojun, Southeast Missouri State University, Cape Girardeau, MO, United States Given the chord length of equal angle isn’t equal on elliptical section of piston skirt with middle‐bulged varying ellipse (PSMVE), a larger theoretical processing error will inevitably be introduced with the interpolation algorithm of equal angle for PSMVE. To improve the manu‐ facturing precision of PSMVE, a novel interpolation algorithm of equal‐length‐chord and spiral‐line (IAES) and a method of tool radius com‐ pensation are presented based on symbolic computation. Firstly, a three‐dimensional model of PSMVE is generated through the symbolic computation method; meanwhile, the coordinate values of arbitrary cutter‐contact point can be expressed accurately. Secondly, the turn‐ ing spiral trajectory is generated via updated cutter‐contact point which can be searched from the obtained cutter‐contact point with equal length chord. Besides, this paper proposes a method of tool radius compensation and obtains the cutter location points through appropri‐ ate transformation of coordinates. Last, some simulation, which mainly includes the establishment of 3D model, the generation of spiral trajectory with equal‐length‐chord, the transformation between cutter‐contact point and cutter‐location points, is carried out. In addition, this paper takes CNC turning center (System: SINUMERIK 802C) as an example to complete the processing of PSMVE. Experiment results verify that the machining method is appropriate for PSMVE.

Cross‐Layer Optimization Model Towards Service‐Oriented Robotic Manufacturing Systems Technical Publication. MSEC2017‐2703 Jiaqiang Zhang, Quan Liu, Wenjun Xu, Zude Zhou, Wuhan University of Technology, Wuhan, China, Duc Truong Pham, University of Birmingham, Birmingham, United Kingdom Service‐oriented robotic manufacturing system is an integrated system, in which the industrial robots (IRs) operate within a ser‐ vice‐oriented manufacturing model, and can be virtualized and servicelized as services, so as to provide on‐demand, agile, configurable and sustainable manufacturing capability services to users in workshop environment. Manufacturing capability of such systems can be divided into three layers, including manufacturing cell layer, production process layer and workshop layer. However, most of existing works carried out the optimization on each layer individually. Manufacturing cells are the component parts of a production process, and there are close relationships between them and can effect the operation and performance for each other, therefore it is essential to jointly consider the manufacturing capability service optimization on both layers. In this context, a cross‐layer optimization model is proposed to conquer the existing limitation and provide a comprehensive performance assurance to service‐oriented robotic manufacturing systems. The proposed 18 model has different decision‐making mechanisms on each layer and the communications and interaction between the two layers can fur‐ ther coordinate the optimizations. A case study based on robotic assembly is implemented to demonstrate the availability and effective‐ ness of the proposed model.

Dynamic Manufacturing Capability Assessment of Industrial Robots Based on Feedback Information in Cloud Manufactur‐ ing Technical Publication. MSEC2017‐2704 Zeyu Zhang, Wenjun Xu, Quan Liu, Zude Zhou, Wuhan University of Technology, Wuhan, China, Duc Truong Pham, University of Birmingham, Birmingham, United Kingdom With the development of information and computer network technology, cloud manufacturing has been developing rapidly, industrial ro‐ bots (IRs) as a vital symbol and an advanced technology of manufacturing industry, in scheduling service, the constantly changing infor‐ mation data will result in the corresponding vary of the manufacturing capability. Under a fixed constraint of some capability service re‐ quest, this will decrease the number of the optimal solutions and provide the inaccurate service to users. So it is important to make the manufacturing capability stable and obtain more optimal solutions to satisfy the constraint, thus the dynamic assessment of manufacturing capability based on information feedback is investigated in this paper. A set of indicators is established considering the IRs’ manufacturing capability and a new dynamic assessment model is proposed to achieve the actual data and the expected data information feedback, using the normal distribution model, which can correct the assessment weight. By the way, a case study is simulated in the MATLAB, which shows the reliability and reasonability of this method in evaluate the manufacturing capability in IR.

Hypergraph‐Based Modeling of Manufacturing Services in Cloud Manufacturing Technical Publication. MSEC2017‐2705 Meng Yu, Wenjun Xu, Jiwei Hu, Zude Zhou, Wuhan University of Technology, Wuhan, China, Duc Truong Pham, University of Birmingham, Birmingham, United Kingdom Cloud manufacturing (CMfg) aims to realize the full‐scale sharing, free circulation and transaction, and on‐demand use of various manufac‐ turing resources and capabilities in the form of manufacturing services. During the whole product life‐cycle, the number of manufacturing services is huge, and services are highly dynamic and changeful. Without the effective operation and technical support of manufacturing service management, the implementation and aim of CMfg could not be achieved. In this paper, a multi‐layer model of manufacturing ser‐ vice is proposed for a job shop in cloud manufacturing, in order to solve the description problem of different manufacturing services from different level view, e.g. machine level, process level and shop level. Consequently, a hypergraph‐based network model of manufacturing service is developed, so as to facilitate the management of different services during the whole production process in job shop. A case study and some applications of the proposed model for supporting the manufacturing services management to practical manufacturing system are studied, to demonstrate the feasibility and efficiency of such model.

Design for Additive Manufacturing in the Cloud Platform Technical Publication. MSEC2017‐2708 Yuanbin Wang, Robert Blache, Xun Xu, University of Auckland, Auckland, New Zealand Additive manufacturing (AM) has experienced a phenomenal expansion in recent years and new technologies and materials rapidly emerge in the market. Design for Additive Manufacturing (DfAM) becomes more and more important to take full advantage of the capabilities pro‐ vided by AM. However, most people still have limited knowledge to make informed decisions in the design stage. Therefore, an interactive DfAM system in the cloud platform is proposed to enable people sharing the knowledge in this field and guide the designers to utilize AM efficiently. There are two major modules in the system, decision support module and knowledge management module. A case study is presented to illustrate how this system can help the designers understand the capabilities of AM processes and make rational decisions.

Experimental Investigations for Wear Properties of Rapid Tooling With Nano Scale Fillers for Grinding Applications Technical Publication. MSEC2017‐2710 Kamaljit Singh Boparai, MRS Punjab Technical University Bathinda, Bathinda, Punjab, India, Rupinder Singh, Guru Nanak Dev Engineering College, Ludhiana, India 19

This work is focused on the experimental investigations for wear properties of rapid tooling with nano scale fillers for grinding applications. The rapid tooling has been prepared by using composite material feed stock filament (consisting of Nylon6 as a binder, reinforced with biocompatible nano scaled Al2O3 particles on fused deposition modeling (FDM) for the development of grinding wheel having customized wear resistant properties. A comparative study has been conducted under dry sliding conditions in order to understand the tribological characteristics of FDM prints of composite material and commercially used acrylonitrile butadiene styrene (ABS) material. This study also highlights the various wear mechanisms (such as adhesive, fatigue and abrasive) encountered with newly prepared composite material while grinding. The FDM printed parts of proposed composite material feedstock filament are more suitable for grinding applications espe‐ cially in clinical dentistry.

Energy Consumption of Feed‐Drive Systems That Depends on the Workpiece‐Setting Position in a Five‐Axis Machining Center Technical Publication. MSEC2017‐2711 Ryuta Sato, Yuta Inoue, Keiichi Shirase, Kobe University, Kobe, Japan, Akio Hayashi, Kanagawa University, Yokohama, OO, Japan Energy consumption of (NC) machine tools is one of the key issues in modern industrial field. This study focuses on re‐ ducing the energy consumed by a five‐axis machining center by changing only the workpiece‐setting position. Previous studies show that the movements along each axis in five‐axis machining centers depend on the workpiece‐ setting position, regardless of whether the same operation is performed. In addition, the energy consumptions required for the movements are different along each axis. From these considerations, an optimum workpiece‐setting position that can minimize the energy consumed during these motions is as‐ sumed to exist. To verify this assumption, in this study, the energy consumed by the feed drive systems of an actual five‐axis machining center is first measured and then estimated using the proposed model in this study. The model for estimating the energy consumption comprises the friction, motor, and amplifier losses along each axis. The total energy consumption can be estimated by adding the energy consumptions along each axis. The effect of the workpiece setting‐position on the energy consumption is investigated by employing the cone‐frustum cutting motion with simultaneous five‐axis motions. The energy consumption that depends on the workpiece‐setting position is first measured and then esti‐ mated. The results confirm that the proposed model can estimate the energy consumption accurately. Moreover, the energy consumption is confirmed to depend on the workpiece‐setting position; the minimum energy consumption is found to be 20% lower than the maximum one.

Chatter Detection in Milling Process Based on Time‐Frequency Analysis Technical Publication. MSEC2017‐2712 Meng‐Kun Liu, Quang M. Tran, Yi‐Wen Qui, Chunhui Chung, National Taiwan University of Science and Technology, Taipei, Taiwan Chatter identification is necessary in order to achieve stable machining conditions. However, the linear approximation in regenerative chatter vibration is problematic because of the rich nonlinear characteristics in machining. In this study, a novel method to detect chatter is proposed. Firstly, measured cutting force signals are decomposed into a set of intrinsic mode functions by using ensemble empirical mode decomposition. Hilbert transform is following to extract the instantaneous frequency. Fast Fourier transform is also utilized for each intrin‐ sic mode function to determine the intrinsic mode function that contains rich chatter. Finally, the standard deviation and energy ratio in frequency domain of intrinsic mode functions are found as simply dimensionless chatter indicators. The effectively proposed approach is validated by analyzing the machined surface topography and also compared to the stability lobe diagram.

Mechanical Properties and Microstructures of A356 Alloy Prepared by Casting Combined With Forging Technical Publication. MSEC2017‐2715 Liang Zhenglong, Qi Zhang, Xian Jiaotong University, Xian, Shanxi, China A novel process which combines casting with forging during one process was proposed to improve mechanical properties and refine micro‐ structure. The microstructure evolution of as‐cast samples and forged samples were analyzed by optical and scanning (SEM). The tensile properties and micro‐hardness were also measured. The results show that combination of casting and forg‐ ing can improve microstructure and decrease porosity of casting samples, consequently contributing to a better fatigue performance. The 20 ultimate tensile strength and elongation were increased after forging process, however, the yield strength and micro‐hardness decreased.

Multi‐Tenant Access Control Model for Cloud Manufacturing Technical Publication. MSEC2017‐2719 Qianwen Chen, Zude Zhou, Xiaomei Zhang, Xuemei Jiang, Wuhan University of Technology, Wuhan, Hubei, China Cloud manufacturing is a new service‐oriented networked manufacturing mode based on the concept of “Manufacture as a Service” and achieves the sharing of manufacturing resources and manufacturing capacity. Multi‐tenancy technology can improve utilization efficiency of manufacturing resources and ensure information security among tenants, enabling users to share the cloud manufacturing resources better. To execute this new mode, isolation access and on‐demand services are indispensable. However, the traditional access control model cannot satisfy the demands of multi‐tenant environment on cloud manufacturing platform. To solve the demands in such an envi‐ ronment, a model named Multi‐Tenant Access Control Model for Cloud Manufacturing (CM‐MTAC) is proposed. Based on cloud manufac‐ turing architecture, we build a hierarchical cloud manufacturing access control architecture combining multi‐tenancy. Considering the de‐ mands under this condition, the elements of cloud manufacturing access control model and the relationships between them are redefined by extending the ABAC model. Then multi‐tenancy authorization framework is proposed and XACML language is used to describe the policy to provide our model with on‐demand service, isolation access and inter‐tenant collaboration. Finally, we develop this model into the cloud manufacturing monitoring platform. Results show that our model, compared with traditional models, has a better performance of on‐demand service, isolation access and inter‐tenant cooperation under the environment of cloud manufacturing.

Order Dataset Release Scheme Based on Safe K‐Anonymization for Privacy Protection in Cloud Manufacturing Technical Publication. MSEC2017‐2720 Hui Xiu, Xuemei Jiang, Xiaomei Zhang, Wuhan University of Technology, wuhan, Hubei, China Cloud Manufacturing is a new model to increase the manufacturing and business benefits by sharing manufacturing resource. These re‐ sources can bring users convenience, but also may be maliciously analyzed by the attacker which may result in personal or corporate priva‐ cy disclosure. In this paper, we discuss the privacy disclosure problem in cloud manufacturing, and propose a method for releasing order data securely with the complex relationship between enterprises and other vendors. Taking into account the risk of privacy leakage in the process of data analysis or data mining, we improve the traditional method of anonymous releasing for original order data, and introduce the thought of safe k‐anonymization to achieve the process. To meet the needs of protecting sensitive information in data, we analyze the users’ different demands for order data in the cloud manufacturing, use the sampling function to satisfy differential privacy to increase the uncertainty, improve the k‐anonymization method, apply the anonymous method with generalization, concealment, and reduce data asso‐ ciations to different attributes. The improved method not only preserves the statistical characteristics of the data, but also protects the privacy information in the order data in the cloud manufacturing environment.

Induction Hardening Process With Preheat to Eliminate Cracking and Improve Quality of a Large Part With Various Wall Thickness Technical Publication. MSEC2017‐2721 Zhichao (Charlie) Li, Blake Ferguson, DANTE Solutions, Inc., Cleveland, OH, United States During an induction hardening process, the electromagnetic field generated by the inductor creates eddy currents that heat a surface layer of the part, followed by spray quenching to convert the austenitized layer to martensite. The critical process parameters include the power and frequency of the inductor, the heating time, the quench delay time, the quench rate, and the quench time, etc. These parameters may significantly affect case depth, hardness, distortion, residual stresses, and cracking possibility. Compared to a traditional hardening process, induction hardening has the advantages of low energy consumption, better process consistency, clean environment, low distortion and formation of beneficial residual stresses. However, the temperature gradient in the part during induction hardening is steep due to the faster heating rate of the surface and the aggressive spray quench rate, which leads to a high phase transformation gradient and high mag‐ nitude of internal stresses. Quench cracks and high magnitude of residual stresses are more common in induction hardened parts than those of conventional quench hardening processes. In this study, a scanning induction hardening process of a large part made of AISI 4340 with varying wall thickness is modeled using DANTE. The modeling results have successfully shown the cause of cracking. Based on the modeling results, a preheat method is proposed prior to induction heating to reduce the in‐process stresses and eliminate the cracking possibility. This process modification not only reduces the magnitude of the in‐process tensile stress, but also converts the surface residual 21 stresses from tension to compression at the critical inner corner of the part, which improves the service life of the part. The modified pro‐ cess has been successfully validated by modeling and implemented in the heat treating plant.

Investigation of the Water Guided Laser Micro‐Jet Machining of Aero Engine Components Technical Publication. MSEC2017‐2723 Zhigang Wang, MAKINO INC., Mason, OH, United States The water guided laser micro‐jet (LMJ) is a new potential method to machine aero engine parts with much less heat affected area and fast‐ er cutting speed than dry laser machining. The focus of this paper is to investigate the energy density and material removal for a dual‐laser LMJ system. Then, the effects of dominated parameters on the energy density of LMJ are analyzed. Finally, a mathematical model is devel‐ oped to describe the relationship between dominant laser parameters with the energy density of LMJ and material removal rate followed by machining case studies of aero engine components.

Investigating Dielectric Impedance Spectroscopy As a Non‐Destructive Quality Assessment Tool for 3D Cellular Constructs Technical Publication. MSEC2017‐2725 Lokesh Karthik Narayanan, Trevor L. Thompson, North Carolina State University, Raleigh, NC, United States, Aditya Bhat, Aber Instruments Ltd, Aberystwyth, United Kingdom, Binil Starly, Rohan A. Shirwaiker, North Carolina State University, Ra‐ leigh, NC, United States In any three dimensional (3D) biofabrication process, assessing critical biological quality attributes of 3D constructs such as viable cell number, cell distribution and metabolic activity is critical to determine the suitability and success of the process. One major limitation in current state‐of‐the‐art is the lack of appropriate methods to monitor these quality attributes in situ in a non‐destructive, label‐free man‐ ner. In this study, we investigate the feasibility of using dielectric impedance spectroscopy to address this gap. We first measured the rela‐ tive permittivity of 3D alginate constructs with four different concentrations of encapsulated MG63 cells (1 6.5 million cells/mL) and found them to be statistically significantly different (p < 0.05). Within the tested range, the relationship between cell concentration and relative permittivity was noted to be linear (R^2 = 0.986). Furthermore, we characterized the dispersion parameters for MG63‐encapsulated in a lginate (6.5 million cells/mL). These results demonstrate that dielectric impedance spectroscopy can be used to monitor critical quality at‐ tributes of cell‐encapsulated 3D constructs. Owing to the measurement efficiency and non‐destructive mode of testing, this method has tremendous potential as an in‐process quality control tool for 3D biofabrication processes and the long‐term monitoring of cell‐encapsulated 3D constructs.

Surface Grinding of CFRP Composites Using Rotary Ultrasonic Machining: Effects of Ultrasonic Power Technical Publication. MSEC2017‐2726 Hui Wang, Yingbin Hu, FUDA NING, Yuzhou Li, Texas Tech University, Lubbock, TX, United States, Meng Zhang, Kansas State University, Manhattan, KS, United States, Weilong (Ben) Cong, Samantha Smallwood, Texas Tech University, Lubbock, TX, Carbon fiber reinforced plastic (CFRP) composites have superior properties, including high strength‐to‐weight ratio, high modulus‐to‐weight ratio, high fatigue resistance, etc.. These properties make CFRP composites being popular in many kinds of industries. Due to the inhomo‐ geneous and anisotropic properties, and high abrasiveness of the reinforcement in CFRP composites, they are classified as difficult‐to‐cut materials in surface grinding processes. Many problems (including high cutting force and low machining efficiency) are generated in con‐ ventional surface grinding processes. In order to reduce and eliminate these problems, rotary ultrasonic machining (RUM) surface grinding of CFRP composites is conducted in this investigation. Effects of ultrasonic power in different machining levels are of great importance in RUM surface grinding processes. However, no investigations on effects of ultrasonic power in different machining levels are conducted in such a process. This investigation, for the first time, tests the effects of ultrasonic power on output variables, including cutting force, torque, and surface roughness in different machining levels. This paper will provide guides for future research on effects of ultrasonic pow‐ er in different combinations of machining variables on output variables

Development and Characterizations of Liquid Bridge Based Microstereolithography (LBMSL) System Technical Publication. MSEC2017‐2731 Yanfeng Lu, Sumanth Kashyap, Md Omar Faruk Emon, Jeongwoo Lee, University of Akron, Akron, OH, United States,

22

Jae‐Won Choi, The University of Akron, Akron, OH, United States In this work, a novel liquid bridge based microstereolithography (LBMSL) was proposed and developed. The liquid bridge was first intro‐ duced into the MSL process by replacing the vat, allowing the entire fabrication process to occur within the liquid bridge. The liquid bridge was studied theoretically and experimentally in order to obtain the stable equilibrium shape and the relationship between the height and the volume of the liquid bridge. Using the LBMSL process, the fabrication layer thickness of 0.5 µm was first reached. This could not be achieved in the vat‐based MSL due to the oxygen inhibition to the photopolymer. Fabrication of high viscosity material greater than 3000 cP was tested and significant results were obtained. Compared with the vat‐based MSL, the material consumption in LBMSL was reduced and the fabrication time was improved greatly, especially when using higher viscous material.

A Case Study Investigating the Environmental Impact of Pelleting in Cellulosic Biofuel Manufacturing Technical Publication. MSEC2017‐2733 Rajkamal Kesharwani, Md Monirul Islam, Missouri University of Science and Technology, Rolla, MO, United States, Xiaoxu Song, Kansas State University, Manhattan, KS, United States, Zeyi Sun, Missouri University of Science and Technology, Rolla, MO, United States, Meng Zhang, Kansas State University, Manhattan, KS, United States, Cihan Dagli, Missouri University of Science and Technology, Rolla, MO, United States manufacturing consists of two major processes, biomass feedstock preprocessing and bioconversion. Traditionally, these two processes are conducted in different locations in practice and transportation is required to connect the two processes. Pelleting in preprocessing can help reduce the size and increase the density of biomass so that the transportation and handling can be more efficient. However, pelleting is also considered an energy‐intensive process that consumes a large amount of energy, which lead to considerable greenhouse gas emis‐ sions. Due to such an environmental and energy related concern, the use of pelleting process in real industry is still in doubt although it has been extensively studied in laboratory scale. In this paper, we analyze the both positive and negative impacts of pelleting in biofuel manu‐ facturing regarding GHG emissions. A numerical case study focusing on the transportation is conducted to examine such impacts through the comparison between the scenarios with and without pelleting process to estimate the net emission due to the pelleting process.

Investigation of Relationship Between Sugar Yield and Particle Size in Biofuel Manufacturing Technical Publication. MSEC2017‐2734 Rajkamal Kesharwani, Missouri University of Science and Technology, Rolla, MO, United States, Xiaoxu Song, Yang Yang, Kansas State University, Manhattan, KS, United States, Zeyi Sun, Missouri University of Science and Technology, Rolla, MO, United States, Meng Zhang, Kansas State University, Manhattan, KS, United States, Cihan Dagli, Missouri University of Science and Technology, Rolla, MO, United States Biofuel manufacturing consists of two major processes, i.e., feedstock preprocessing and bioconversion. The preprocessing includes size reduction and pelleting. The bioconversion includes pretreatment, hydrolysis, and fermentation. Various studies have been implemented for these two processes. Most existing literature focuses on a specific process, while very few of them consider the possible interactions between the two processes. In this paper, we investigated the relationship between the particle size in feedstock preprocessing and the sugar yield (proportional to biofuel yield) in bioconversion. The method of design of experiments was used to design experiments and ana‐ lyze the experimental results of sugar yield with different particle sizes for three different types of biomass. Critical parameters that signifi‐ cantly influence the sugar yield were identified. The optimal configurations of the particle size were recommended.

Energy Efficiency State Identification in Milling Processing Based on Improved HMM Technical Publication. MSEC2017‐2735 YUN CAI, Hua Shao, Shanghai Jiaotong University, Shanghai, Shanghai, China Energy efficiency state identification of milling process plays an important role in energy saving efforts for manufacturing systems. Howev‐ er, it is very difficult to track energy efficiency state in machining processes based on traditional signal processing strategies due to the fact that energy state is usually coupled with a lot of factors like machine tool states, tool conditions, and cutting conditions. An identification method of information reasoning and Hidden Markov model (HMM) for energy efficiency state is proposed in this paper. Utilizing cutting conditions, empirical models of the energy efficiency, experimental data and signal features, an expert system is established for initial probability optimization and the state is further identified by HMM. The experiments show that energy efficiency state can be identified with this method. 23

A Data‐Driven Approach to Detect Mechanical Faults in Wind Turbine Gearbox Technical Publication. MSEC2017‐2736 Ruoyu Li, National Oilwell Varco, Houston, TX, United States, Zeyi Sun, Missouri University of Science and Technology, Rolla, MO, United States Online condition monitoring systems play an important role in preventing catastrophic failure, reducing maintenance costs, and improving the system reliability. In this paper, wind turbine gearbox mechanical fault detection system is developed. An adaptive filtering technique is applied to separate the impulsive components from the periodic components of the vibration signals. Then different features of the pe‐ riodic components and impulsive components are extracted. An extreme learning machine based classifier is designed and trained by using the features extracted from simulated vibration data of wind turbine gearbox. Simulated vibration signals of wind turbines gearbox are used to demonstrate the effectiveness of the presented methodology

Effect of Cryogenic Conditions on the Drilling Performance of Carbon‐Carbon (C‐C) Composites Technical Publication. MSEC2017‐2737 Y.‐Q. Wang, School of Mechanical Engineering, Dalian University of Technology, Dalian, China, L.‐S. Han, Dalian University of Technology, Dalian, China, H.‐B. Liu, Dalian University of Technology, Liaoning, China, K. Li, Y. Ma, Dalian University of Tech‐ nology, Dalian, China C‐C composite is a kind of typical difficult‐to‐machine materials due to its high hardness, high strength, and obvious anisotropy features. But, water‐based or oil‐based coolant cannot be used during its machining process. As a result, the machining defects, including burrs, ori‐ fice ripping, and interlayer delamination, are always unavoidable. In this article, taking the liquid nitrogen as coolant, C‐C composite cryo‐ genic drilling is researched experimentally. Taking the way of LN2 external spray cooling, a series of cryogenic drilling experiments were designed. Comparing with dry drilling, the thrust force was reduced, the machining defects were significantly inhibited, and a better roundness of holes was achieved in cryogenic drilling. It indicates that cryogenic condition has a positive effect on improving the C‐C com‐ posite drilling quality.

Rapid Intense Pulse Light Sintering of Sulphide Nanoparticle Films Technical Publication. MSEC2017‐2739 Shalu Bansal, Oregon State University, Corvallis, OR, United States, Zhongwei Gao, Oregon State Univ, Corvallis, OR, United States, Chih‐hung Chang, Oregon State University, Corvalis, OR, United States, Rajiv Malhotra, Oregon State University, Cor‐ vallis, OR, United States Copper sulphide (CuxS, x=1 to 2) is a metal chalcogenide semiconductor that exhibits useful optical and electrical properties due to the presence of copper vacancies. This makes CuxS thin films useful for a number of applications including infrared absorbing coatings, solar cells, thin‐film electronics, and as a precursor for CZTS thin films. Post‐deposition sintering of CuxS nanoparticle films is a key process that affects the film properties and hence determines its operational characteristics in the above applications. Intense pulse light (IPL) sintering uses visible broad‐spectrum xenon light to rapidly sinter nanoparticle films over large‐areas, and is compatible with methods such as roll‐to‐roll deposition for large‐area deposition of colloidal nanoparticle films and patterns. This paper experimentally examines the effect of IPL parameters on sintering of CuxS thin films. As‐deposited and sintered films are compared in terms of their crystal structure, as well as optical and electrical properties, as a function of the IPL parameters.

Study on the Generation and Redistribution Mechanism of Residual Stress in Bilateral Rolling Correction Process for Thin‐Walled Parts Technical Publication. MSEC2017‐2741 Laixiao Lu, Shandong University, Ji’nan, China, Jie Sun, Shandong University, Shandong, China, Kai Guo, Shandong University, Ji’nan, China, Jianfeng Li, Shandong University, Jinan, Select State/Province, China The distortion and dimensional instability is one of the main problems in the machining of thin‐walled parts with high‐strength aluminum alloys. To ensure the accuracy of aircraft assembly, distortion correction process is inevitable. Bilateral rolling process has been used to correct the distorted parts in the aerospace industries because it can introduce a proper plastic deformation and residual stresses. Howev‐ er, the generation and redistribution mechanism of residual stresses in bilateral rolling correction process remains unclear. This internal mechanism was investigated by finite element method (FEM) in this paper. Firstly, the FE models were verified by experiments in terms of

24 residual stresses and strain. Then, simulation results (e.g. plastic strain, true strain and part distortion) were extracted for further analysis. It was shown that the residual stresses are produced in the deformation coordination process of plastic and elastic strain, and a large plas‐ tic deformation can lead to a high amplitude residual stresses. Besides, the binding force from the surrounding materials also resulting in higher strain gradient and amplitude of residual stresses. Although part distortion has little effect on the limit value of residual stresses, it has an important influence on the redistribution of the residual stresses.

Crimped Fiber Printing via E‐Jetting for Tissue Engineering Technical Publication. MSEC2017‐2742 Yang Wu, Jerry YH Fuh, Yoke San Wong, National University of Singapore, Singapore, Singapore A regular pattern called crimp is an essential morphological feature of collagen fibers in native tendon. In this study, the direct crimp writ‐ ing (DCW) and zig‐zag pattern writing (ZPW) were developed based on electrohydrodynamic jet printing (E‐jetting) process to fabricate the crimped fibers. For the DCW process, the fibers were deposited with the linear movement of stage, and the crimps (crimp angle: ~46 º; crimp length: ~630 µm; fiber diameter: ~100 µm) were formed from the spinning of fibers. For the ZPW process, the fibers was printed via the zig‐zag moving path, and the effects of a vital process parameter (i.e. dwell time) on the fiber characteristics were investigated to ob‐ tain controllable and regular crimped fibers. The result of mechanical testing showed that the ZPW fibers exhibited the toe and linear re‐ gions with different Young’s modulus (4 ± 1 MPa and 23 ± 4 MPa, respectively), while DCW fibers were found only with linear region. Com‐ pared with DCW process, the ZPW process was able to fabricate crimped fibers in a more controllable pathway. The human tenocytes were also seeded on the ZPW fibers to investigate the cellular alignment. This study suggested that ZPW process was capable of printing crimped fibers which mimicked the fiber morphology in human tendon, and has the potential in scaffold fabrication for tendon tissue engineering.

Static Recrystallization Behavior of a Nitrogen Controlled Z2CN19‐10 Austenitic Stainless Steel Technical Publication. MSEC2017‐2746 Min Luo, Chun Xu, Bing Zhou, Yan‐hui Guo, Shanghai Institute of Technology, shanghai, China, Rong‐bin Li, Shanghai DianJi University, shanghai, China In order to increase the hot workability and provide proper hot forming parameters for nitrogen controlled Z2CN19‐10 austenitic stainless steel, the static recrystallization behavior was investigated by double‐pass hot compression tests in the temperature range of 950?1100?, initial grain size of 72?m‐152?m, and the strain rates of 0.01, 0.1, 1, and 5 s‐1. The tests were conducted with inter‐pass times varying be‐ tween 1 and 100 s after achieving a pass strain of 0.05, 0.1, 0.15 and 0.2 in the first pass on a Gleeble‐1500 thermo‐mechanical simulator. The static recrystallization fraction has been predicted by the 2 offset stress method and verified by metallographic observations. The metallographic results indicate the crystallized grains generate at the cross of the prior austenite grain boundary and grow up. Also the kinetics of static recrystallization behavior for Z2CN19‐10 steel are proposed. Experimental results show that the volume fraction of static recrystallization increases with the increase of deformation temperature, strain rates, pass strain and interval time, while it decreases with the increase of initial grain size. According to the present experimental results, the activation energy (Q) and Avrami exponent (n) was de‐ termined as 199.02kJ/mol and 0.69. The established equations can give a reasonable estimate of the static recrystallization behavior for Z2CN19‐10 steel.

Probabilistic Model for Online 3D Printing Service Evaluation Technical Publication. MSEC2017‐2747 Jin Cui, Lin Zhang, Lei Ren, Beihang University, Beijing, China By enabling consumer products to be made on‐demand and eliminating waste from overproduction and transport, online 3D printing ser‐ vice is more and more popular with unprofessional customers. As a growing number of 3D printers are becoming accessible on various online 3D printing service platforms, there raises the concern over online 3D printing service evaluation and selection for novices as well as users with 3D printing experience. In this paper, we analyze this problem using information transformation techniques and multinomial distribution probabilistic model. Evaluation factors, the major attributes that significantly affect the performance of an online 3D printing service, are described with standard description form. Meanwhile, historical service data is introduced to identify and update these evalua‐ tion factor values. Based on these parameters, evaluation and comparison can be implemented upon online 3D printing services using the probabilistic model. An example is presented to illustrate the assessment process based on the proposed evaluation model. The presented objective probabilistic evaluation method can serve as the basis of online 3D printing service evaluation and selection on an online 3D 25 printing service platform. Although the focus of the work was on 3D printing service, the idea can be applied to other online rapid proto‐ typing sharing systems.

Machining Operation Process Planning System Considering User Strategies and Intentions Technical Publication. MSEC2017‐2749 Taishi Hirai, Isamu Nishida, KobeUniversity, Kobe, Hyogo, Japan, Ryuta Sato, Keiichi Shirase, Kobe University, Kobe, Japan In this study, a new machining process planning system considering user’s strategies or intentions for machining operations is proposed. In our previous study, the machining sequence can be calculated geometrically based on the Total Removal Volume (TRV) and the machining primitive region divided from TRV. However, it is difficult to determine the best machining sequence among the huge numbers of the ma‐ chining sequence calculated by the previous process planning system. Furthermore, there is no method to determine properly the machin‐ ing sequence according to the user’s strategies or intentions. In this study, the method, which can store the geometrical properties of the machining primitives when the user selects the machining sequence, is developed. According to the geometrical properties to select the machining sequence, it becomes possible to determine the machining sequence automatically. In this case, the user’s strategies or inten‐ tions are considered to determine the machining sequence based on the learned geometrical properties. A case study was conducted to show the effectiveness of the proposed method. The different machining sequences can be determined automatically for different users based on the relation among the geometrical properties of the machining primitives and the user’s strategies or intentions.

Pricing Method for Service‐Oriented Manufacturing With Support Vector Machine Technical Publication. MSEC2017‐2752 Qiunan Meng, Jian Lou, DALIAN UNIVERSITY OF TECHNOLOGY, Dalian, Liaoning, China, Xun Xu, Shiqiang Yu, University of Auckland, Auckland, New Zealand To evaluate the effects of customers’ participation levels in various business activities on pricing in service‐oriented manufacturing, the indices of pricing are proposed through extracting the influential factors in the four stages (i.e., design, manufacturing, production and services) from the whole value chain to comprehensively reflect customers’ demands. A new pricing model based on these indices is for‐ mulated by Support Vector Machine (SVM). It can predict a more accurate product price regarding the products similarity by the values of the influential factors that are determined in terms of business activities participated by customers. Finally, a case study from a molding company in China is conducted to verify the effectiveness of this pricing methodology. The results indicate that the model by SVM fares better in comparison with that by Back Propagation Neural Networks in small scale samples, especially in the performances of generaliza‐ tion and robustness. The outcomes also testify that this price prediction methodology can increase the accuracy of a product’s price as well as the customer’s satisfaction.

Effects of Surface Roughness on Bonding Behavior of Cold Spray Ti6Al4V Coatings Technical Publication. MSEC2017‐2753 WEN SUN, Adrian Wei Yee Tan, Nanyang Technological University, SINGAPORE, Please choose a State, Singapore, Iulian Marinescu, Rolls‐Royce Singapore Pte Ltd, SINGAPORE, Please choose a State, Singapore, Erjia Liu, Nanyang Technological University, SINGAPORE, Singapore In this study, a penitential additive manufacturing method ‐ cold spray was used to deposit Ti6Al4V powders onto Ti6Al4V substrates with different surface roughness by using a high pressure cold spray system. The coating quality was good with limited porosity without phase transition. Interface bonding behavior between coating and substrate was studied, which indicates that smoother substrate surface would increase the bonding strength. Bending test shows that all the coated samples started to delaminate before substrate failure and smoother surface samples could resist higher stress than the rougher surface samples.

Integrative Technology and Inspection Planning: A Case Study in Medical Industry Technical Publication. MSEC2017‐2755 Fritz Klocke, Johannes Müller, Patrick Mattfeld, Jan Kukulies, Robert H. Schmitt, Laboratory for Machine Tools and Produc‐ tion Engineering (WZL) of RWTH Aachen University, Aachen, Nordrhein‐Westfalen, Germany In most trendsetting industries like the aerospace, automotive and medical industry functionally critical parts are of highest importance. 26

Due to strict legal requirements regarding the securing of the functionality of high‐risk parts, both production costs and quality costs con‐ tribute significantly to the manufacturing costs. Thus, both types of costs have to be taken into consideration during the stage of technolo‐ gy planning. Due to the high variety of potential interactions between individual component properties as well as between component properties and manufacturing processes, the analysis of the influence of the manufacturing history on an efficient design of inspection processes and inspection strategies is extremely complex. Furthermore, the effects of inspection strategies and quality costs on the plan‐ ning of manufacturing process sequences cannot be modeled to date. As a consequence, manufacturing and inspection processes are de‐ signed separately and thus a high cost reduction potential remains untapped.

In this paper a new approach for an integrative technology and inspection planning is presented and applied to a case study in medical industry. At first, existing approaches with regard to technology and inspection planning are reviewed. After a definition of relevant terms the case study is introduced. Following, an approach for an integrative technology and inspection planning is presented and applied to the case study. In the presented approach the complex causalities between technology planning, manufacturing history and inspection plan‐ ning are considered to enable a cost‐effective production process and inspection sequence design.

Vibration Control of Computer Numerically Controlled With CFRP Pipe Frame Technical Publication. MSEC2017‐2756 Honoka Yamada, Kazuki Sawatani, Yoshitaka Morimoto, Kanazawa Institute of Technology, Kanazawa, Ishikawa, Japan, Naohiko Suzuki, Yoshiyuki Kaneko, Takamaz Machinery Co., Ltd., Hakusan, Ishikawa, Japan A new computer numerically controlled lathe containing a carbon fiber‐reinforced plastic pipe frame was developed in this study. The pipe frame structure is lightweight and allows the machine size and stiffness to be adjusted by varying the parameters of the frame structure. Furthermore, using carbon fiber‐reinforced plastic instead of steel improves the heat deformation properties of the frame. When employing a pipe frame structure for machine tools, structural vibration can be problematic. In particular, the relative vibration be‐ tween the tool and the workpiece must be suppressed to improve the accuracy of the machined surface. To achieve this vibration suppres‐ sion, an actuator driven by piezoelectric elements was installed in the frame of the developed CNC lathe structure to counteract the vibra‐ tion at specific modes by applying active vibration control. As a result of using the proposed vibration control method, the vibration ampli‐ tude was reduced by up to 88.6% compared with that without control. Additionally, the circularity of workpiece was improved by 27%.

Ductile Regime Scratching of a Rock Sample in a Laser Assisted Machining Technique Technical Publication. MSEC2017‐2758 BARKIN BAKIR, Hossein Mohammadi, John Patten, Western Michigan University, KALAMAZOO, MI, United States Rocks are playing an important role in the life of mankind since ancient times. One of the most significant characteristics of the rocks is their brittleness, which makes them exhibit a very poor machinability and usually severe fracture results during machining. In this paper, Micro‐Laser Augmented Machining (µ‐LAM) technique is applied on scratching a commercial rock, Gabbro‐Labradorite, which is a compo‐ site of grained natural minerals such as feldspar, magnetite and mica. In the µ‐LAM process, a laser is used to locally heat and thermally soften the materials below the scratching tool during the machining operation. In this paper, scratching tests have been done on the Gab‐ bro‐Labradorite minerals, with and without laser heating and results are compared and reported. Micro‐laser assisted scratch tests (with an actual cutting tool) were successful in demonstrating the enhanced thermal softening of the feldspar and magnetite minerals. The effect of the laser power was studied by measuring the depths of the cuts for the scratch tests. When generating the scratches with a diamond tool, load range was increased from 50 to 500 mN. Laser powers of 10, 15, 20, and 25 Watt (W) have been utilized. All the tests were repeated two times to increase the reliability of the results. 3D profiles were generated by using a white light interferometer and microscopic images of the cuts have been reported. Results show that Ductile to Brittle Transition (DBT) depth, which is the critical depth for machining brittle materials, increased with the aid of the laser. Results are very important for the machining of the Gabbro‐Labradorite to get a high material removal rate (MRR), low tool wear and better surface quality.

Modeling of the Grinding Wheel Topography Depending on the Recipe‐Dependent Volumetric Composition Technical Publication. MSEC2017‐2759 Fritz Klocke, Sebastian Barth, Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Aachen, Nordrhein‐Westfalen, Germany, Michael Rom, bInstitute for Geometry and Applied Mathematics (IGPM) of RWTH

27

Aachen University, Aachen, Nordrhein‐Westfalen, Germany, Christian Wrobel, Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Aachen, Nordrhein‐Westfalen, Germany In this paper, an innovative approach for modeling the grinding wheel structure and the resultant grinding wheel topography is discussed. The overall objective of the underlying research project was to create a mathematical‐generic grinding wheel model in which the spatial arrangement of the components grains, bond and pores is simulated in a realistic manner starting from the recipe‐dependent volumetric composition of a grinding wheel. With this model it is possible to determine the resulting grinding wheel structure and the grinding wheel topography of vitrified and synthetic resin‐bonded CBN grinding wheels and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of grinding wheels, taking into account the entire grinding wheel structure and build up the topography based on it. Using original mathematical methods, the components of grinding wheels were analyzed and distribution functions of the components were determined. Thus the statistical character of the grinding wheel structure was taken into account. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of grinding processes.

Investigation of Structure‐Property Relationships in Thermoplastic Polyurethane/Multiwalled Carbon Nanotube Composites Technical Publication. MSEC2017‐2760 Felicia Stan, Catalin Fetecau, Nicoleta V. Stanciu, Razvan T. Rosculet, Laurentiu I. Sandu, Dunarea de Jos University of Galati, Galati, Romania In this study, the structure‐property relationships in thermoplastic polyurethane (TPU) filled with multi‐walled carbon nanotubes (MWCNTs) were investigated. Firstly, the contribution of MWCNTs to the melt shear viscosity and the pressure‐volume‐temperature (pVT) behavior was investigated. Secondly, injection‐molded samples and 2 mm diameter filaments of TPU/MWCNT composites were fabricated and their mechanical and electrical properties analyzed. It was found that the melt processability of TPU/MWCNT composites is not affect‐ ed by the addition of a small amount (1‐5 wt.%) of MWCNTs, all composites displaying shear‐thinning at high shear rates. The mechanical and electrical properties of the TPU/MWCNT composites were substantially enhanced with the addition of MWCNTs. However, the conduc‐ tivity values of composites processed by injection molding were two and three orders of magnitude lower than those of composites pro‐ cessed by extrusion, highlighting the role of melt shear viscosity on the dispersion and agglomeration of nanotubes.

Fabrication of Micro‐Channels in PMMA by Tip‐Based Microfabrication Technique: Depth and Friction Analysis Technical Publication. MSEC2017‐2763 Catalin Fetecau, Nicoleta V. Stanciu, Dunarea de Jos University of Galati, Galati, Romania In this paper, millimeter‐scale straight parallel micro‐channels were fabricated in PMMA (Polymethyl‐methacrylate) using the tip‐based micro‐fabrication method. The dimensional characteristics (channel width, channel depth and pile‐up height) of micro‐channels were eval‐ uated and the effects of normal load and speed on the micro‐channel geometry and friction were examined. A logarithmic relationship between the normal load and micro‐channel depth was identified. The experimental results indicate that the selection of the normal load is critical to achieve a desired micro‐channel geometry using a single pass scratching. To machine a micro‐channel with a finite depth in PMMA, the normal load must be higher than 4.5 N. Within the range of the tested normal loads, about 70% of the channel height was elas‐ tically recovered after a single pass, and pile‐ups as high as 50‐60% of the depth were observed along the micro‐channel sides.

Remaining Useful Life Estimation Based on a Segmental Hidden Markov Model With Continuous Observations Technical Publication. MSEC2017‐2765 Zhen Chen, Tangbin Xia, Ershun Pan, Shanghai Jiaotong University, Shanghai, China In this paper, a segmental hidden Markov model (SHMM) with continuous observations, is developed to tackle the problem of remaining useful life (RUL) estimation. The proposed approach has the advantage of predicting the RUL and detecting the degradation states simul‐ taneously. As the observation space is discretized into N segments corresponding to N hidden states, the explicit relationship between ac‐ tual degradation paths and the hidden states can be depicted. The continuous observations are fitted by Gaussian, Gamma and Lognormal distribution, respectively. To select a more suitable distribution, model validation metrics are employed for evaluating the goodness‐of‐fit of the available models to the observed data. The unknown parameters of the SHMM can be estimated by the maximum likelihood method with the complete data. Then a recursive method is used for RUL estimation. Finally, an illustrate case is analyzed to demonstrate the ac‐ 28 curacy and efficiency of the proposed method. The result also suggests that SHMM with observation probability distribution which is closer to the real data behavior may be more suitable for the prediction of RUL.

An Investigation of Electroplastic Drilling of Mild Steel Technical Publication. MSEC2017‐2766 Brandt Ruszkiewicz, Clemson University, International Center for Automotive Research, Greenville, SC, United States, Eliza‐ beth Gendreau, Clemson University, Lexington, SC, United States, Farbod Akhavan Niaki, Clemson University, Greenville, SC, United States, Laine Mears, Clemson University, Anderson, SC, United States Increasing governmental fuel economy requirements force automakers to increase the fuel economy of their fleets. One of the methods for improving fuel economy is through the use of materials with high strength to weight ratios to decrease the weight of the vehicle, known as lightweighting. Some of these new metals entering the automotive sector are difficult to machine and cause drastically reduced tool life and increased machining cost. It has been shown that electricity has the ability to reduce cutting force during orthogonal cutting and turning. This paper conducts a design of experiment study on an electrically assisted drilling operation to determine the impact and in‐ teraction between the following input parameters: applied electric current, feedrate, spindle RPM, and number of holes cut. These varia‐ bles used to determine impact and interaction on the following output variables: flank wear, axial cutting force, temperature evolution, and heat affected zone. A 2D finite volume method model is used to predict drilling temperature during the process and is used to aid in pre‐ dicting axial force. It is found that electric current can reduce cutting force at the cost of increased temperature, however, arcing at initial contact causes increased tool wear.

Effect of Different Heat Treatments on Mechanical Properties of Laser Sintered Additive Manufactured Parts Technical Publication. MSEC2017‐2769 Sagar Sarkar, Siva Kumar Cheruvu, Indian Institute of Technology, Kharagpur, Kharagpur, West Bengal, West Bengal, India, Ashish Kumar Nath, Indian Institute of Technology, Kharagpur, Kharagpur, West Bengal, India most popular additive manufacturing processes is laser based direct metal laser sintering process which enables us to make complex three dimensional parts directly from CAD models. Due to layer by layer formation, parts built in this process tend to be anisotropic in nature. Suitable heat treatment can reduce this anisotropic behaviour by changing the microstructure. Depending upon the applications, a wide range of mechanical properties can be achieved between 482‐ 621o C temperature for precipitation‐hardened stainless . In the pre‐ sent study effect of different heat treatment processes, namely solution annealing, ageing and overaging, on tensile strength, hardness and wear properties has been studied in detail. Suitable metallurgical and mechanical characterization techniques have been applied wherever required, to support the experimental observations. Results show H900 condition gives highest yield strength and lowest tensile strain at break whereas solution annealing gives lowest yield strength and as‐built condition gives highest tensile strain at break. SEM images show that H900 and H1150 condition produces brittle and ductile morphology respectively which in turn gives highest and lowest hardness value respectively.XRD analysis shows presence of austenite phases which can increase hardness at the cost of ductility. Average wear loss for H900 condition is highest whereas it is lowest for solution annealed condition. Further optical and SEM images have been taken to under‐ stand the basic wear mechanism involved.

Reinforcement Learning Based Real‐Time Control Policy for Two‐Machine‐One‐Buffer Production System Technical Publication. MSEC2017‐2771 Wei Zheng, Yong LEI, Zhejiang University, Hangzhou, Zhejiang Province, China, Qing Chang, Stony Brook University, Melville, NY, United States It is attractive to reduce the total cost of a manufacture system with real‐time control of the production. The total cost mainly consists of the production cost, the penalty of the permanent production loss, and the Work‐In‐Process (WIP) inventory level cost. However, it is diffi‐ cult to derive an analytical model of manufacture system due to the complexity of starved and blocked phenomena, the random failure and maintenance processes. Therefore, finding a real‐time control policy for the manufacture system without exact analytical model is dearly needed. In this paper, a novel reinforcement learning based control decision policy is proposed based on the action of switching themachines on or off at the start of each time slot. Firstly, a simulation model is developed with MTBF and MTTR evaluated from the history data to collect samples. Then, a reinforcement learning 29 method, specifically, Least‐Square‐Policy‐Iteration method,is applied to obtain a sub‐optimal policy. The simulation results show that the proposed method performs well in reducing the total discounted cost.

Measurement‐Based Adaptive Machining by Direct Spatial Deformation of Template CAM Data Technical Publication. MSEC2017‐2773 Zhengcai Zhao, Yucan Fu, Jiuhua Xu, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu, China, Yong Chen, University Of Southern California, Los Angeles, CA, United States In production and manufacturing engineering, some redesign, distorted or worn parts cannot be milled according to their original CAD ge‐ ometries due to the existed shape deviations. Generating CAM data in traditional manner for each individual part is time‐consuming and labor intensive. This paper proposes a quick and convenient adaptive machining approach, in which a template CAM data is spatially de‐ formed according to some measured points from actual shape. The actual shape of the part was firstly inspected by on‐machine measure‐ ment method. The measured points’ data was matched to the original nominal CAD geometry with ICP algorithm afterwards, by which the point‐pairs between the measurement points and their corresponding points were established. Based on the distance deviations between these point‐pairs, global and local modifying methods of template CAM data were developed using spatial deformation. By embedding the template CAM data in the calculated deformation volume, a new CAM data was achieved. Finally, a series of measurement and machining tests were performed, which validates the feasibility of proposed adaptive machining approach in this paper.

Analysis of Innovative Incremental Cold Forming Process for the Manufacturing of Aerospace Rotating Parts Technical Publication. MSEC2017‐2774 Marcos Perez, University of Strathclyde, Inchinnan, United Kingdom Cold rotary forging is an innovative incremental metal forming process in which the work‐piece is only partially in contact with a conical tool, reducing therefore the required forging loads. However, in spite of many benefits of such a process, wide industrial implementation of rotary forging is not possible without proper understanding of material behaviour. In the present work, the capability of rotary forging process was explored for the manufacturing of flared cylindrical parts by cold forming. Another main aim was to assess the cold formability of high‐strength materials for aerospace applications under incremental processes. In order to understand the impact of rotary forging on the final properties of formed components, microstructural and mechanical analysis were performed. Microstructural and hardness analy‐ sis were conducted in order to study the grain flow orientation and strain distribution. In a similar fashion, mechanical test specimens were machined from different positions and orientations along the rotary forged component. Further analysis was performed on the compo‐ nents in the as‐treated condition in order to understand the response of cold‐worked Jethete M152 components to subsequent heat treatments.

Microstructural and hardness analysis clearly reveals a strong grain reorientation and strain localization around pickup defects (material attached to the upper tool) observed on the flange top surface, close to the flange edge. These results suggest that an excessive defor‐ mation is localized during the early stages of the flange formation. Another characteristic feature is the presence of a buckling phenome‐ non which appears in later stages of the rotary forging process. Strain hardening along with the increasing flange length requires higher levels of forging loads to keep forming the flange. This results into a significant accumulation of compressive stresses in the transition re‐ gion between the flange and the straight region. Gradually the resultant compressive force exceeds the critical buckling load, leading to the occurrence of the buckling phenomenon. This latter issue determines the limit of the cold flaring process. From the mechanical testing results, large differences were found as a function of both position and orientation throughout the rotary forged components. Concerning the impact of heat treatments on cold‐worked components, no differences were found in the as‐treated condition, in terms of microstruc‐ tural and mechanical properties between regions with a large difference in strain distribution. These results denote the normalizing effect of conventional hardening treatments on cold‐worked Jethete M152 components, restoring the homogeneous and isotropic properties across the whole component.

Conceptual Design of an Experiment for the International Space Station About Cosmic Ray Shielding Materials Technical Publication. MSEC2017‐2775 Fabrizio Quadrini, Loredana Santo, University of Rome Tor Vergata, Rome, Italy Cosmic ray (CR) shielding is the main issue for future long missions far for the protection of the Earth?s magnetic field. Many experiments 30 have been performed in Space to evaluate the effect of the Space environment on the material stability (mainly MISSE experiments from NASA). However those experiments were not able to evaluate CR shielding performances of materials, and results are mainly present in the form of erosion yield due to atomic oxygen erosion. In this study, a conceptual design is shown for further experiments on the International Space Station by focusing on the effect of cosmic rays on material aging. Shields will be made by using polyolefin sheets coupled or not with metallic foils. Polymeric sheets will be filled or coated with magnetic nano‐particles to provide a small magnetic activity.

Conceptual Design of an Experiment for the International Space Station About Shape Memory Composite in Space Envi‐ ronment Technical Publication. MSEC2017‐2776 Loredana Santo, Denise Bellisario, Giovanni Matteo Tedde, Fabrizio Quadrini, University of Rome Tor Vergata, Rome, Italy Shape memory polymers (SMP) and composites (SMPC) may be used for many applications in Space, from self‐deployable structures (such as solar sails, panels, shields, booms and antennas), to grabbing systems for Space debris removal, up to new‐concept actuators for tele‐ scope mirror tuning. Experiments on the International Space Station are necessary for testing prototypes in relevant environment, above all for the absence of gravity which affects deployment of slender structures but also to evaluate the aging effects of the Space environment. In fact, several aging mechanisms are possible, from polymer cracking to cross‐linking and erosion, and different behaviors are expected as well, from consolidating the temporary shape to composite degradation. Evaluating the possibility of shape recovery because of sun expo‐ sure is another interesting point. In this study, a possible experiment on the ISS is shown with the aim of evaluating the aging effect of Space on material performances. The sample structure is described as well as the testing strategy.

Cutting Force Prediction of Ball End Milling Based on Fully Voxel Representation of Cutting Edge and Instantaneous Work‐ piece Shape Technical Publication. MSEC2017‐2777 Isamu Nishida, KobeUniversity, Kobe, Japan, Ryuma Okumura, Ryuta Sato, Keiichi Shirase, Kobe University, Kobe, Japan A new cutting force simulator has been developed to predict cutting force in ball end milling. This new simulator discretely calculates uncut chip thickness based on a fully voxel representation of the cutting edge and instantaneous workpiece shape. Previously, a workpiece voxel model was used to calculate uncut chip thickness under a complex change of workpiece shape. Using a work‐ piece voxel model, uncut chip thickness is detected by extracting the voxels removed per cutting edge tooth for the amount of material fed into the cutting edge. However, it is difficult to define the complicated shape of a cutting edge using the workpiece voxel model; the shape of the cutting edge must be defined by a mathematical expression. It is also difficult to model the voxels removed by the cutting edge when the tool posture is non‐uniformly changed. We therefore propose a new method to detect uncut chip thickness, one in which both the cutting edge and the instantaneous workpiece shape are fully represented by a voxel model. Our proposed method precisely detects uncut chip thickness at minute tool rotational angles, making it possible to detect the uncut chip thickness between the complex surface shape of the workpiece and the particular shape of the cutting edge. To validate the effectiveness of our proposed method, experimental 5‐axis milling tests using a ball end mill were conducted. Estimated milling forces for several tool postures were found to be in good agreement with the measured milling forces. Results from the experi‐ mental 5‐axis milling validate the effectiveness of our proposed method.

3D Printing of Microfluidics for Point of Care Diagnosis Technical Publication. MSEC2017‐2778 John Sibbitt, Mei He, Kansas State University, Manhattan, KS, United States Microfluidic lab‐on‐a‐chip (MLOC) technology is a promising approach for point‐of‐care (POC) diagnosis; low reagent consumption, high sensitivity and quick analysis time are the most prominent benefits. However, microfabrication of MLOCs utilizes specialized techniques and infrastructure, making conventional fabrication time consuming and difficult. While relatively inexpensive production techniques exist for POC diagnoses, such as replication of polymer‐based (e.g., PDMS) microfluidic POC devices on lithographic molds, this approach has limitations including: further hydrophilic surface modifications of PDMS, inability to change lithographic mold Z dimensions, and slow pro‐ totyping. In contrast, stereo‐lithographical (SLA) printing can integrate all of the necessary fabrication resources in one instrument, allowing

31 highly versatile microfluidic devices to be made at low cost. In this paper, we report two microfabrication approaches of microfluidics uti‐ lizing (SLA) 3D printing technology: I) Direct SLA printing of channels and structures of a monolithic microfluidic POC device; II) Indirect fab‐ rication, utilizing SLA 3D printed molds for PDMS‐based microfluidic device replication. Additionally, we discuss previous work providing a proof of concept of applications in POC diagnosis, using direct 3D printing fabrication (approach I). The robustness and simplicity of these protocols allow integrating 3D design and microfabrication with smartphone‐based disease diagnosis as a stand‐alone system, offering strong adaptability for establishing diagnostic capacity in resource‐limited areas and low‐income countries.

Active Mixing Nozzle for Multi‐Material and Multi‐Scale 3D Printing Technical Publication. MSEC2017‐2779 Hongbo Lan, Qingdao Technological University, Qingdao, Shandong, China Multi‐scale and multi‐material 3D printing is next frontier in additive manufacturing. It has shown great potential to implement the simul‐ taneous and full control for fabricated object including external geometry, internal architecture, functional surface, material composition and ratio as well as gradient distribution, feature size ranging from nano, micro, to marco‐scale, embedded components and electro‐circuit, etc. Furthermore, it has the ability to construct the heterogeneous and hierarchical structured object with tailored properties and multiple functionalities which cannot be achieved through the existing technologies. That paves the way and will result in great breakthrough in various applications, e.g., functional tissue and organ, functionally graded material/structure, wearable devices, soft robot, functionally embedded electronics, metamaterial, multi‐functionality product, etc. However, very few of the established additive manufacturing pro‐ cesses have the capability to implement the multi‐material and multi‐scale 3D printing. This paper presented a single nozzle‐based mul‐ ti‐scale and multi‐material 3D printing process by integrating both the electrohydrodynamic jet (E‐jet) printing and the active mixing mul‐ timaterial nozzle. The AM technology has the capability to create multifunctional heterogeneously structured objects with control of the macro‐scale external geometry and micro‐scale internal structures as well as functional surface features, particularly, the potential to dy‐ namically mix, grade and vary the ratios of different materials. An active mixing nozzle, as a core functional component of the 3D printer, is systematically investigated by combining the theoretical analysis, numerical simulation and experimental verification. This goal of the study is to explore a feasible solution to implement the multi‐scale and multi‐material 3D printing at low cost.

Surface Grinding of Optical BK7/K9 Using Rotary Ultrasonic Machining: An Experimental Study Technical Publication. MSEC2017‐2780 Yingbin Hu, Hui Wang, FUDA NING, Weilong (Ben) Cong, Yuzhou Li, Texas Tech University, Lubbock, TX, United States BK7/K9 glass is regarded as a difficult‐to‐machine material due to its high hardness and high brittleness properties as well as high tool wear rate during machining. Facing to these challenges, an efficient and effective rotary ultrasonic machining (RUM) process, consisting of grind‐ ing process and ultrasonic machining process, was provided to process BK7/K9 glass. In this investigation, the effects of ultrasonic power on cutting forces, torque, and edge chipping of surface grinding in RUM of BK7/K9 glass were studied. Results showed that, by introducing ultrasonic vibration to surface grinding process, both cutting forces in feeding direction and in axial direction as well as torque values were reduced. The higher the ultrasonic power was, the lower the forces and torque values would be. Edge chipping, which was detrimental to the qualities of machined slots and would cause high machining cost, was significant reduced with the help of ultrasonic vibration.

Control of Pressing Force in Magnetic Abrasive Finishing Using Permanent Magnet End‐Mill Tool Technical Publication. MSEC2017‐2781 Lei Ma, Doshisha University, Kyotanabe‐shi, Kyoto‐fu, Japan, Toshiki Hirogaki, Eiichi Aoyama, Doshisha Univ, Kyoto, Japan, Furuki Tatsuya, Gifu University, Gifu, Japan, Wei Wu, Doshisha University, Kyoto, Japan The magnetic abrasive finishing (MAF) process is well known because of its high efficiency in yielding a mirror gloss finish zone. Clarification of the high efficiency machining mechanism has indicated that this high efficiency is obtained by particle cutting and the simultaneous polishing of alumina abrasives. This process yields unevenness, which is often evident on the workpiece surface. The MAF technique pro‐ vides many other attractive advantages, such as self‐sharpening, and self‐adaptation to different processing sites. Magnetic abrasive fin‐ ishing has, therefore, been used to solve many surface finishing problems affecting the lining of precision vessels, and been applied in the fabrication of oil and gas transmission pipelines, the various valves of hydraulic components bearing retainers, and numerous other prod‐ ucts. This technique also constitutes an effective method for finishing curved surfaces, or rounding the edges of a stepped surface. In this paper, we make slight changes to the steel‐ball shape, obtaining saddle and barrel‐shaped iron particles via stamping processing. We ob‐ 32 serve the characteristics of the polishing force and contact condition for these three different iron particle shapes and for different particle numbers, using a force sensor and a high‐speed camera. The relationship between the particle shape and the polishing force is also ex‐ plored in an attempt to construct a predictive model for the polishing force. It is found that the force variation can be reduced by adjusting the particle shape and number, which effectively reduces the damage caused when the brush approaches the workpiece surface.

Accuracy Degradation Analysis for Industrial Robot Systems Technical Publication. MSEC2017‐2782 Guixiu Qiao, NIST, Gaithersburg, MD, United States, Brian Weiss, National Institute of Standards and Technology, Gaithersburg, MD, United States As robot systems become increasingly prevalent in manufacturing environments, the need for improved accuracy continues to grow. Re‐ cent accuracy improvements have greatly enhanced automotive and aerospace manufacturing capabilities, including high‐precision assem‐ bly, two‐sided drilling and fastening, material removal, automated fiber placement, and in‐process inspection. The accuracy requirement of those applications is primarily a function of two main criteria: (1) The pose accuracy (position and orientation accuracy) of a robot system’s tool center position (TCP), and (2) the ability of a robot system’s TCP to remain in position or on‐path when loads are applied. The degrada‐ tion of a robot system’s tool center accuracy can lead to a decrease in manufacturing quality and production efficiency. Given the high output rate of production lines, it is critical to develop technologies to verify and validate robot systems’ health assessment techniques, particularly the accuracy degradation. In this paper, the National Institute of Standards and Technology’s (NIST) effort to develop the measurement science to support the monitoring, diagnostics, and prognostics (collectively known as prognostics and health management (PHM)) of robot accuracy degradation is presented. This discussion includes the modeling and algorithm development for the test method, the advanced sensor development to measure 7‐D information (time, X, Y, Z, roll, pitch, and yaw), and algorithms to analyze the data.

Towards a Robot Task Ontology Standard Technical Publication. MSEC2017‐2783 Stephen Balakirsky, Georgia Tech Research Institute, Atlanta, GA, United States, Craig Schlenoff, NIST, Gaithersburg, MD, United States, Sandro Rama Fiorini, Universite Paris‐Est Creteil, Vitry sur Seine, Ile d’France, France, Signe Redfield, Robot‐ istry.org, Pomfret, MD, United States, Marcos Barreto, Federal University of Bahia, City Salvador, Bahia, Brazil, Hirenkumar Nakawala, Politecnico di Milano, Milan, Milan, Italy, Joel Luis Carbonera, Federal University of Rio Grande do sul, Porto Ale‐ gre, Rio Grande do Sul, Brazil, Larisa Soldatova, Brunel University, London, Middlesex, United Kingdom, Julita Berme‐ jo‐Alonso, Universidad Politécnica de Madrid, Madrid, Madrid, Spain, Fatima Maikore, Brunel University, London, Middlesex, United Kingdom, Paulo Goncalves, Instituto Politecnico de Castelo Branco, Castelo Branco, Branco, Portugal, Elena De Momi, Politecnico di Milano, Milan, Milan, Italy, Veera Ragavan Sampath Kumar, Monash University, Sunway, Selangor, Malaysia, Tamas Haidegger, Obuda University, Budapest, Budapest, Hungary Ontologies serve robotics in many ways, particularly in describing and driving autonomous functions. These functions are built around ro‐ bot tasks. In this paper, we introduce the IEEE Robot Task Representation Study Group, including its work plan, initial development efforts, and proposed use cases. This effort aims to develop a standard that provides a comprehensive ontology encompassing robot task struc‐ tures and reasoning across robotic domains, addressing both the relationships between tasks and platforms and the relationships between tasks and users. Its goal is to develop a knowledge representation that addresses task structure, with decomposition into subclasses, cate‐ gories, and/or relations. It includes attributes, both common across tasks and specific to particular tasks and task types.

Investigation of the Cleaning and Welding Steps From the Friction Element Welding Process Technical Publication. MSEC2017‐2786 Jamie D. Skovron, Clemson University, Greenville, SC, United States, Brandt Ruszkiewicz, Clemson University, International Center for Automotive Research, Greenville, SC, United States, Ankit Varma, Yuxin Li, Clemson University, Clemson, SC, United States, Laine Mears, Clemson University, Anderson, SC, United States, Xin Zhao, Clemson University, Clemson, SC, United States, Tim Abke, Honda R&D Americas, Raymond, OH, United States, Hongseok Choi, Clemson University, Clemson, SC, United States The requirement of increased fuel economy standards has forced automakers to incorporate multi‐materials into their current steel domi‐ nant vehicles in order to lightweight their fleets. Technologies such as Self Piercing Rivets and Flow Drill Screws are currently implemented 33 for joining aluminum to high‐strength steels but only one‐technology is viable for joining aluminum to ultra‐high‐strength steels without pre‐holes, namely Friction Element Welding. This study is aimed at investigating how variations in the cleaning and welding steps of the Friction Element Welding process influence joint quality. A design of experiment was conducted to understand the influence of key process parameters (endload, spindle RPM, and relative distance) during these steps on the pre‐defined joint quality metrics of head height, weld zone diameter, under‐head fill area, temperature, and microhardness. It is found that cleaning step parameters have the greatest influence on process time and energy consumption, while welding step parameters greatly influence maximum torque on the element, head height, and underhead fill, with both cleaning force and weld force influencing weld diameter, all parameters influence temperature.

“Hierarchical Decomposition of a Manufacturing Work Cell to Promote Monitoring, Diagnostics, and Prognostics” Technical Publication. MSEC2017‐2787 Brian Weiss, National Institute of Standards and Technology, Gaithersburg, MD, United States, Guixiu Qiao, NIST, Gaithersburg, MD, United States Manufacturing operations are typically complex, especially when considering industrial robot systems. The execution of robot‐driven tasks requires the integration of multiple layers of hardware and software. The development and integration of monitoring, diagnostic, and prognostic (collectively known as prognostics and health management (PHM)) technologies can aid manufacturers in maintaining the per‐ formance of robot systems by providing intelligence to enhance maintenance and control strategies. If appropriately designed and inte‐ grated, PHM can improve asset availability, product quality, and overall productivity. It is unlikely that a manufacturer has the capability to implement PHM in every element of their robot system. This limitation makes it imperative that the manufacturer understand the com‐ plexity of their robot system, especially the influences that each element has on one another. Typical robot systems include one or more robot arm(s), controller(s), end‐effector(s), sensor(s), and safety system(s). Each of these elements is bound, both physically and function‐ ally, to one another and thereby holds a measure of influence. This paper will focus on research that is aimed at hierarchically structuring the complex robot system work cell to promote an understanding of the physical and functional relationships among all of the system?s elements. These relationships will be leveraged to support the identification of areas of risk, which in turn drives a manufacturer to imple‐ ment PHM within specific areas.

Axial Control of Two‐Photon Polymerization With Femtosecond Bessel Beam Technical Publication. MSEC2017‐2788 Xiaoming Yu, University of Central Florida, Orlando, FL, United States, Meng Zhang, Shuting Lei, Kansas State Univ, Manhat‐ tan, KS, United States Stereolithography of three‐dimensional, arbitrarily‐shaped objects is achieved by successively curing photopolymer on multiple 2D planes and then stacking these 2D slices into 3D objects. Often as a bottleneck for speeding up the fabrication process, this layer‐by‐layer ap‐ proach originates from the lack of axial control of photopolymerization. In this paper, we present a novel stereolithography technology with which two‐photon polymerization can be dynamically controlled in the axial direction using Bessel beam generated from a spatial light modulator (SLM) and an axicon. First, we use unmodulated Bessel beam to fabricate micro‐wires with an average diameter of 100 µm and a length exceeding 10 mm, resulting in an aspect ratio >> 100:1. A study on the polymerization process shows that a fabrication speed of 2 mm/s can be achieved. Defect and deformation are observed, and the micro‐wires consist of multiple narrow fibers which indicate the existence of the self‐writing effect. A test case is presented to demonstrate fast 3D printing of a hollow tube within one second. Next, we modulate the Bessel beam with an SLM and demonstrate the simultaneous generation of multiple focal spots along the laser propagation direction. These spots can be dynamically controlled by loading an image sequence on the SLM. The theoretical foundation of this technol‐ ogy is outlined, and computer simulation is conducted to verify the experimental results. The presented technology extends current stereo‐ lithography into the third dimension, and has the potential to significantly increase 3D printing speed.

Replacing Mechanized Oxyfuel Cutting Sensors With Ion Current Sensing Technical Publication. MSEC2017‐2789 Christopher Martin, Penn State University; Altoona College, Hollidaysburg, PA, United States This paper describes a method using electrical characteristics of the torch, flame, and work piece to replace active sensing elements most commonly used for mechanized oxyfuel cutting applications; height, fuel/oxygen ratio, work temperature, and preheat flow rate. Calibra‐ tions are given for the torch under test for standoff accurate to +/‐ 1/32in (0.8mm) and F/O ratio accurate to +/‐ .008. Methods are pro‐ 34 posed for balancing flow across multi‐torch systems, and detecting the work kindling temperature. Additional work is needed if calibrated flow and work temperatures are to be measured electrically.

Developing a Capability‐Based Similarity Metric for Manufacturing Processes Technical Publication. MSEC2017‐2790 Kevin Li, University of Maryland, Clarksville, MD, United States, William Bernstein, National Institute of Standards and Tech‐ nology, Gaithersburg, MD, United States Manufacturing taxonomies and accompanying metadata of manufacturing processes have been catalogued in both reference books and databases on‐line. However, such information remains in a form that is uninformative to the various stages of the product life cycle, in‐ cluding the design phase and manufacturing‐related activities. This challenge lies in the varying nature in how the data is captured and represented. In this paper, we explore measures for comparing manufacturing data with the goal of developing a capability‐based similarity metric for manufacturing processes. To judge the effectiveness of these metrics, we apply permutations of them to 26 manufacturing process models, such as blow molding, die casting, and milling, that were created based on the ASTM E3012‐16 standard. Furthermore, we provide directions towards the development of an aggregate similarity metric considering multiple capability features. In the future, this work will contribute to a broad vision of a manufacturing process model repository by helping ease decision‐making for engineering design and planning.

New Model for Hyper‐Elastic Materials Behavior With an Application on Natural Rubber Technical Publication. MSEC2017‐2792 Ahmed Korba, Mark E Barkey, The University of Alabama, Tuscaloosa, AL, United States This paper is concerned with defining a new Weight Function Based model (WFB), which describes the hyper‐elastic materials stress‐strain behavior. Numerous hyper‐elastic theoretical material models have been proposed over the past 60 years capturing the stress‐strain be‐ havior of large deformation incompressible isotropic materials. The newly proposed method has been verified against the historic Treloar?s test data for uni‐axial, bi‐axial and pure shear loadings of Treloar?s vulcanized rubber material, showing a promising level of confidence compared to the Ogden and the Yeoh methods. A non‐linear least square optimization Matlab tool was used to determine the WFB, Yeoh and Ogden models material parameters. A comparison between the results of the three models was performed showing that the newly proposed model is more accurate for uni‐axial tension as it has an error value which is less than the Ogden and Yeoh models by 1.0 to 39%. Also, the WFB model has reduced processing time for the model parameters calculation by more than 95%, for the bi‐axial and pure shear loading cases compared to the Ogden model. Natural rubber test specimens have been tensioned using a tensile testing machine and the WFB model was applied to fit the test data results showing a very good curve fitting with an average error of 0.44%.

Assessing the Geometric Integrity of Additive Manufactured Parts From Point Cloud Data Using Spectral Graph Theoretic Sparse Representation‐Based Classification Technical Publication. MSEC2017‐2794 M. Samie Tootooni, Binghamton University, Binghamton, NY, United States, Prahalad Rao, University of Nebraska‐Lincoln, Lincoln, NE, United States, Ashley Dsouza, Ryan Donovan, Binghamton University, Binghamton, NY, United States, Zhenyu (James) Kong, Virginia Tech, Blacksburg, VA, United States, Peter Borgesen, Binghamton University, Binghamton, NY, United States This work proposes a novel approach for geometric integrity assessment of additive manufactured (AM, 3D printed) components, exempli‐ fied by acrylonitrile butadiene styrene (ABS) polymer parts made using fused filament fabrication (FFF) process. The following two research questions are addressed in this paper: (1) what is the effect of FFF process parameters, specifically, infill percentage (If) and extrusion tem‐ perature (Te) on geometric integrity of ABS parts?; and (2) what approach is required to differentiate AM parts with respect to their ge‐ ometric integrity based on sparse sampling from a large (~ 2 million data points) laser‐scanned point cloud dataset? To answer the first question, ABS parts are produced by varying two FFF parameters, namely, infill percentage (If) and extrusion temperature (Te) through design of experiments. The part geometric integrity is assessed with respect to key geometric dimensioning and tolerancing (GD&T) fea‐ tures, such as flatness, circularity, cylindricity, root mean square deviation, and in‐tolerance percentage. These GD&T parameters are ob‐ tained by laser scanning of the FFF parts. Concurrently, coordinate measurements of the part geometry in the form of 3D point cloud data is also acquired. Through response surface statistical analysis of this experimental data it was found that discrimination of geometric integ‐ 35 rity between FFF parts based on GD&T parameters and process inputs alone was unsatisfactory (regression R2 < 50%). This directly moti‐ vates the second question. Accordingly, a data‐driven analytical approach is proposed to classify the geometric integrity of FFF parts using minimal number (< 2% of total) of laser‐scanned 3D point cloud data. The approach uses spectral graph theoretic Laplacian eigenvalues extracted from the 3D point cloud data in conjunction with a modeling framework called sparse representation to classify FFF part quality contingent on the geometric integrity. The practical outcome of this work is a method that can quickly classify the part geometric integrity with minimal point cloud data and high classification fidelity (F‐score >> 95%), which bypasses tedious coordinate measurement.

Multi‐Objective Build Orientation Optimization for Powder Bed Fusion by Laser Technical Publication. MSEC2017‐2796 Salah Eddine Brika, Yaoyao Fiona Zhao, Mathieu Brochu, Justin Mezzetta, McGill University, Montreal, QC, Canada This paper proposes an integrated approach to determine optimal build orientation for (SLM), by simultaneously optimizing mechanical properties, surface roughness, the amount of support structure and build time‐cost. Experimental data analysis has been used to establish the objective functions for different mechanical properties and surface roughness. Geometry analysis of the part has been used to estimate the needed support structure and thus evaluate the build time and cost. Normalized weights are assigned to differ‐ ent objectives depending on their relative importance allowing solving the multi‐objective optimization problem using a genetic optimiza‐ tion algorithm. A study case is presented to demonstrate the capabilities of the developed system. The major achievements of this work are the consideration of multiple objectives, establishment of objective function considering different load direction and heat treatments. A user friendly graphical user interface was developed allowing to control different optimization process factors and providing different visu‐ alization and evaluation tools.

“Impact of Non‐Isothermal Warm Rolling on Microstructure, Texture and Mechanical Properties” Technical Publication. MSEC2017‐2797 Chun Xu, Xing‐zhou AN, Xiao‐hua RAO, Ya‐nan Li, Shanghai Institute of Technology, Shanghai, China To study the influence of non‐isothermal deformation on microstructure, texture and mechanical properties, the CP Ti sheets were rolled to approximately 10% reduction per pass under a pair of rolls with different surface temperatures (i.e. non‐isothermal rolled). The progress of recrystallization was enhanced with the increase of the difference in surface temperature between upper and lower rolls. When CP Ti sheets were non‐isothermally rolled under the upper and lower rolls with surface temperatures of 210 and 120?, respectively, complete recrystallization occurred. Under such circumstances, it was found that the microstructure consists of equiaxed grains with the average size of 13?m and with mainly high‐angle boundaries. Pyramidal > slip was the dominant deformation mechanism, and the elongation at room temperature was three times of that in the initial state. However, CP Ti sheets were rolled under a pair of roll with the same surface temperatures of 120 or 210?(i.e. isothermal rolled), recrystallization did not occur?and the microstructure, texture and mechanical proper‐ ties of CP Ti isothermal rolling sheets were similar to those of conventional hot rolled CP Ti sheets.

Investigation of the Effects of Microgrooved Cutting Tool in High Speed Machining of AISI 1045 Steel Technical Publication. MSEC2017‐2798 Xingbang Chen, Nick Duong, Jianfeng Ma, Saint Louis University, Saint Louis, MO, United States, Shuting Lei, Kansas State Univ, Manhattan, KS, United States In this paper, numerical investigation of the effects of microgroove textured cutting tools in high speed machining of AISI 1045 is conducted using Finite Element Method (FEM). Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting in‐ serts. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of main cutting force, thrust force, and tool‐chip contact length. It is found that microgrooved cutting tools generate lower cutting force and consequently lower the energy necessary for machining. This research provides insightful guidance for optimizing tool life and reducing energy consumption in high‐speed machining of AISI 1045 steel.

Electrically Assisted Friction Stir Spot Welding of Aluminum Alloy to Advanced High Strength Steel Technical Publication. MSEC2017‐2803 Kai Chen, Xun Liu, Jun Ni, University of MICHIGAN, Ann Arbor, MI, United States 36

This paper studies an electrically assisted friction stir spot welding (FSSW) process for joining aluminum alloy 6061‐T6 to TRIP 780 steel. The electrical current shows to reduce the axial plunge force and assist the material flow of the aluminum matrix during the welding process. When electrical pulses and direct current (DC) with the same energy input are applied, the results show insignificant differences. Bulk ma‐ terial flow can be observed in the weld cross sections. A more uniform hook is generated at the Fe/Al interface after applying the current. Besides, the diffusion of aluminum atoms into the steel matrix is enhanced. Regarding the weld quality, electrically assisted FSSW improves the joint lap shear strength when compared with regular FSSW process.

The Behavior Simulation of Manufacturing Services in a Service‐Oriented Networked Manufacturing Environment Technical Publication. MSEC2017‐2807 Jingbo Wang, Ping Lou, Xuemei Jiang, Qin Wei, Yongzhi Qu, Wuhan University of Technology, Wuhan, China In a service‐oriented networked manufacturing (SONM) environment, geographically distributed manufacturing resources are encapsulated as various manufacturing services. These manufacturing services release via the Internet and can provide services on the demand of manu‐ facturing tasks. Usually one manufacturing task needs several different services belonged to different organizers to work together. Hence, effective cooperation among services is the foundation of the efficient operation of SONM. In this paper, a bipartite network model is presented to describe the relationship of two different kinds of nodes in SONM, and also is projected as a weighed network for further exploring the behaviors of service nodes. Furthermore, an agent‐based model is built for modeling the interactive behaviors of service nodes in a cooperative network and an agent‐based simulating system is developed with Repast. The simulation results show that the emergence of cooperative behaviors among service nodes is related to both the cost of cooperation and initial trust of services in the SONM environment.

The Effect of Polyethylene (Glycol) Diacrylate Post‐Fabrication Rest Time on Compressive Properties Technical Publication. MSEC2017‐2809 Ozlem Yasar, City University of New York, Brooklyn, NY, United States, Serkan Inceoglu, Loma Linda University, Loma Linda, CA, United States, Ramesh Prashad, City University of New York, Brooklyn, NY, United States In recent years, tissue engineering has been utilized as an alternative approach for the organ transplantation. The success rate of tissue regeneration is influenced by the type of biomaterials, cell sources, growth factors and scaffold fabrication techniques used. The proper design and precise fabrication of scaffolds are crucial in supporting cells to expand and migrate throughout the 3D structure. In current tissue engineering technologies, synthetic and natural polymers and linear aliphatic polyesters are widely used as a scaffold material. The poly(ethylene glycol) diacrylate (PEGDA) is one of commonly used biomaterials because of its biocompatibility, biodegradability, ease of use, and porous microstructure. PEGDA based scaffolds can be easily fabricated by exposing to ultraviolet (UV) light after mixing it with water and a photo‐initiator. The mechanical properties of PEGDA have been studied to some extent by several research groups. However, the stability of the mechanical properties by time has not been investigated. In this research, we studied the change in water content in PEGDA as a function of post‐fabrication rest time and the effect of loss of water on mechanical properties of PEGDA. PEGDA based cylindrical blocks were made at 20%, 40%, 60%, 80%, and 100% concentration by mixing with appropriate amounts of water. Next, each PEGDA group was mixed with a photo‐initiator, poured into cylindrical molds with a diame‐ ter and a height of 15 x 15 mm, and placed under the UV light for 45 minutes to cure. Each PEGDA group consisted of 5 test samples. After the solidification process was complete, the weight of each cylindrical block sample was monitored until the mechanical testing. New sets of PEGDA blocks were prepared to study 0, 2, 4, 6, and 24 hours post‐fabrication rest time for various PEGDA concentration. Compressive Elastic Modulus and strength were calculated and statistically analyzed. Our results indicated that the water content of each PEGDA group constantly decreased by time, however, this loss significantly affected the Elastic Modulus and strength only after 6 hours in some PEGDA concentration

Effect of Particle Shape on Neck Growth and Shrinkage of Nanoparticles Technical Publication. MSEC2017‐2811 Elham Mirkoohi, Rajiv Malhotra, Oregon State University, Corvallis, OR, United States Sintering of nanoparticles to create films and patterns of functional materials is emerging as a key manufacturing process in applications like flexible electronics, solar cells and thin‐film devices. Further, there is the emerging potential to use nanoparticle sintering to perform additive manufacturing as well. While the effect of nanoparticle size on sintering has been well studied, very little attention has been paid to the effect of nanoparticle shape on the evolution of sintering. This paper uses Molecular dynamics (MD) simulations to determine the influence of particle shape on shrinkage and neck growth for two common nanoparticle shape combinations, i.e., sphere‐sphere and 37 sphere‐cylinder nanoparticles of different sizes. These sintering indicators are examined at two different temperature ramps. The results from this work show that depending on their relative sizes, degree of neck growth and shrinkage are both significantly affected by the na‐ noparticle shape. The possibility of using this phenomenon to control density and stresses during nanoparticle sintering are discussed.

Design and Analysis of Soft Grippers for Hand Rehabilitation Technical Publication. MSEC2017‐2814 Hongying Zhang, National University of Singapore, Singapore, Singapore, Singapore, Yiqiang Wang, Hong Kong University of Science and Technology, Hong Kong, Hong Kong, Michael Wang, Hong Kong University of Science & Technology, Kowloon, Hong Kong, Jerry YH Fuh, A Senthil Kumar, National University of Singapore, Singapore, Select State/Province, Singapore The goal of this paper is to develop a design methodology to create customized biomedical devices which can be fabricated through 3D printing technology. Due to the increasing demands of hand rehabilitation and prosthetic accessories, we focus on designing a pneumati‐ cally actuated soft gripper applicable on these issues. The gripper is composed of 3D printable soft material, which results in a safe interac‐ tion with human bodies due to inherently low modulus. Each gripper finger is designed to mimic the real‐world movement of a human fin‐ ger, where the complex physical finger locomotion is modelled as the continuous bending deformation of the soft gripper finger. Working as a compliant mechanism, the design process is performed to maximize the possible bending deformation. The topology optimization method is adopted to design the best performance gripper finger. The optimized gripper shows high consistence with human fingers be‐ cause of the pseudo‐joints. Furthermore, the designed gripper can be directly fabricated by using 3D printing technology without additional effort in the assembly process.

Cloud Manufacturing‐Enabled Production Logistics Service System in Industrial Park Technical Publication. MSEC2017‐2815 Kai Kang, Guangdong University of Technology, Guangzhou, Guangdong, China, Ting Qu, Hao Luo, Suxiu Xu, Congdong Li, Jinan University, Zhuhai, China, George Huang, Department of IMSE, The University of Hong Kong, Hong Kong, Hong Kong An industrial park is a cluster of enterprises who locate in the same location to share common infrastructures with governmental or pri‐ vately finance support, which plays an important role in promoting regional economic and industrial development. However, demand vola‐ tilities push manufacturing enterprises in a dilemma that excessive resource configuration leads to waste of resource and high production cost when customer demands is low, or lack of resource and capacity for satisfying customer demands when customer demands is high. Therefore, how to temporarily configure dynamic resource for satisfying customer demand with high quality and quick delivery at low cost is a burning issue. To solve above‐named issue, combining advantages of both Cloud Manufacturing (CMfg) and product service system (PSS), this paper design CMfg‐enabled production logistics service system (CMPLSS) to handle demand volatilities together by sharing re‐ source as service in industrial park. The use of CMPLSS leads to benefits for enterprises in industrial park.

An Individual Requirements‐Oriented Service Scheduling Method in Cloud Manufacturing Technical Publication. MSEC2017‐2817 Longfei Zhou, Lin Zhang, Lei Ren, Beihang University, Beijing, Beijing, China Cloud manufacturing is a novel service‐oriented networked manufacturing paradigm for the manufacturing industry. Through aggregating distributed manufacturing resources from different enterprises and transforming them into services, cloud manufacturing is able to provide on‐demand manufacturing services to customers. Scheduling, including resource scheduling and task scheduling, is a critical instrument for achieving on‐demand service provisioning, and also an important research issue in cloud manufacturing. In the process of service schedul‐ ing in cloud manufacturing, the manufacturing services are firstly matched according to the service demander’s functional requirements and service availability to form the candidate service sets. And then the optimized service scheduling scheme is generated according to the service demander’s non‐functional requirements. The individual requirements of service demanders are analyzed from aspects of function‐ al and non‐functional requirements in this paper. On this basis, the scheduling process for individual requirements in cloud manufacturing system is studied and a cloud manufacturing service scheduling model is proposed. This work can provide support and foundation for the related research of task planning and scheduling in cloud manufacturing system.

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Transport and Interfacial Phenomena in Nanoscale Confined Laser Crystallization Technical Publication. MSEC2017‐2818 Wan Shou, Heng Pan, Missouri University of Science and Technology, Rolla, MO, United States Laser processing (sintering, melting, crystallization and ablation) of nanoscale materials has been extensively employed for electronics manufacturing including both integrated circuit and emerging printable electronics. Many applications in semiconductor devices require annealing step to fabricate high quality crystalline domains on substrates that may not intrinsically promote the growth of high crystalline films. The recent emergence of FinFETs (Fin‐shaped Field Effect Transistor) and 3D Integrated Circuits (3D‐IC) has inspired the study of crystallization of amorphous materials in nano/micro confined domains. Using Molecular Dynamics (MD) simulation, we study the charac‐ teristics of unseeded crystallization within nano/microscale confining domains. Firstly, it is demonstrated that unseeded crystallization can yield single crystal domains facilitated by the confinement effects. A phenomenological model has been developed and tailored by MD simulations, which was applied to quantitatively evaluate the effects of domain size and processing laser pulse width on single crystal for‐ mation. Secondly, to predict crystallization behaviors on confining walls, a thermodynamics integration scheme will be used to calculate interfacial energies of Si‐SiO2 interfaces.

Construction‐Scale 3D Printing: Shape Stability of Fresh Printing Concrete Technical Publication. MSEC2017‐2823 Ali Kazemian, Xiao Yuan, Univ. of Southern California, Los Angeles, CA, United States, Ryan Meier, University of Southern Cal‐ ifornia, Los Angeles, CA, United States, Evan Cochran, Behrokh Khoshnevis, Univ. of Southern California, Los Angeles, CA, United States Building 3D objects in sequential layers is a technique employed by rapid manufacturing processes and allows great design freedom in manufacturing. Scaling up such automated additive fabrication from building small industrial parts to constructing buildings has been chal‐ lenging for researchers during the recent years. Compared to the traditional construction methods, numerous advantages are offered by a well‐developed layer based automated construction process, including architectural design freedom, lower construction cost, superior construction speed, and higher degree of customization. Concrete has been recognized as most viable option as the material to be used with such a process. However, there are several main challenges that yet have to be solved. Obtaining a mixture with high shape stability in the fresh state is among these challenges. Ideally, non‐stop printing of successive layers is desired in building a structure, so the total con‐ struction time is minimized. In this paper, an experimental investigation of the shape stability of freshly printed concrete layers using a small‐scale linear concrete printing setup with remote control capability is outlined. First, longer stoppage time between successive layers is examined to determine the effects on the deformations of fresh printing concrete. Then, heat application is proposed and studied as a measure to improve the shape stability of freshly printed concrete without adding any delay to the construction process. Furthermore, a one‐story building is con‐ sidered and the influence of each scenario on the total construction time is discussed.

On the Application of Model‐Based Definition Strategies to the Delivery of Technical Training Technical Publication. MSEC2017‐2825 Jorge Camba, University of Houston, Houston, TX, United States, Manuel Contero, David Pérez‐López, Universitat Politècnica de València, Valencia, OO, Spain, Pedro Company, Universitat Jaume I, Castellón de la Plana, Spain The application of computer technology to engineering and manufacturing domains has drastically transformed the way products and sys‐ tems are designed and produced. However, a major drawback of CAD/CAM/CAE systems is the steep learning curve required to understand and master their extensive and increasingly complex set of functionalities. In this paper, we present a new approach to deliver CAD training materials that is inspired by Model‐Based Definition (MDB) strategies, where annotated 3D models become the center of the training pro‐ cess. In our system, textual 3D annotations are connected to a Product Lifecycle Management (PLM) system to provide access to interactive video tutorials which are linked to specific features of a CAD model. As a proof of concerto to validate this approach, a plugin for a com‐ mercial CAD package was developed that enhances the functionality of standard 3D annotation mechanisms and enables users to interact with the technical training materials directly within the CAD interface. New data structures were implemented to support the connection and integration with PLM systems. A group of tutorials are described to illustrate the system architecture and implementation details.

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Analytical and Experimental Evaluation of Flow Characteristics of Annealed AISI 304 Stainless Steel Sheet in Multi‐Scale Bulge Forming Technical Publication. MSEC2017‐2826 Ayotunde Olayinka, Mechanical Engineering Dept., University of Louisiana at Lafayette, Lafayette, LA 70503, Lafayette, LA, United States, William Emblom, University Of Louisiana‐Lafayette, Lafayette, LA, United States, Scott Wagner, School of Technology, Michigan Technological University, Atlantic Mine, MI, United States The demand for miniature devices has increased the need for utilizing multi‐scale hydroforming processes. Qualities in hydroformed parts such as reduced internal stresses and more homogeneous stress distributions compared to stamp formed parts result in reduced part fail‐ ures. In addition, there is less material waste, high dimensional accuracy and less spring back which make hydroforming viable processes for micro‐scale metal forming production. The objective of the present research is to evaluate the properties of 0.2 mm thick AISI 304 stainless steel using circular and elliptical hydraulic bulge forming processes. The circular dies had die cavities of 5 mm and 11 mm, while the elliptical dies were formed with elliptical cavity dies aspect ratios of 0.5, 0.8, and 0.67 and minor diameters of 11 mm. Analytical meth‐ ods for circular dies proposed by Chakrabarty, Ekineev‐Kruglov, Jovane, and Marciniak for the determination of the flow curve in circular dies were compared to experimental results obtained by evaluating the thickness of sectioned work pieces. The outcome indicates that the Ekineev ‐ Kruglov method has the best correlation with the experimental. For the elliptical dies, the material properties of the flow curve obtained using an improved Banabic method and the original Banabic method were compared. While the improved Banabic method pro‐ vided improved predictive results for the material properties, the error in the determined material properties are still significant

Disruption Recovery Model for Complex Flow Shop Scheduling With Considering Behavior Under Environment of the In‐ ternet of Things Technical Publication. MSEC2017‐2827 Bo Hongguang, Li Huanzhi, Zhang Huilin, Dalian University of Technology, Dalian, Liaoning, China, Guo Yi, Dalian Huatie Haixing Science and technology co., LTD, Dalian, Liaoning, China, Mu Wei, CSR Qingdao Sifang Co., Ltd. Qingdao, Qingdao, Shandong, China Disruptions happen in the actual manufacturing system under environment of the Internet of Things and they make the system difficult to manage. However, the convenient access to information of orders, equipment and participants make disruption recovery easier. In this paper we build a disruption recovery scheduling integer programming model considering the objective of minimizing total weighted com‐ pletion‐time (as the original objective) and the objectives of maximizing total consumer satisfaction degree & minimizing total deviation degree (as the revising objective). A PVPS (PSO & VNS Parallel Search) algorithm is proposed. The experiments results prove all above are effective.

Design and Development of Double Spiral Shaped Flexural Feed Stage for Micro‐Drilling Workstation Technical Publication. MSEC2017‐2829 KIRAN BHOLE, Sardar Patel College of Engineering Andheri, NAVI MUMBAI, India, Megha Janbandhu, Sardar Patel College of Engineering, Mumbai, Maharashtra, India, SACHIN MASTUD, VJTI Mumbai, Maharashtra, Maharashtra, India Flexure based system allows motion by bending the load elements and provide accurate linear motion. Due to these advantages flexural based mechanisms are used in various applications demanding micro and nano positing accuracy. The established high positioning accuracy of flexural mechanisms sets the motivation and promise for its utility in development of economical micro‐drilling work station. This paper presents development of flexural guideways for micro‐drilling workstation. Flexural systems are light in weight; possess low friction, no lubrication and hysteresis. Use of spiral shape flexural guideways is the key element for accurate linear motion in feed direction in the developed system. The propose spiral shape flexural mechanism is very first analyzed for its linear motion and strength using finite element analysis. The linear motion of the flexural feed stage is observed under feed force and undesirable lateral forces. The low axial stiffness and high radial stiffness is required to provide accurate linear motion even under presence of the undesirable lateral forces. Based on finite element analysis, the flexural design is converged and then accordingly fabricated for its implementation. The fabricated flexural feed stage has provided accurate linear motion with resolution 40 within ±5 microns. The inherent accuracy in linear motion of the flexural guideways has enabled to make micro‐drilling up to 50 microns with ease and simplicity in design.

Research on the Coordination of Multiple Air Circulating Tempering Furnaces Using System Identification and Predictive Control in Manufacturing of Non‐Combustible Aluminum Composite Panels Technical Publication. MSEC2017‐2830 Renhe Ji, Dong Du, Baohua Chang, Li Wang, Jinle Zeng, Yuxiang Hong, Tsinghua University, Beijing, Beijing, China Non‐combustible aluminum composite panel is a new type of green building and decoration material with high security. However, during its manufacturing process, the incongruity of temperature cyclings between a series of air circulating tempering furnaces on the production line may cause a serious negative impact on the stability of product quality. In this paper, a model of the temperature control system of a tempering furnace was built at first by applying parameter identification technique to the off‐line data of the furnace. Then, an approach based on online parameter identification and model predictive control was proposed to solve the dilemma that the specific temperature range of one single tempering furnace and the temperature cyclings coordination of multiple tempering furnaces cannot be attained at the same time when using PID or On‐Off control method. A method was presented to optimize the phase difference between the temperature cyclings of differents furnaces’ to lower the fluctuation of product quality. Finally, experiments are used to demonstrate the descent in fluctuation using the methods proposed in this paper.

Rational Synthesis of Nanostructured Electrode Materials for High‐Performance Supercapacitors Technical Publication. MSEC2017‐2833 CP Wong, The Chinese University of Hong Kong, Hong Kong, Hong Kong A nanocasting strategy is utilized to synthesize graphene/porous Fe2O3 nanocomposite, which integrates high redox activity of Fe2O3 with high electronic conductivity of graphene scaffold. Thanks to its nanostructure, porous structure and heterostructure, this material shows a significantly high capacitance of 1095 F g?1 at the current density of 3A g?1. An aqueous asymmetric pseudocapacitor is assembled by combing the graphene/porous Fe2O3 nanocomposite and a Co‐Ni‐layered double hydroxide (LDH) composite, and delivers very promising energy and power densities of 98.0 W h kg?1 and 22,826 W kg?1, ranking among the best supercapacitors. Besides, we have developed other supercapacitor systems, e.g., curved‐graphene‐based symmetric supercapacitor, Cu(OH)2//activated carbon all‐solid‐state asymmet‐ ric supercapacitor, and Co‐Ni‐LDH//FeOOH aqueous pseudocapacitor. The material synthesis conditions are optimized to realize great en‐ ergy storage performances.

Improving the Energy Efficiency of Adsorption Chillers by Intensifying Thermal Management Systems in Sorbent Beds Technical Publication. MSEC2017‐2834 Brian K. Paul, Oregon State Univ, Corvallis, OR, United States, Kijoon Lee, Hailei Wang, Oregon State University, CORVALLIS, OR, United States The objective of this study was to develop a strategy for miniaturizing heat exchangers used for the thermal management of sorbent beds within adsorption refrigeration systems. The thermal mass of the microchannel heat exchanger designed and fabricated in this study is compared with that of commercially available tube‐and‐fin heat exchangers. Efforts are made to quantify the overall effects of miniaturiza‐ tion on system coefficient of performance and specific cooling power. A thermal model for predicting the cycle time for desorption is developed and experiments are used to quantify the effect of the intensified heat exchanger on overall system performance.

Characterization of Lattice Structures for Additive Manufacturing of Lightweight Mechanical Components Technical Publication. MSEC2017‐2835 Erica Liverani, Adrian Lutey, Università di Bologna, Bologna, Italy, Alessandro Fortunato, Alessandro Ascari, University of Bologna, Bologna, Italy Tensile and compression test specimens comprising lattice structures with simple cubic, crossing‐rod and body‐centered cubic (BCC) unit cells are produced via SLM additive manufacturing (AM) of AISI 316L stainless steel and CoCr powder. Equivalent stress‐elongation curves are obtained, with equivalent strength, specific strength, stiffness modulus and specific stiffness calculated based on specimen density and sample cross‐section. The obtained results highlight the fact that analogous structures can behave very differently depending on the cho‐ sen material. While large differences are obtained in strength and stiffness between the different unit cell types, specific strength and spe‐ 41 cific stiffness vary to a lesser extent. Two case studies are presented, including a porous structure suitable for bone implants in the field of biomedical engineering and an AISI 316L food packaging machine component. The results obtained in this study provide useful guidelines and equivalent properties for designers wishing to exploit the advantages of internal lattice structures in AM.

Multi‐Task Scheduling Based on QoS Evaluation in Cloud Manufacturing System Technical Publication. MSEC2017‐2839 Feng Li, Lin Zhang, Yuanjun Laili, Beihang University, Beijing, China Cloud manufacturing (CMfg) mode provides an effective means to intensely utilize distributed resources and manufacturing capability for personalized production. Increasing personalized customization implies more and more heterogeneous tasks and hence more sorts of re‐ quirements for services. As the granularity of tasks vary with changing users and products, the solution (or scheme) of task scheduling should be different. In order to efficiently provide the most suitable solution for each kind of tasks, different scheduling ways should be adopted under different circumstances. In this paper, we study scheduling issues for heterogeneous tasks with variable granularity and present two kinds of optimal scheduling mode based on user‐oriented comprehensive evaluation. Then different encoding schemes relied on the genetic algorithm are proposed according to different scheduling strategies

Approaches to Implement Statistical Process Control for Manufacturing in Big Data Era Technical Publication. MSEC2017‐2840 Shing Chang, Kansas State University, Manhattan, KS, United States overdue to revamp existing statistical process control (SPC) approaches in manufacturing since Water Shewhart first proposed the use of control charts in 1924. The combination development of big data, cloud computing, and manufacturing reshoring back to Untied States has opened up the opportunities to rethink implementation strategies of SPC for manufacturing. This paper first reviews the history of SPC development in traditional manufacturing environments and then contrasts it with the opportunities presented in big data era. Five SPC implementation approaches are proposed based on the opportunities identified.

Investigation of Wear and Corrosion Characteristics of Stellite‐6 and Stellite‐21 Layers Deposited by Co‐Axial Laser Cladding Technical Publication. MSEC2017‐2841 Debapriya Patra Karmakar, GOPINATH MUVVALA, Indian Institute of Technology Kharagpur, Kharagpur, West Bengal, India, Soham Harmalkar, Ashish Kumar Nath, Indian Institute of Technology, Kharagpur, Kharagpur, West Bengal, India Layers of Stellite‐6 and Stellite‐21 were deposited on tool steel substrates using co‐axial laser cladding process with a goal to obtain hard, wear and corrosion resistant coatings. Clad‐layers of the two types of Stellite alloys were investigated and compared in terms of micro‐ structure, hardness and sliding wear resistance. Corrosion tests were also performed to study their corrosion behaviour. Micrographs indicated that both the Stellite grades form dendritic structure. However, there were certain differences in composition of dendritic and interdendritic regions of tungsten (W) containing Stellite‐6 and molybdenum containing Stellite‐21. Stellite‐6 clad‐layer was found to be slightly harder than Stellite‐21 clad‐layer near the top surface. Wear resistance of Stellite‐21found to be marginally higher than that of Stel‐ lite‐6 due to lower coefficient of friction. However, Stellite‐21layer was found to be more corrosion resistant. Hence, for application involv‐ ing mechanical loading and wear, both Stellite‐6 and Stellite‐21 could be a good choice as a clad‐material on engineering components; but if the component is going to be subjected to mechanical loading and wear under corrosive environment Stellit‐21 could be a better choice.

Fundamental Study of Fused‐Coating Based Metal Additive Manufacturing Technical Publication. MSEC2017‐2843 Xuewei Fang, Jun Du, Xi’an Jiaotong University, Xi’an, China, Zhengying Wei, Xi’an Jiaotong Univeristy, Xi’an, China, Xin Wang, Pengfei He, Hao Bai, Bowen Wang, Bingheng Lu, Xi’an Jiaotong University, Xi’an, China Fused‐coating based metal additive manufacturing (FCAM) is a newly established direct metal forming process. This method is character‐ ized by deposition metal materials in a crucible and under the driving pressure the molten metal is extruded out from a special designed nozzle. Hence, dense metal parts with different kind of materials can be built on the moving substrate layer by layer. It provides a method to fabricate metal components with lower costs, clean and cheap materials compared with other AM processes. To study the feasibility of this new AM methodology, an experimental system with a molten metal stream generator, a fused‐coating nozzle, a process monitor unit, an inert atmosphere protection unit and a temperature measurement unit has been established. In order to determine the proper param‐ 42 eters in the building process, a metal fused‐coating heat transfer model analysis and experimental study is performed by using Sn63‐37Pb alloy in building three‐dimensional components. The process parameters that may affect fabrication are molten and substrate tempera‐ ture, layer thickness, the substrate‐speed, the temperature of substrate, the distance between the nozzle and substrate and the pressure. Microscopy images were used to investigate the metallurgical bonding between layers. The influence of different parameters on the layer thickness and width was studied quantitatively. At last, the optimal parameter was used to fabricate complex metal parts to demonstrate the feasibility of this new technology compared with other AM methods.

Ultrasonic Nano‐Crystal Surface Modification Assisted Gas Nitriding of Ti6Al4V Alloy Technical Publication. MSEC2017‐2847 Jun Liu, University of Akron, AKRON, OH, United States, Zhencheng Ren, Chi Ma, The University of Akron, Akron, OH, United States, Yalin Dong, Chang Ye, University of Akron, AKRON, OH, United States The effects of Ultrasonic Nanocrystal Surface Modification (UNSM) on the gas nitriding of Ti6Al4V alloy has been investigated. The gas ni‐ triding was performed at 700 and 800 °C. The microstructure after UNSM and gas nitriding was characterized using X‐ray diffraction and scanning electron microscopy. Microstructural investigations revealed the formation of an approximately 10 um thick severe plastic defor‐ mation (SPD) layer after UNSM treatment. After nitriding at 700 °C and 800 °C, a compound layer consisting of an approximately 0.2 um and 1.9 um thick nitride layer was observed in UNSM‐treated Ti6Al4V alloy, which exhibits a nearly two‐fold increase in nitride layer thick‐ ness as compared with the un‐treated sample. This suggests that the nitrogen adsorption and the reaction capability are enhanced in the UNSM‐treated Ti6Al4V alloy. This enhancement can be attributed to the high density dislocations and grain boundaries introduced by UNSM that serve as efficient diffusivity channels for interstitial gaseous atoms.

Asymmetric Flexure Hinge for Compliant Vibrational Tissue Cutting Technical Publication. MSEC2017‐2850 Justin Jones, The Pennsylvania State University, university Park, PA, United States, Yuan‐Shin Lee, NC State University, Ra‐ leigh, NC, United States, Jason Moore, The Pennsylvania State Univ, University Park, PA, United States The purpose of this work is to investigate a novel flexure hinge mechanism. This hinge will be coupled with ultrasonic axial vibration that will induce translational displacement. This translational motion will aid in needle cutting. The finite element method, FEM, is used to eval‐ uate several flexural hinge designs to develop an empirical equation for the compliance in the x, y and ? directions. In order for the axially applied ultrasonic vibration to create appreciable translational motion, an asymmetric monolithic right circle flexure hinge design was ex‐ plored. The ratio of thickness, length, and distance between the hinges were iterated while end loads were applied to derive the compli‐ ance equations. The empirical models are presented for each design study. It is shown that the rotational stiffness dominates the stiffness matrix. It is shown that for a range of 0.05?d/D?0.2 the hinge can be modeled as a lumped element. Outside of this range the stiffness of the beam dominates and a piecewise function should be used. Further, it is also shown that the rotational stiffness changes nearly linearly with the change in length and the thickness of the hinge.

A Methodology for Quantifying Cell Density and Distribution in Multidimensional Bioprinted Gelatin‐Alginate Constructs Technical Publication. MSEC2017‐2853 Houzhu Ding, Stevens Institute of Technology, Jersey City, NJ, United States, Enyan Dai, Filippos Tourlomousis, Robert Chang, Stevens Institute of Technology, Hoboken, NJ, United States Bioprinted tissue constructs are enabled by microextrusion‐based co‐printing of cells and hydrogel materials. In this paper, a gela‐ ‐alginate hydrogel material formulation is implemented as the bio‐ink towards a 3D cell‐laden tissue construct. However, of fundamental importance during the printing process is the interplay between the various parameters that yield the final cell distribution and cell density at different dimensional scales. To investigate these effects, this study advances a multidimensional analytical framework to determine the spatial variations and temporal evolution of cell distribution and cell density within a bioprinted cell‐laden construct. In the one dimension‐ al (1D) analysis, the cell distribution and cross‐sectional shape for a single printed fiber are observed to be dependent on the process tem‐ perature and material concentration parameters. This is illustrated by the reliable fabrication and image line profile analysis of the fiber prints. Round fiber prints with a measured width of 809.552.3m maintain dispersive cells with a degree of dispersion (at 96.8 % that can be achieved at high relative material viscosities under low temperature conditions (21 °C) or high material concentrations (10 % w/v gelatin). On the other hand, flat fiber prints with a measured width of 63.6 m coalesce cells towards the fiber midline with that can be fabricated 43 at low relative material viscosities under high temperature (24 °C) or low material concentrations (7.5 % w/v gelatin). In the 2D analysis, a printed grid structure yields differential cell distribution whereby differences in localized cell densities are observed between the strut and cross regions within the printed structure. At low relative viscosities, cells aggregate at the cross regions where two overlapping filaments fuse together, yielding a cell density ratio of 2.060.44 between the cross region and strut region. However, at high relative viscosities, the cell density ratio decreases to 0.960.03. In the 3D analysis, the cell density attributed to the different layers is studied as a function of printing time elapsed from the initial bio‐ink formulation. Due to identifiable gravity and extrusion process‐induced effects, the cell distri‐ bution within the original bio‐ink cartridge or material reservoir is altered over time to yield initial quantitative increases in the cell density over the first several printed layers, followed by quantitative decreases in the subsequent printed layers. Finally, in the time‐dependent analysis, the evolution of cell density and the emergence of material degradation effects is studied over a time course study. Variable initial cell densities (0.6 x 106 cells/ml, 1.0 x 106 cells/ml, and acellular control group) printed and cross‐linked into cell‐laden constructs for the 48 hr time course study exhibit a time‐dependent increase in cell density owing to proliferation within the constructs that are presumed to accelerate the degradation rate.

Gantry Scheduling for Two‐Machine One‐Buffer Composite Work Cell by Reinforcement Learning Technical Publication. MSEC2017‐2854 Jorge Arinez, GM Global Research and Development, Detroit, MI, United States, Xinyan Ou, Stony Brook University, Stony Brook, NY, United States, Qing Chang, Stony Brook University, Melville, NY, United States In this paper, a manufacturing work cell with a gantry that is in charge of moving materials/parts between machines and buffers is consid‐ ered. With the effect of the gantry movement, the system performance becomes quite different from traditional serial production lines. In this paper, reinforcement learning is used to develop a gantry scheduling policy in order to improve system production. The gantry learns to take proper actions under different situations to reduce system production loss by using Q‐Learning algorithm and finds the optimal moving policy. A two‐machine one‐buffer work cell with a gantry is used for case study, by which reinforcement learning is applied. Com‐ pare with the FCFS policy, the fidelity and effectiveness of the reinforcement learning method are also demonstrated.

Co‐Simulation Research of the Balancing Control of the Moving Beam of a Heavy Hydraulic Press During the Die Forging Process Technical Publication. MSEC2017‐2856 Wenzhu Wang, Tsinghua University, Beijing, China, Dong Du, Tsinghua University, Beijing, Beijing, China, Rendong Wu, Chaolong Yuan, Tsinghua University, Beijing, Select State/Province, China, Baohua Chang, Tsinghua University, Beijing, Bei‐ jing, China A virtual prototype of the moving beam balancing system of a heavy‐duty hydraulic press working under die forging function is built with Adams, AMESim and Simulink, and the balancing control process is analyzed using this prototype. The moving beam of the heavy‐duty hy‐ draulic press may tilt due to the eccentric load during the die forging processing, and thus affect the forging quality and the safety of the press. So it is necessary to research the beam balancing control process. Compared to the traditional methods based on simplified mathe‐ matical models, virtual prototype technology can obtain a more accurate simulation model, i.e., a co‐simulation model, avoid tedious for‐ mula derivation and solving work, and save test time and cost. Based on the analysis of the working principle of balancing system, this pa‐ per establishes a dynamical model of the moving beam, a hydraulic circuit model of the single balancing system and a controller model using Adams, AMESim and Simulink, respectively. Then a virtual prototype is built using the three models via co‐simulation interface files. The eccentric load signal is constructed in AMESim according to the variation of eccentric load during die forging process. By adjusting the controller parameters, the rapid balancing of the moving beam under eccentric load conditions is realized, and high precision of dynamic balancing and steady equilibrium is obtained. The simulation results show that the single balancing unit can achieve effective balancing of the moving beam, and he co‐simulation analysis method based on the virtual prototype built with Adams, AMESim and Simulink is feasible in the research of the synchronous rectification of the moving beam. This work is a useful exploration in the research of synchronous recti‐ fication of moving beams.

Augmented Reality Solutions in Mechanical Engineering Technical Publication. MSEC2017‐2858 Philipp Klimant, Christian Kollatsch, Marco Schumann, Technische Universität Chemnitz, Chemnitz, Germany 44

Augmented reality is currently riding a wave of success in the consumer sector. In manufacturing, in spite of the global hype surrounding Industry 4.0 and the ever growing demand for more personalized and more complex products, there are currently only a handful of viable augmented reality applications that have actually made their way onto the production line. But why is this, and what applications genuinely bring added value? These are the questions that will be considered in this paper, presenting four examples of augmented reality concepts that have made their way from research into manufacturing. The augmented reality examples range from process support on a machine and support for a process chain, to use in education and training and even marketing applications.

Thermal Load Determination in Dry Machining Through a Fixed Identifiability Conjugate Gradient Method Technical Publication. MSEC2017‐2860 Patric Figueiredo, Marc Deppermann, Institut of Heat and Mass Transfer, RWTH Aachen University, Aachen, Germany, Rein‐ hold Kneer, RWTH Aachen University, Aachen, Germany A Fixed Identifiability Conjugate Gradient Method (FIX‐CGM) was proposed and used to solve an inverse heat conduction problem for re‐ covering a transient boundary heat flux. The algorithm converged faster and with better accuracy than the standard CGM found in litera‐ ture. The algorithm succeeded in recovering the heat flux for a linear problem where the condition of maximum identifiability of the un‐ known parameters on the measurement site was known. Further, performance analysis is required to verify its suitability for non‐linear problems. The sensitivity of the FIX‐CGM to noisy measurement data was analysed for a test case. The FIX‐CGM computed an inverse solu‐ tion which resembles the exact solution quantitatively and qualitatively. The present algorithm can be used in further work to estimate the heat flux arising in machining outgoing from infrared measurement performed in experimental conditions.

Rotary Ultrasonic Machining: Effects of Tool End Angle on Delamination of CFRP Drilling Technical Publication. MSEC2017‐2863 Palamandadige Fernando, Kansas State University, Manhattan, KS, United States, Meng Zhang, Kansas State Univ, Manhat‐ tan, KS, United States, Zhijian Pei, Texas A&M University, College Station, TX, United States, Weilong (Ben) Cong, Texas Tech University, Lubbock, TX, United States Carbon fiber reinforced plastic (CFRP) have wide‐spread engineering applications, particularly in aerospace and automotive industries due to their superior properties, such as lower density than aluminum; higher strength than high‐strength metals; higher stiffness than titanium etc. Rotary ultrasonic machining, a non‐traditional machining process for CFRP, is a hybrid machining process that combines the material removal mechanisms of diamond abrasive grinding and ultrasonic machining. Hole‐making is the most common machining operations done on CFRP, where delamination is a major issue. Delamination reduces structural integrity and increases assembly tolerance, which lead to rejection of a part or a component. Comparatively, RUM has been successfully applied to hole‐making in CFRP. As reported in the litera‐ ture, RUM is superior to twist drilling of CFRP in six aspects: cutting force, torque, surface roughness, delamination, tool life, and material removal rate. This paper investigates the effects of tool end angel on delamination in rotary ultrasonic machining of CFRP. It is found on this investigation, tool end angel has more significant influence on the delamination in RUM of CFRP comparing to cutting force and torque.

Development of Multi‐Axis Laser‐Assisted Milling Device Technical Publication. MSEC2017‐2864 Dong‐Hyeon Kim, Seoul National University, Seoul, Korea (Republic), Wan‐Sik Woo, Changwon National University, Chang‐ won, Korea (Republic), Won‐Shik Chu, Seoul National University, Seoul, Korea (Republic), Sung‐Hoon Ahn, Seoul National University, Seoul 151 744, Korea (Republic), Choon‐Man Lee, Changwon National University, Changwon, Korea (Republic) Laser‐assisted machining (LAM) process is an effective method to facilitate material removal processes for difficult‐to‐cut materials. In LAM process, the mechanical strength of various materials is reduced by a laser heat source focused in front of the cutting tool during machin‐ ing. Since the laser heat source is located ahead of the cutting tool, the workpiece is preheated by the heat source. This enables diffi‐ cult‐to‐cut materials to be machined more easily with low cutting energy, increasing the machining productivity and accuracy. It is difficult to apply laser‐assisted milling (LAMilling) to workpieces having complex shapes, because it is not easy to control laser preheating and the cutting tool path for three‐dimensionally shaped workpieces. LAMilling has only been used in limited fields such as single‐direction ma‐ chining of flat surfaces. To apply this process in the industrial field, studies on workpieces having various shapes are needed. This study aims to develop a laser‐assisted milling device having multiple axes and to investigate the machining characteristics of several diffi‐ cult‐to‐cut materials.

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Measuring the Complexity of Additive Manufacturing Supply Chains Technical Publication. MSEC2017‐2871 Ardeshir Raihanian Mashhadi, Sara Behdad, University At Buffalo, State University of New York, Amherst, NY, United States Complexity has been one of the focal points of attention in the supply chain management domain, as it deteriorates the performance of the supply chain and makes controlling it problematic. The complexity of supply chains has been significantly increased over the past couple of decades. Meanwhile, Additive Manufacturing (AM) not only revolutionizes the way that the products are made, but also brings a paradigm shift to the whole production system. The influence of AM extends to product design and supply chain as well. The unique capa‐ bilities of AM suggest that this manufacturing method can significantly affect the supply chain complexity. More product complexity and demand heterogeneity, faster production cycles, higher levels of automation and shorter supply paths are among the features of additive manufacturing that can directly influence the supply chain complexity. Comparison of additive manufacturing supply chain complexity to its traditional counterpart requires a profound comprehension of the transformative effects of AM on the supply chain. This paper first ex‐ tracts the possible effects of AM on the supply chain and then tries to connect these effects to the drivers of complexity under three main categories of 1) market, 2) manufacturing technology, and 3) supply, planning and infrastructure. Possible impacts of additive manufactur‐ ing adoption on the supply chain complexity have been studied using information theoretic measures. An Agent‐based Simulation (ABS) model has been developed to study and compare two different supply chain configurations. The findings of this study suggest that the adoption of AM can decrease the supply chain complexity, particularly when product customization is considered.

Manufacturing Self‐Healing Composites with Automated Fiber Placement Oral Presentation. MSEC2017‐2872 Konstantine Fetfatsidis, Aurora Flight Sciences, Cambridge, MA, United States, Christopher Hansen, Andrew Burke, Universi‐ ty of Massachusetts Lowell, Lowell, MA, United States Automated Fiber Placement (AFP) is an automated manufacturing process for composite materials, in which spooled thermoset or thermo‐ plastic matrix, fiber‐reinforced pre‐preg is transferred through a tensioning and compaction head onto a mold surface. AFP processing is expanding within aerospace and other market segments due to the benefits of precise placement, reproducibility, minimal defect count, and documentation for quality assurance purposes. Multifunctional materials systems, in which function(s) beyond the primary structural function exist, have been demonstrated in the labor‐ atory for composites structures. This multifunctionality improves the system‐level performance, and benefits aerospace and other high‐performance applications in which mass or volumetric constraints dominate. Composites which incorporate synthetic vasculature enable self‐healing or thermal regulation of structures, thereby increasing confidence in their structural integrity, extending their service life, and opening new operational envelopes such as hypersonic transport. To date, however, these demonstrations have yet to extend beyond the laboratory‐scale and their integration into existing industrial processing routes remains an unresolved issue. In this presentation, the integration of self‐healing materials within existing AFP manufacturing processes will be discussed. Two primary approaches for AFP manufacturing of composites with vascular features will be presented and their relative benefits discussed. One ap‐ proach is to integrate vascular pathways with the spooled unidirectional pre‐preg; this pre‐preg/vascular material system is subsequently transferred through the AFP deposition head. The impact of active transfer by restart rollers and compaction onto the mold surface on the vascular network quality will be shown. The second approach is to transfer vascular designs onto the surface of composite structures man‐ ufactured by AFP; in this scheme, the vascular features do not enter the AFP head. Considerations of the vascular feature deposition and the machine parameters ? such as pressure and offset distances ? will be discussed.

Numerical Modeling of Grain Growth in Laser Engineered Net Shaping (LENS) of AISI 316 Stainless Steel Technical Publication. MSEC2017‐2873 Wenda Tan, Xuxiao LI, University of Utah, Salt Lake City, UT, United States A multi‐scale modeling framework is developed in this work to simulate the transport phenomena and grain growth in Laser Engineered Net Shaping process of austenitic stainless steel AISI 316. A three‐dimensional (3D) model is included to simulate the transient molten pool geometry and heat/mass transfer on a macro‐scale; and a 3D meso‐scale model based on the Cellular Automata method is included to predict the grain growth during molten pool solidification. The predicted grain structure is found to be qualitatively consistent with the experimental results and reveals that the grain structure is highly dependent on the molten pool geometry. 46

Hypothetical Sustainability Axioms for Axiomatic Design With an Application in Grinding Machine Design Technical Publication. MSEC2017‐2874 Ian Garretson, UC Davis, Davis, CA, United States, Bernd Peukert, Technische Universität Berlin, Berlin, Germany, Barbara S. Linke, University of California Davis, Davis, CA, United States, Eckart Uhlmann, Technische Universität Berlin, Berlin, Germany The design of a high precision machine tool presents one main goal for an engineer: to maximize productivity while minimizing resource inputs and wasted outputs. Incorporating additional design requirements to improve the sustainability of the machine tool presents chal‐ lenges to design engineers. Should productivity be sacrificed for resource efficiency improvements? Previous tools used for incorporating sustainability principles into design provide guidance but lack necessary detail for making informed decisions, or the tools rely on the engi‐ neer?s previously developed knowledge in sustainable design. Axiomatic design, being an already accepted system design framework, pro‐ vides an opportunity to incorporate sustainability considerations into the core of design activities rather than having sustainability be a side activity. A methodology for designing sustainable machine tools using axiomatic design is presented, and a case study on a grinding ma‐ chine is investigated. A list of hypothetical sustainability axioms are proposed, similar to how the original axioms of axiomatic design were proposed. The axioms are then discussed using the example of a grinding machine

Procedure for Selecting Key Performance Indicators for Sustainable Manufacturing Technical Publication. MSEC2017‐2877 Shaw C Feng, NIST, Gaithersburg, MD, United States, Deogratias Kibira, Morgan State University, Baltimore, MD, United States, Michael P. Brundage, National Institute of Standards and Technology (NIST), Gaithersburg, MD, United States, KC Morris, National Institute of Standards and Technology, Gaithersburg, MD, United States The need for an open, inclusive, and neutral procedure for developing key performance indicators (KPIs) has been increasing as manufac‐ turers seek to determine what to measure in order to improve environmental sustainability of their products and manufacturing processes. A difficulty arises in understanding and selecting specific indicators from a large number of stand‐alone indicator sets available. This paper presents a procedure for individual manufacturers to establish KPIs for measuring, monitoring and improving environmental aspects of manufacturing processes. The procedure is the basis for a guideline, being proposed for standardization within ASTM International, for identifying candidate KPIs from existing sources, defining new candidate KPIs, selecting appropriate KPIs based on KPI criteria, and com‐ posing the selected KPIs with assigned weights into a set. The paper explains how the developed procedure complements existing indicator sets and sustainability measurement approaches at the manufacturing process level.

Characterization of Machining Distortion due to Residual Stresses in Quenched Aluminum Technical Publication. MSEC2017‐2878 Destiny R. Garcia, University of California, Davis, Davis, CA, United States, Michael R. Hill, University Of California Davis, Da‐ vis, CA, United States, Jan C. Aurich, University of Kaiserslautern, Institute for Manufacturing Technology and Production Sys‐ tems, Kaiserslautern, Rhineland‐Palatinate, Germany, Barbara S. Linke, University of California Davis, Davis, CA, United States Manufacturing methods and procedures are advancing through research and development, to optimize machine tools, machining strate‐ gies, and the overall manufacturing system. In the aerospace industry, machining distortions, or the deviation of part shape from the origi‐ nal intent after being released from a fixture, occur, reducing productivity. A primary factor contributing to machining distortions are re‐ sidual stresses, i.e. internal stresses locked into the workpiece. The residual stresses are induced by prior material processing steps such as rolling, forging, heat treating, etc. ? which are needed in the aerospace industry for high strength.

Machining distortions result in economic losses due to reworking, remanufacturing, and/or rejecting components in the manufacturing and aerospace industries. Quenched 7050 T74 aluminum was used to investigate material removal with respect to milling distortions. Using material with a known residual stress profile, a prismatic u‐shape geometry was machined and distortions were characterized, quantified, and described in detail. This paper shows a method for characterizing distortion for machined parts. The results from the distorted u‐shapes indicate similar characteristics and suggest further work on understanding clamping.

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Performance Evaluation of Superhard Coatings in Drilling of Ti‐6Al‐4V Alloy Technical Publication. MSEC2017‐2879 Dinh Nguyen, Michigan State Universty, East Lansing, MI, United States, Patrick Kwon, Michigan State University, East Lan‐ sing, MI, United States, Vadim Voznyuk, Washingon State University, Vancouver, WA, United States, Dae‐wook Kim, Wash‐ ingon State Univ, Vancouver, WA, United States In the aerospace industry, titanium (Ti) alloys, especially Ti6Al4V, has been extensively used over other light weight alloys due to their high strength‐to‐weight ratio. However, the material and production costs have been major obstacles in extensively adopting Ti alloys for a wide variety of applications. Among many manufacturing processes used in aerospace manufacturing, machining Ti alloys is one of the most time‐consuming and expensive mechanical processes. Based on few successes with coated drills reported in literature, this paper makes a comparative study of drilling Ti6Al4V plates with several super hard coated drills with the coatings of Diamond‐like‐Carbon (DLC), AlMgB14 (BAM) and nanocomposite AlCrSiN and compared the results with uncoated carbide drills. Working with a coating supplier, sever‐ al variations of BAM coating have been applied and used in our drilling experiments. To evaluate the performance of these drills, the scanning electron microscopy and confocal laser microscopy were used to assess the wear progress of each drill qualitatively and quantita‐ tively. In drilling Ti alloys, the main wear mechanisms of flank wear are abrasion, microscopic fracture (chipping) and attrition when the adhesion layer detached at the cutting edge. For all the drills, the predominant wear occurs near to the margin. Through our drilling ex‐ periments, BAM and AlCrSiN drills have survived up to 58 holes and over 60 holes, respectively, while both uncoated and DLC drills were experienced with catastrophic fracture at less than 40 holes.

A New Reinforcement Learning Algorithm With Fixed Exploration for Semi‐Markov Control in Preventive Maintenance Technical Publication. MSEC2017‐2880 Angelo Encapera, Abhijit Gosavi, Missouri University of Science and Technology, Rolla, MO, United States Artificial intelligence techniques can play a significant role in solving problems encountered in the domain of Total Productive Maintenance (TPM). This paper considers a new reinforcement learning algorithm called i‐SMART, which can solve semi‐Markov decision processes un‐ derlying control problems related to TPM. The algorithm uses a constant exploration rate, unlike its precursor R‐SMART, which requires exploration decay. Numerical experiments conducted here show encouraging behavior with the new algorithm.

Understanding Plastic Deformation Mechanism(s) in Recrystallized Zircaloy‐4 Technical Publication. MSEC2017‐2882 Nilesh Kumar, Abdullah Alomari, K. L. Murty, North Carolina State University, Raleigh, NC, United States It is essential to understand basic deformation mechanism(s) of conventional alloys in order to develop improved or novel alloys for their applications in much more challenging conditions. Zircaloy‐4 is extensively used in pressurized water reactor for nuclear fuel cladding ap‐ plication. It operates at very high temperature in the presence of mechanical loads, corrosive atmosphere, and neutron irradiation envi‐ ronment. Present work explores the fundamental plastic deformation mechanism(s) of Zircaloy‐4 in the temperature range 25 to 600 °C by subjecting tensile samples to uniaxial tensile loads under quasi‐static deformation conditions. Based on the results of uniaxial tensile testing as a function of temperature, repeated stress‐relaxation experiments were carried out to determine the activation volume of the alloy at 25 and 500 °C. The results from uniaxial tensile and stress‐relaxation testing were used to insight into potential deformation mecha‐ nism(s) in Zircaloy‐4.

Experimental Evaluation of Cutting Kinematics and Chip Evacuation in Drilling With Low‐Frequency Modulation‐Assisted Machining Technical Publication. MSEC2017‐2886 Yang Guo, Michigan State University, East Lansing, MI, United States, James Mann, M4 Sciences LLC, West Lafayette, IN, United States Modulation assisted machining (MAM) superimposes a low‐frequency oscillation onto the cutting process. The otherwise continuous cut‐ ting is transformed into a series of discrete, intermittent cutting events. A primary benefit of this process is to form discrete chips of small sizes and hence to improve chip evacuation. For applications in drilling the ability to control the chip size offers a direct route to improving process efficiency and stability. In this paper, the MAM process is evaluated for drilling applications via systematic experiments in drilling

48 copper and Ti6Al4V with a two‐flute twist drill and a single‐flute gun drill. Based on the measurement of thrust force and examination of chip morphology, the continuous cutting and intermittent cutting regimes of MAM are determined experimentally in the normalized fre‐ quency and amplitude parameter space. The results are compared with those predicted by the kinematic model of MAM. Furthermore, the results clearly demonstrate the effect of chip morphology control on chip evacuation and process stability in drilling. The modulation condi‐ tions leading to the best performance in chip evacuation are discussed. The study shows that MAM is a promising process for enhancing the efficiency and stability in drilling difficult‐to‐cut materials and/or holes with high length‐to‐diameter ratio..

In‐Situ Observations and Pressure Measurements for Autoclave Co‐Cure of Honeycomb Core Sandwich Structures Technical Publication. MSEC2017‐2887 Mark Anders, Daniel Zebrine, Timotei Centea, Steven Nutt, University of Southern California, Los Angeles, CA, United States In this paper we describe an experimental method for investigating the autoclave co‐cure of honeycomb core composite sandwich struc‐ tures. The design and capabilities of a custom‐built, lab‐scale ?in situ co‐cure fixture? are presented, including procedures and representa‐ tive results for three types of experiments. The first type of experiment involves measuring changes in gas pressure on either side of a pre‐ preg laminate to determine the prepreg air permeability. The second type involves co‐curing composite samples using regulated, constant pressures, to study material behaviors in controlled conditions. For the final type, ?realistic? co‐cure, samples are processed in conditions mimicking autoclave cure, where the gas pressure in the honeycomb core evolves naturally due to the competing effects of air evacuation and moisture desorption from the core cell walls. The in situ co‐cure fixture contains temperature and pressure sensors, and derives its name from a glass window that enables direct in situ visual observation of the skin/core bond‐line during processing, shedding light on physical phenomena that are not observable in a traditional manufacturing setting. The experiments presented here are a first step within a larger research effort, whose ultimate goal is to develop a physics‐based process model for autoclave co‐cure.

Using Standards in a Competition to Measure and Solve Industrial Robotics Agility Challenges Technical Publication. MSEC2017‐2888 Anthony Downs, William Harrison, National Institute of Standards and Technology, Gaithersburg, MD, United States, Craig Schlenoff, NIST, Gaithersburg, MD, United States Researchers at the National Institute of Standards and Technology (NIST) have developed a set of draft standard test methods for measur‐ ing and promoting software agility in industrial robots. These test methods are being used as the basis for an upcoming competition called Agile Robotics for Industrial Applications Competition (ARIAC). ARIAC is being used to promote and push forward the state of the art in software agility and enable technology transfer between academia and industry. This paper describes the background about the test methods, how they were developed, how they will be applied to the ARAIC Competition, and additional information about the ARIAC Competition

Business Process Model Life‐Cycle Management in Cloud Manufacturing Technical Publication. MSEC2017‐2889 Miroslav Ljubicic, National Institute of Standards and Technologies, Gaithersburg, MD, United States, Nenad Ivezic, National Institute of Standards and Technology (NIST), Gaithersburg, MD, United States, Boonserm Kulvatunyou, National Institute of Standards and Technology, Gaithersburg, MD, United States, Scott Nieman, Land O’Lakes, Shoreview, MN, United States, Nenad Anicic, Zoran Marjanovic, University of Belgrade, Belgrade, Serbia To facilitate the vision of service‐oriented manufacturing, Cloud Manufacturing (CMfg) will need to support business process model life‐cycle management. In this paper, we propose the Business Process Cataloging and Classification System (BPCCS) to support that role. BPCCS can facilitate adaptation of business process models. We validate life‐cycle management requirements for such a system and pro‐ pose capabilities the system must have to address these requirements. We analyze related work in academia and industry as a basis for synthesizing a meta‐model and a conceptual architecture for the system. We conclude that contextual information for business process models is a critical part of such a system and where the CMfg community can contribute new and valuable results.

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Variable Damping Profiles for Laser Shock Simulation Using Modal Analysis and the SEATD Method Technical Publication. MSEC2017‐2891 Mohammad Hatamleh, The University of Texas at Dallas, Richardson, TX, United States, Jagannathan Shankar Mahadevan, The University of Texas at Dallas, Dallas, TX, United States, Arif Malik, University of Texas at Dallas, Richardson, TX, United States, Dong Qian, University of Texas At Dallas, Dallas, TX, United States Laser shock peening (LSP) is a surface engineering technique, which aims to increase the fatigue life of various metallic components by in‐ ducing compressive residual stress at or near their surface. The finite element method (FEM) is used to identify the most suitable parame‐ ters in LSP. Various explicit analyses with artificial material damping are used to attain quasi‐static equilibrium between laser shots. Dy‐ namic relaxation (DR) is a well‐known conventional technique that uses constant artificial damping to settle an excited model to qua‐ si‐static equilibrium. In contrast, the recently developed ?Single Explicit Analysis using Time‐Dependent Damping? (SEATD) method employs variable damping and performs better in terms of simulation time and accuracy. While recent study has shown that a variable damping profile used in the SEATD technique is beneficial for an LSP set up, identifying the most suitable variable damping profile in general is still ambiguous, given the variety of possible set‐ups and boundary conditions. In this paper, a systematic procedure to strive for the best varia‐ ble damping profile is developed, based on the excited modal parameters of the model. The simulation results are compared with those of an optimum constant damping profile developed using the conventional dynamic relaxation technique, as well as for the best variable damping profile based on exhaustive trial‐and‐error. The simulation case studies involve circular LSP shot(s) of 5.5 mm diameter spot size applied to Al 2024‐T351 aluminum alloy plate under different boundary conditions. Dissipation rates of stain energy, kinetic energy, and total energy and the accuracy of surface residual stresses are investigated to compare the performance of different damping profiles. The results indicate that the proposed method involving modal analysis to systematically identify a variable damping profile, to promote simu‐ lation efficiency, appears to work well.

Accelerated Geometry Accuracy Optimization of Additive Manufacturing Parts Technical Publication. MSEC2017‐2892 Amir M. Aboutaleb, Linkan Bian, Mississippi State University, starkville, MS, United States, Prahalad Rao, University of Ne‐ braska‐Lincoln, Lincoln, NE, United States, Mark Tschopp, U.S, Army Research Laboratory, Aberdeen Proving Ground, MD, United States Despite recent advances in improving mechanical properties of parts fabricated by Additive Manufacturing (AM) systems, optimizing ge‐ ometry accuracy of AM parts is still a major challenge for pushing this cutting‐edge technology into the mainstream. This work proposes a novel approach for improving geometry accuracy of AM parts in a systematic and efficient manner. Initial experimental data show that different geometric features of part are not necessary positively correlated. Hence, it may not be possible to optimize them simultaneously. The proposed methodology formulates the geometry accuracy optimization problem as a multi‐objective optimization problem. The de‐ veloped method targeted minimizing deviations within part?s major Geometric Dimensioning and Tolerancing (GD&T) features (i.e. Flat‐ ness, Circularity, Cylindricity, Concentricity and Thickness). First, Principle Component Analysis (PCA) is applied to extract key components within multi‐geometric features of parts. Then, experiments are sequentially designed in an accelerated and integrated framework to achieve sets of process parameters resulting in acceptable level of deviations within principle components of multi‐geometric features of parts. The efficiency of proposed method is validated using simulation studies coupled with a real world case study for geometry accuracy optimization of parts fabricated by Fused Filament Fabrication (FFF) system. The results show that optimal designs are achieved by fewer numbers of experiments compared with existing methods.

Deposition of Bead Arrays With Variable Diameter by Self‐Focusing of Electrohydrodynamic Jets Technical Publication. MSEC2017‐2893 Nicolas Martinez‐Prieto, Gabriela Fratta, Northwestern University, Evanston, IL, United States, Jian Cao, Kornel Ehmann, Northwestern Univ, Evanston, IL, United States Electrohydrodynamic processes were used for direct‐writing of bead arrays with controllable bead sizes. Experiments were conducted to align layers of bead‐on‐string structures in an effort to create three‐dimensional patterns. The results show that the jet focuses on previ‐ ously deposited droplets allowing for the selective deposition of material over already deposited patterns. Jet attraction to already depos‐ ited solutions on the substrate is attributed to the charge transport at the liquid ink‐metal collector interface and the dielectric properties of the water/poly(ethylene oxide) solution under an electric field. The deposition process consists of 3 steps: (1) deposition of a layer of bead‐on‐string structures, (2) addition of extra volume to the beads by subsequent passes of the jet, and (3) evaporation of the solvent 50 resulting in an array of beads with varying sizes. Patterns with up to 20 passes were experimentally obtained. The beads? height was seen to be independent of the number of passes. The process reported is a simple, fast, and low‐cost method for deposition of bead arrays with varying diameters.

Ultrasonic Pelleting and Synchronized Torrefaction of Cellulosic Biomass for Bioenergy Production Technical Publication. MSEC2017‐2894 Yang Yang, Nicholas Eisenbarth, Xiaoxu Song, Kansas State University, Manhattan, KS, United States, Meng Zhang, Kansas State Univ, Manhattan, KS, United States, Donghai Wang, Kansas State University, Manhattan, KS, United States The U.S. is sustainably producing of over 1 billion dry tons of biomass annually. This amount of biomass is sufficient to produce bioenergy that can replace about 30% of the nation?s current annual consumption of conventional fossil fuels. This then gives us the opportunity to turn waste into bioenergy that can assist in meeting the U.S. Renewable Fuel Standard (RFS). Besides being converted into bioethanol through the biochemical platform, biomass can also be utilized solid fuels to generate bioenergy through the thermochemical platform. Co‐firing power plants use torrefied biomass pellets combined with coal for electricity generation. A two‐step process, torrefaction fol‐ lowed by pelleting, is the prevailing technique that the industry is currently using to produce torrefied biomass pellets. Torrefaction con‐ verts biomass into biochar with high heating value, and pelleting densifies torrefied biochar into pellets with high durability and density. For the same purpose, we developed the ultrasonic pelleting and synchronized torrefaction of cellulosic biomass process, which is a single‐step process to generate high quality solid fuel pellets with high heating value together with good durability and density. This study reports the first experimental investigation to demonstrate the feasibility of the novel process. Key process parameters have been identified, and their effects on the feasibility of generating quality torrefied biomass pellets are reported. Pellets are evaluated from the aspects of density, durability, heating value, and thermal stability.

Boundary Control on Embedded Heaters for Composite Joining Technical Publication. MSEC2017‐2895 Brandon Smith, University of Washington, Seattle, WA, United States, Mahdi Ashrafi, U. of Washington, Seattle, WA, United States, Mark Tuttle, Santosh Devasia, Univ Of Washington, Seattle, WA, United States This paper demonstrates the use of boundary control on embedded resistive heaters with the purpose of precision temperature control for curing high strength adhesives when joining composite adherends. This is particularly useful in the presence of heatsinks, where a uniform heating technique will lead to temperature variations in the bondline. The major contribution of this work is to reduce such temperature variations by using boundary control on the embedded heater. This technique is demonstrated experimentally for bonding a single‐lap joint, and the temperature variation in the bond area was reduced from 20.3% to 2.7%.

Smart Production Line: Common Factors and Data‐Driven Implementation Method Technical Publication. MSEC2017‐2896 Yongping Zhang, Ying Cheng, School of Automation Science and Electrical Engineering, Beihang University, Beijing, China, Fei Tao, School of Automation Science and Electrical Engineering, BeihangUniversity, Beijing, Beijing, China Smart factory and smart production are the common aims for many countries’ manufacturing development strategies, which have attract‐ ed attentions from both academia and industry. Smart production line, which is a basic unit for implementing smart factory and smart production, is emphasized in this paper. The evolution process of production line is summarized first. Then the common factors for smart production line are investigated. Accordingly, a data‐driven method for realizing smart production line is proposed. At the same time, the corresponding applications and attainable goals are given. Finally, a case for data‐driven energy emulation and analysis in production line is illustrated.

Bingham Fluid‐Assisted Fabrication of 3D Vascular‐Like Constructs of Interpenetrating Network Hydrogel Technical Publication. MSEC2017‐2898 Srikumar Krishnamoorthy, Mengyun Zhang, Hongtao Song, Changxue Xu, Texas Tech University, Lubbock, TX, United States Organ printing, which utilizes advanced manufacturing technologies to fabricate 3D functional organs based on layer‐by‐layer mechanism, is emerging as a promising solution to solve the organ donor shortage problem affecting all over the world. One of the biggest challenges for fabrication of functional and effective thick tissues/organs is the engineering of vascular networks. This paper introduces a Bingham

51 fluid (Carbopol gel) to assist fabrication of 3D vascular‐like constructs of interpenetrating network (IPN) hydrogels. Carbopol gel as a Bing‐ ham fluid exhibits a characteristic yield stress behavior. As the nozzle moves inside Carbopol, the shear stress is larger than the yield stress and the Carbopol gel behaves like a viscous fluid with a specific viscosity. After the nozzle moves away, the shear stress decreases below the yield stress and the Carbopol gel rapidly solidifies behaving like a solid. This unique rheological property is utilized to support and maintain the shape of the fabricated 3D structures, although the fluid printed is not crosslinked. Finally, the fabricated structures are sub‐ ject to a two‐step gelation process to successfully form 3D vascular‐like constructs of IPN hydrogels. This novel approach enables effective and efficient fabrication of complex vascular network of IPN hydrogels.

Powder‐Based Additive Manufacturing of Li‐Ion Batteries and Micropowder Mixing Characteristics Technical Publication. MSEC2017‐2900 Brandon Ludwig, Missouri University of Science and Technology, Rolla, MO, United States, Jin Liu, Zhangfeng Zheng, Yan Wang, Worcester Polytech Institute, Worcester, MA, United States, Heng Pan, Missouri University of Science and Technology, Rolla, MO, United States Lithium ion battery electrodes were manufactured using a new additive manufacturing process based on dry powders. By using dry powder based process, solvent and drying process used in conventional battery process can be removed which allows large‐scale Li‐ion battery production be more economically viable in markets such as automotive energy storage systems. Thermal activation time has been greatly reduced due to the time and resource demanding solvent evaporation process needed with slurry‐cast electrode manufacturing being re‐ placed by a hot rolling process. It has been found that thermal activation time to induce mechanical bonding of the thermoplastic polymer to the remaining active electrode particles is only a few seconds. By measuring the surface energies of various powders and numerical sim‐ ulation of powder mixing, the powder mixing and binder distribution, which plays a vital role in determining the quality of additive manu‐ factured battery electrodes, have been predicted and compared favorably with experiments.

Research on Data Generation Method in Cloud Manufacturing Simulation Platform Technical Publication. MSEC2017‐2904 Lin Zhang, Chun Zhao, Beihang University, Beijing, China Cloud manufacturing simulation platform is used to simulate the collaboration and evolution, which among the resources, services, tasks, participants in cloud manufacturing environment. As an important part of the platform of simulation, simulation data generation method can effectively support the simulation accuracy. Data in cloud manufacturing environment are not completely random, and are closely re‐ lated to the actual environment and resource characteristics. The workload of traditional random generate method or artificial method is very heavy and cannot completely rebuild the simulation environment. In this paper, using clustering method to extract characteristics from an actual environment, and then extend the characteristics to generate new simulation data. To build a similar environment to the real environment used in the simulation. The result is shown that compared with the method to generate random data. This method can generate the reference data similar environment, the simulation can reflect the real effect in the process.

Discrete Element Simulation of the Stress Wave in High Speed Milling Technical Publication. MSEC2017‐2906 Yifei Jiang, Jun Zhang, Yong He, Hongguang Liu, Afaque R. Memon, Wanhua Zhao, Xi’an Jiaotong University, Xi’an, China As cutting tool penetrates into workpiece, stress waves are induced and propagate in the workpiece. This paper aims to propose a two‐dimensional discrete element method to analyze the stress waves effects during high speed milling. The dependence of the stress waves propagation characteristics on rake angle and cutting speed was studied. The simulation results show that the energy distribution of stress waves is more concentrated near the tool tip as the rake angle or the cutting speed increases. In addition, the density of initial cracks in the workpiece near the cutting tool increases when the cutting speed is higher. The high speed milling experiments indicate that the chip size decreases as the cutting speed increases, which is just qualitatively consistent with the simulation.

Simulation Optimization for Computer Models With Multivariate Output Technical Publication. MSEC2017‐2907 Raed Kontar, University of Wisconsin ‐ Madison, Madison, WI, United States, Shiyu Zhou, Univ Of Wisconsin, Madison, WI, 52

United States, John Horst, National Institute of Standards and Technology, Gaithersburg, MD, United States This paper explores the potential of Gaussian process based metamodels for simulation based optimization with multivariate outputs. Spe‐ cifically we focus on Multivariate Gaussian process models established through separable and non‐separable covariance structures. We discuss the advantages and drawbacks of each approach and their potential applicability in manufacturing systems. The advantageous fea‐ tures of the Multivariate Gaussian process models are then demonstrated in a case study for the optimization of manufacturing perfor‐ mance metrics.

A Methodology for Predicting Porosity From Thermal Imaging of Melt Pools in Additive Manufacturing Thin Wall Sections Technical Publication. MSEC2017‐2909 Mojtaba Khanzadeh, Sudipta Chowdhury, Linkan Bian, Mississippi State University, starkville, MS, United States, Mark Tschopp, U.S, Army Research Laboratory, Aberdeen Proving Ground, MD, United States The microstructure and mechanical properties of Laser Based Additive Manufacturing (LBAM) are often inconsistent and unreliable for many industrial applications. One of the key technical challenges is the lack of understanding of the underlying process‐structure‐property relationship. The objective of the present research is to use the melt pool thermal profile to predict porosity within the LBAM process. Herein, we propose a novel porosity prediction method based on morphological features and the temperature distribution of the top sur‐ face of the melt pool as the LBAM part is being built. Self‐organizing maps (SOM) are then used to further analyze the 2D melt pool dataset to identify similar and dissimilar melt pools. The performance of the proposed method of porosity prediction uses X‐Ray tomography char‐ acterization, which identified porosity within the Ti‐6Al‐4V thin wall specimen. The experimentally identified porosity locations were com‐ pared to the porosity locations predicted based on the melt pool analysis. Results show that the proposed method is able to predict the location of porosity almost 85% of the time when the appropriate SOM model is selected. The significance of such a methodology is that this may lead the way towards in situ monitoring and on‐the‐fly modification of melt pool thermal profile to minimize or eliminate pores within LBAM parts.

Investigation of Porosity and Mechanical Properties of Graphene Nanoplatelets Reinforced AlSi10Mg by Selective Laser Melting Technical Publication. MSEC2017‐2911 Yachao Wang, Jing Shi, University of Cincinnati, Cincinnati, OH, United States, Shiqiang Lu, Weihan Xiao, Nanchang Hang‐ kong University, Nanchang, Jiangxi, China Graphene possesses many outstanding properties, such as high strengths, light weight, making it an ideal reinforcement for metal matrix composite (MMCs). Meanwhile, fabricating MMCs through laser assisted additive manufacturing (LAAM) has attracted much attention in recent years due to the advantages of low waste, high precision, short production lead time, and high flexibility. In this study, graphene reinforced aluminum alloy AlSi10Mg is fabricated using selective laser melting. Composite powder is prepared using high‐energy ball mill‐ ing. Room temperature tensile tests are conducted to evaluate the tensile properties. Scanning electron microscopy (SEM) observations are conducted to investigate the microstructure and fracture surface of obtain composite. It is found that adding GNPs significantly increases porosity and therefore deteriorates material tensile performance. The relationship between porosity and material strength are numerically investigated. Taking into consideration the strength reduction caused by large porosity, the strengthening effect of GNPs turns out to be significant, which reaches 60.2 MPa.

On the Fatigue Performance of Nanoparticles Reinforced Iron by Selective Laser Melting Technical Publication. MSEC2017‐2913 Yachao Wang, Jing Shi, University of Cincinnati, Cincinnati, OH, United States, Shiqiang Lu, Weihan Xiao, Nanchang Hang‐ kong University, Nanchang, Jiangxi, China Selective laser melting (SLM) is an additive manufacturing process that uses laser beam to melt metal powders and allow the melt to solidi‐ fy in a layerwise way. SLM has drawn much attention from industry and academia in recent years. Improving the mechanical properties and performance of components fabricated by SLM has been a focused research area. Adding hard second phase particles into metal matrix has been proven an effective measure to strengthen metal material by SLM. In this research, we adopt nano sized TiC particles to reinforce pure iron matrix using the SLM process. The reinforced TiC/iron composite with 0.5 wt.% TiC is successfully fabricated. Tensile tests and fatigue tests are carried out to demonstrate the strengthening effect, and fatigue fracture surfaces are characterized by SEM to understand 53 the fatigue failure mechanism. The obtained experimental data are compared with an existing composite fatigue life prediction model. The results indicate that nano TiC is effective in improving the tensile performance of pure iron, where the ultimate tensile strength (UTS) and yield strength (YS) increase by 17% and 6.3% respectively. TiC nano particles improve the fatigue life principally at lower cycle fatigue re‐ gime, while the beneficial effect at high cycle fatigue regime is not significant, mainly due to the large porosity introduced in SLM process. In addition, it is discovered that traditional Ding?s model does not accurately predict the fatigue life of nano TiC/iron composite, and thus more accurate fatigue modeling work is called for.

Subsurface Microstructure and Crystallographic Texture in Surface Severe Plastic Deformation Processes Technical Publication. MSEC2017‐2915 Zhiyu Wang, Georgia Institution of Technology, Atlanta, GA, United States, Saurabh Basu, Pennsylvania State University, State College, PA, United States, Christopher Saldana, Georgia Institute of Technology, Atlanta, GA, United States Severe plastic burnishing was investigated as a promising surface severe plastic deformation technique for generating gradient microstruc‐ ture surfaces. The deformed state of oxygen free high conductivity copper workpieces during the surface deformation process was deter‐ mined with high‐speed imaging, this complemented by microstructure characterization using orientation image microscopy based on elec‐ tron backscatter diffraction. Varying deformation levels in terms of both magnitude and gradient on the processed surface were achieved through control of the incident tool angle. Refined microstructures, including laminate grains elongated in the velocity direction and equi‐ axed sub‐ micron grains were observed in the subsurface and were found to be controlled by the combined effects of strain and strain rate in the surface deformation process. Additionally, crystallographic texture evolutions were characterized, showing typical shear textures predominately along the <110>> partial fiber. The rotation of texture from original ideal orientation positions was related directly to the deformation history produced by sliding process. Based on these observations, a controllable framework for producing the processed sur‐ face with expected mechanical and microstructural responses is suggested.

Residual Stress Enhancement in 3D Printed Inconel 718 Superalloy Treated by Ultrasonic Nano‐Crystal Surface Modification Technical Publication. MSEC2017‐2918 Jing Shi, Kuldeep Sidhu, Vijay Vasudevan, Seetha Mannava, University of Cincinnati, Cincinnati, OH, United States Inconel 718 (IN718) is a nickel based Ni‐Cr‐Fe super alloy. It has a unique set of properties such as good workability, corrosion resistance, high temperature strength, favorable weldability and excellent manufacturability. Due to its wide range of applications, IN718 is an alloy of great interest for many industries. Meanwhile, additive manufacturing assisted with laser has caught much interest from researchers and practitioners in the past three decades. In this study, IN718 alloy coupons are manufactured by selective laser melting (SLM) technique. The SLMed IN718 alloys are treated by ultrasonic nanocrystal surface modification (UNSM), and the residual stress distributions underneath the surfaces are measured. It is found that residual stress mostly tensile is induced while building the part by the SLM technique. The tensile stresses can be reduced to almost zero value by post heat treatment. Moreover, the heat treatment helps to homogenize the microstruc‐ ture, and results in the increase in hardness. More importantly, it is observed that UNSM effectively induces compressive residual stresses in the as‐built and heat‐treated parts. The residual stresses of compressive nature in as built parts has depth of around 530 µm where as in heat treated parts has a depth of around 530?m.

Study of Living Cell Distribution During Inkjet Printing of Bioink Technical Publication. MSEC2017‐2921 Mengyun Zhang, Srikumar Krishnamoorthy, Hongtao Song, Changxue Xu, Texas Tech University, Lubbock, TX, United States Inkjet printing as a viable technology has been widely adapted for various biomedical applications, such as 3D biofabrication which utilizes the droplets generated from inkjet printing of bioink to build 3D viable structures. One of the key challenges is cell distribution which is cell number embedded per droplet/microsphere. It significantly affects the post‐printing cell viability and proliferation. This paper focuses on the effect of excitation voltage on the living cell distribution during drop‐on‐demand inkjet printing of bioink containing living cells. The cell distribution results are compared under two different excitation voltages of 40V and 50V. The normal distribution is used to fit the experimental results. It is found that 1) at both 40V and 50V, the mean cell number of the experimental results is always smaller than the theoretical value due to cell motion inside the nozzle; and 2) the mean cell number errors are 3% at 40V and 18% at 50V, which is due to different ligament flow near the nozzle orifice. The resulting knowledge benefits efficient and effective fabrication of 3D cellular con‐ structs with uniform cell distribution

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Studying Chip‐Breakers for Finish Turning of 1035 Carbon Steel Oral Presentation. MSEC2017‐2924 Chandra Nath, Ippei Kono, Hitachi America Ltd., Farmington Hills, MI, United States Achieving high quality products is always a big challenge for industries. When turning cylindrical bars, end‐to‐end taperness, taperness er‐ ror/stability w.r.t. tool wear/life, roughness values and their stability w.r.t. tool life define product quality. Chipbreaker (CB) geometries that define chip formation characteristics play a vital role in determining these quality measures at the end. This report aims to investigate chip formation behavior of different CB geometries and suggest the most suitable one for finish turning of 1035 carbon steel. For turning with specific tool geometry TNMG 331, nine (9) different CB geometries defined with protrusion/obstruction size, it position, rake angle are selected from two tool companies. Experiments are performed in two phases as follows. In the first phase, number of CB geometries is narrowed down to four by evaluating machining performance in terms of chip formation, cutting force, surface roughness, and taperness error when cutting one pass over 50 mm traverse cutting length on cylindrical rods of 7.6 mm dia at 0.25 mm depth of cut (DOC), 3400 rpm and 0.23 mm/rev feed rate. All test conditions are repeated three times to ensure the results (a total of 27 tests). In the second phase, fur‐ ther experiments are performed to select the most suitable CB geometry by evaluating tool life, taperness error and roughness variations over tool life along with the performance criteria stated in the first phase. 1035 carbon steel rod of 16.1 mm dia was considered to be tested with 18 passes over 50 mm traverse cutting length on each sample. Machining performances suggest the tool CB geometry with the largest 20o positive rake angle that creates a big groove due to an obstruction tip at 1.8 mm away from the nose tip point is superior to all other tools.

Investigation on Drilling Performance of Titanium Alloy Ti6Al4V Based on Response Surface Method Technical Publication. MSEC2017‐2926 Zhaoju Zhu, Shandong University, Jinan, China, Shaochun Sui, AVIC Cheng Du Aircraft Industrial (Group) Co.,Ltd., Chengdu, China, Jie Sun, Jianfeng Li, Kai Liu, Shandong University, Jinan, Select State/Province, China In order to break the bottleneck of low efficiency, bad quality following drilling alloy Ti6Al4V, the effect of cutting parameters on thrust force, drilling vibration, burr height and surface roughness was studied based on response surface method. The optimized parameters were obtained. Results showed that feed rate had significant effect on thrust force and little on drilling vibration, while cutting speed had signifi‐ cant effect on vibration and little on thrust force. It is also observed that surface roughness decreased with cutting speed increasing, as well as increased with feed rate increasing. In addition, microstructure on the drilled hole surface showed mobility along feeding direction. Grain refinement on the drilling hole surface became serious with the increase of cutting speed and feed rate.

Correlation of Process Parameters to Surface Integrity Responsible for Wear Resistance of HVOF Sprayed WC‐Ni Coatings Technical Publication. MSEC2017‐2927 P.C. Du, X.P. Zhu, Y. Meng, M.K. Lei, D.M. Guo, Dalian University of Technology, Dalian, China Surface integrity of high performance components has a profound influence on the final performance. Therefore, surface integrity is a key point for realizing high performance manufacturing by which manufacture processes and parameters can be pre‐selected according to a required functional performance of components, i.e., solving inverse problem of manufacturing, as long as correlations could be estab‐ lished respectively for between processes and surface integrity, and between surface integrity and performance. However, in practice it is still difficult in correlating processes to performance through surface integrity, due to material and geometry constraints hindering achiev‐ ability of a desired surface integrity during conventional manufacturing as well as complicated influence of multiple surface integrity pa‐ rameters on a final performance. In this study, thermally sprayed WC‐10Ni coatings onto stainless steel are investigated using high velocity oxy‐fuel (HVOF) spraying process to identify the surface integrity predominantly determining the water‐lubricated wear performance of coated steel, subsequently to correlate it to process parameters. The controllable surface integrity facilitates identifying responsible surface integrity parameters for a required high performance, and subsequently deriving the necessary process parameters for achieving the de‐ sired responsible surface integrity. Specifically, HVOF parameters are adjusted by changing the oxygen‐to‐fuel (O/F) ratio to control thermal and mechanical processing loads, i.e. temperature of heated in‐flight sprayed powders and impact velocity of the molten splats onto stain‐ less steel to form the coatings. Surface features including porosity and phase structure, and surface characteristics including hardness, elas‐ tic modulus, and fracture toughness were studied with respect to the wear performance. The porosity and WC phase composition of coat‐ ings are identified responsible for the wear performance, as two essential surface integrity parameters that in turn greatly affect the sur‐ face characteristics including coating hardness, elastic modulus and fracture toughness. Consequently, the process parameter O/F is feasi‐ bly correlated to wear resistance through the responsible surface integrity parameters, as elucidating the coating formation mechanism of 55 influence of particle velocity and temperature on the coating porosity and WC decomposition.

Design of Anisotropic Boring Tools With L/D = 10 for Chatter Free Cutting Technical Publication. MSEC2017‐2928 Wataru Takahashi, Mitsubishi Materials Corporation, Joso‐shi, Japan, Norikazu Suzuki, Shamoto Eiji, Nagoya University, Na‐ goya, Aichi, Japan With a lack of enough dynamic stiffness of cutting system consisting of mechanical structures and feed drive system, chatter vibration can generate easily while cutting. This unstable phenomena deteriorates surface roughness, machining accuracy, and tool life resulting in less productivity. Inner boring of mechanical parts is well‐known as typically difficult process involved with chatter vibration due to dynamics of boring bars. A diameter of the boring bar needs to be smaller than the hole diameter. A projection length needs to be longer than the hole depth, as well. Because of this nature, the dynamic compliance of the long slender boring bars can be large easily. In order to attain chatter avoidance, selection of the most effective cutting conditions is important. When the chatter stability is not im‐ proved enough by use of the optimal conditions, the boring bars with turned mass damper (TMD) mechanisms are also utilized in industry, where resultant dynamic compliance can be decreases in some degree. This approach is also useful to increase chatter stability, however only limited effect can be obtained. On the other hand, Suzuki et al. proposed a unique tool design method, where dynamic stiffness for chatter vibration is increased by de‐ signing anisotropic dynamics of the boring bar. The orthogonal compliances in bending directions are designed homothetic and to have a constant compliance ratio of about 1.5 to 2. In addition, the mode directions are inclined to the cutting directions with a certain angle. Consequently, the vibrations due to principal and thrust forces are cancelled out each other in this dynamics design, and thus chatter sta‐ bility can be increased. However, the design model with L/D of 4 is not attractive considering industrial demands. In addition, effective con‐ ditions, i.e., depth of cut, feed rate, nose radius, compliance ratio, and mode inclination angle, are not clarified. In the present study, the design of a long slender boring bar with L/D of 10 is challenged by utilizing finite element analysis (FEA). Through analytical investigations by FEA, two kinds of tool designs were conducted and the compliance ratio of 1.53 or 1.88 was accomplished. The model for chatter stability analysis is formulated and influence of the conditions on the chatter stability was investigated. Analytical inves‐ tigation revealed that the chatter stability is significantly improved at a depth of cut of around 0.5 mm or 1 mm by utilizing the proposed designs regardless of the feed rate.

Dynamic Manufacturing Scheduling Under Real‐Time Electricity Pricing Based on MILP and ARIMA Technical Publication. MSEC2017‐2930 Yuxin Zhai, Purdue University, West Layette, IN, United States, Haiyan Wang, Jiaxing University, Jiaxing, Zhejiang, China, Fu Zhao, John Sutherland, Purdue University, West Lafayette, IN, United States The scheduling of manufacturing equipment is critical in production facilities. Research on production scheduling has traditionally fo‐ cused on component throughput and cycle time. However, the increase of electricity price in the United States following the market dereg‐ ulation in 1990s has led to efforts on reducing energy cost via manufacturing scheduling. This paper explores the possibility of reducing electricity cost of a manufacturing facility subject to real time electricity pricing by dynamically changing operation schedules, while main‐ taining a pre‐determined production throughput. A time series model is developed to forecast the hourly electricity price and time‐indexed integer programing is used to determine the manufacturing schedule. The electricity price forecast is updated every hour based on the price history, and manufacturing schedule is updated according to the updated price forecast. A hypothetical flow line with 3 processes operating 16 hours per day is used as a case study. The line has a limited public buffer between processes and all machines in the shop have three operational states. With a throughput of 60 work pieces on flow line, the results suggest that it is possible to reduce the cost by 3.6% comparing with schedule based on day‐ahead price forecast.

CEL FEM Investigation of Effects of Microgrooved Cutting Tools in High Speed Machining of AISI 1045 Steel Technical Publication. MSEC2017‐2932 Han Wu, Nick Duong, Jianfeng Ma, Saint Louis University, Saint Louis, MO, United States, Shuting Lei, Kansas State Univ, Manhattan, KS, United States In this paper, the commercial FEM software package Abaqus is used to investigate the effects of microgrooved cutting tools in high speed orthogonal cutting of AISI 1045. Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. A

56 coupled Eulerian‐Lagrangian (CEL) finite element model is developed based on Abaqus to solve the evolution of the cutting temperature, chip morphology, cutting force, and phase constitutes simultaneously. This model is validated by comparing the numerical results with the experimental data for orthogonal high speed cutting of AISI 1045 with various cutting conditions. In addition, this model is also validated by comparing with the experimental data of regular tool and microgrooved cutting tool under the cutting speed of 120m/min. This validated CEL FEM model is then utilized to investigate the effects of microgrooved cutting tools on the phase transformation, cutting force, cutting temperature, and chip morphology in high speed orthogonal cutting of AISI 1045. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of cutting force, cutting temperature, chip morphology, and phase transformation. It is found that this CEL FEM model can capture the essential features of or‐ thogonal high speed cutting of AISI 1045 using microgrooved cutting tools. This research provides insightful guidance for optimizing the cutting performance in terms of cutting temperature, cutting force, chip morphology, and phase transformation.

Tool‐Chip Interface Temperature Measurement in Interrupted and Continuous Oblique Cutting Technical Publication. MSEC2017‐2934 Sinan Kesriklioglu, Justin Morrow, University of Wisconsin‐Madison, Madison, WI, United States, Frank Pfefferkorn, Univ of Wisconsin‐Madison, Madison, WI, United States The objective of this work is to fabricate instrumented cutting tools with embedded thermocouples to accurately measure the tool‐chip interface temperature in interrupted and continuous turning. Thin‐film thermocouples were sputtered directly onto the flat rake face of a commercially available tungsten carbide cutting insert using micro machined stencils and coated the measurement junction with a protec‐ tive layer to obtain temperature data 1.3 µm below the tool‐chip interface. Oblique interrupted cutting tests on AISI 12L14 steel were per‐ formed to observe the influence of varying cutting speeds and cooling intervals on tool chip interface temperature. An additional cutting experiment was conducted to monitor the interface temperature change between interrupted and continuous cuts.

Experimental Tool Wear Observation of Assisted High Pressure Cryogenic Jet in Hard Turning Process Technical Publication. MSEC2017‐2935 Dong Min Kim, Do young Kim, Hyung Wook Park, In Su Jo, Ulsan National Institute of Science and Technology, Ulsan, Korea (Republic), Tae Jin Song, Kyung Soo Paik, Hyundai WIA, Gyeonggi‐do, Korea (Republic) Hard turning process has been widely applied in automobile, heavy machinery industries. In the process, tool wear is an important issue due to the cost of cutters. The objective of this study is to investigate the tool wear of CBN, Ti‐coated alumina ceramic cutting tools in the hard turning using cryogenic cooling techniques. Cryogenic cooling is a method which applies cryogenic liquid as a coolant. Hard turning experiments of AISI52100 steel were conducted under dry and cryogenic (high pressure cryogenic‐jet) conditions. This result evaluated that Ti‐caoted alumina ceramic with cryogenic jet provide to alternative CBN cutting tool. It is shown that tool life of Ti‐coated alumina ceramic under cryogenic cooling techniques were longer than tool life of CBN under dry condition. Ti‐coated ceramic under cryogenic jet may re‐ duce total tooling cost compared with CBN cutting tool.

Framework and Sensitivity Analysis of Joint Energy and Maintenance Planning Considering Production Throughput Re‐ quirements Technical Publication. MSEC2017‐2936 Fadwa Dababneh, Rahul Shah, University of Illinois at Chicago, Chicago, IL, United States, Zeyi Sun, Missouri University of Science and Technology, Rolla, MO, United States, Lin Li, University of Illinois at Chicago, Chicago, IL, United States As the U.S. manufacturing sector becomes more and more competitive, manufactures are seeking to adopt more cost and resource effi‐ cient operation practices. Several research studies that optimize production, maintenance, and energy have been conducted. However, research integrating them all in one model is less developed. In this paper, we present a framework on joint maintenance and energy plan‐ ning while considering production throughput target and buffer constraints. The problem considers a Time‐of‐Use (TOU) demand response program such that the cost of production, energy, and maintenance is reduced. A sensitivity analysis considering the effect of production system parameters, such as machine rated power, machine production rate, number of maintenance crew resources, etc., on the cost per part is conducted. In addition, the sensitivity due to varying the individual unit costs incurred from production throughput, power demand, and maintenance is investigated. This study can guide manufacturers and researchers in determining the value of using such joint methods. Furthermore, the sensitivity analysis considering joint energy and maintenance can aid manufacturers and researchers in data acquisition 57 so that the most sensitive parameters are given priority, help identify which controllable parameters have the largest impact on the system performance; and determine which parameters are most impactful.

Smart Manufacturing Through a Framework for a Knowledge‐Based Diagnosis System Technical Publication. MSEC2017‐2937 Michael P. Brundage, National Institute of Standards and Technology (NIST), Gaithersburg, MD, United States, Boonserm Kulvatunyou, National Institute of Standards and Technology, Gaithersburg, MD, United States, Toyosi Ademujimi, Badarin‐ ath Rakshith, Pennsylvania State University, State College, PA, United States Various techniques are used to diagnose problems throughout all levels of the organization within the manufacturing industry. Often times, this root cause analysis is ad‐hoc with no standard representation for artifacts or terminology (i.e., no standard representation for terms used in techniques such as fishbone diagrams, 5 why?s, etc.). Once a problem is diagnosed and alleviated, the results are discarded or stored locally as paper/digital text documents. When the same or similar problem reoccurs with different employees or in a different fac‐ tory, the whole process has to be repeated without taking advantage of knowledge gained from previous problem(s) and corresponding solution(s). When discussing the diagnosis, personnel may miscommunicate over terms used in the root cause analysis leading to wasted time and errors. This paper presents a framework for a knowledge‐based manufacturing diagnosis system that aims to alleviate these mis‐ communications. By learning from diagnosis methods used in manufacturing and in the medical community, this paper proposes a frame‐ work which integrates and formalizes root cause analysis by categorizing faults and failures that span multiple organizational levels. The proposed framework aims to enable manufacturing operations by leveraging machine learning and semantic technologies for the manu‐ facturing system diagnosis. A use case for the manufacture of a bottle opener demonstrates the framework.

*A Study of Chip‐Breaker Geometries for Wide‐Range DOCs when Turning 1035 Carbon Steel Oral Presentation. MSEC2017‐2938 Chandra Nath, Ippei Kono, Hitachi America Ltd., Farmington Hills, MI, United States During machining, especially turning, long chips are prone to entangle the product being turned, while also negatively affect product quali‐ ty, tool wear, and waste management. Chip control becomes even more difficult when cutting at different depth of cuts (DOCs) by a single insert due to productivity requirement. The aim of this study is to investigate the performance of different chipbreaker (CB) insert geom‐ etries for finding the best CB geometry suitable for different depth of cuts (DOCs) when turning 1035 carbon steel. With a survey per‐ formed with four renowned tool companies, thirty four (34) tools were selected for performing rough turning experiments on three differ‐ ent sizes of cylindrical rod (16.1, 14.1, and 12.6 mm) at four DOCs. Experiments are performed in two sets as follows: i) first, two best CBs are determined from each company by testing the maximum DOC on the largest and the minimum DOC on the smallest rods (204 tests with 34 tools), and ii) then the best CB geometry is selected by further testing these eight CBs for all four DOCs on each rod size (224 tests with 8 tools). Machining performances are evaluated in terms of chip morphology, taperness from cutting start‐to‐end, diametrical error w.r.t. target dia, and cutting forces. An overall performance rank is modeled by assigning a fractional weight factor for each performance criterion and by grading all four tools for each criterion (best is ranked as 1). Findings suggest a CB with geometry such as multiple groove steps and 8o positive rake that starts at 0.25 mm from the cutting edge line is superior in turning wide range DOCs. Relationships between the machining performance measures and corresponding CB geometry are discussed.

Numerical Modeling of Metal‐Based Additive Manufacturing Process Using Level Set Methods Technical Publication. MSEC2017‐2939 Qian Ye, Shikui Chen, State University of New York at Stony Brook, Stony Brook, NY, United States Modern computation technology enables people to simulate additive manufacturing (AM) process at high fidelity, which has proven to be an effective way to analyze, predict, and design the AM processes. In this paper, a new method is proposed to simulate the melting process of metal powder based AM. The physics is described using partial differential equations for heat transfer and Laminar flow. The level set methods are employed to track the motion of free surface between liquid and solid phases. The issues including free surface evolution, phase changes, and velocity field calculation are investigated. The convergence problem is examined in order to improve the efficiency of solving this multiphysics problem.

58

Joint Production and Maintenance Decision‐Making in Mixed‐Model Assembly Systems Technical Publication. MSEC2017‐2940 Xi Gu, University of Michigan, Ann Arbor, MI, United States, Weihong Guo, Rutgers, The State University of New Jersey, Pis‐ cataway, NJ, United States Mixed‐model assembly systems (MMASs) have been well recognized for their ability to handle product variants, and thus are particularly useful to meet the requirement brought by mass personalization. However, operational decision‐making in MMASs is challenging due to the system complexity. Production selection and maintenance are two important operational decisions. In this paper, we investigate the joint production and maintenance policies in MMASs that consist of both common and variant operation stations. Markov Decision Process (MDP) is used to formulate the problem and numerical examples are presented to illustrate the structure of the policy in an MMAS that produces two types of product variants.

Real‐Time Resilient Control for Stochastic Production System Energy Efficiency Technical Publication. MSEC2017‐2941 Jorge Arinez, GM Global Research and Development, Detroit, MI, United States, Jing Zou, Stony Brook University, Stony Brook, NY, United States, Qing Chang, Stony Brook University, Melville, NY, United States, Yong LEI, Zhejiang University, Hangzhou, China For multi‐stage manufacturing system, considerable amount of energy may be wasted and energy efficiency may be hindered due to idle‐ ness or constraints from the interactions between the machines and buffers. In this paper, a real‐time system performance diagnostic method is developed to identify energy waste due to machine and buffer interactions, and system resilience against random disruption events. Furthermore, by utilizing the real‐time system diagnostic information, a novel real‐time resilient feedback control policy is proposed to improve system energy efficiency and deliver resilient performance against random disruption events. A case study is presented to demonstrate the effectiveness of the proposed control policy.

Measurement of the Melt Pool Length During Single Scan Tracks in a Commercial Laser Powder Bed Fusion Process Technical Publication. MSEC2017‐2942 Jarred Heigel, National Institute of Standards and Technology, Gaithersburg, MD, United States, Brandon Lane, NIST, Gaithersburg, MD, United States This work presents high speed thermographic measurements of the melt pool length during single track laser scans on nickel alloy 625 substrates. Scans are made using a commercial laser powder bed fusion machine while measurements of the radiation from the surface are made using a high speed (1800 frames per second) infrared camera. The melt pool length measurement is based on the detection of the liquidus‐solidus transition that is evident in the temperature profile. Seven different combinations of programmed laser power (49 W to 195 W) and scan speed (200 mm/s to 800 mm/s) are investigated and numerous replications using a variety of scan lengths (4 mm to 12 mm) are performed. Results show that the melt pool length reaches steady state within 2 mm of the start of each scan. Melt pool length increases with laser power, but its relationship with scan speed is less obvious because there is no significant difference between cases performed at the highest laser power of 195 W. Although keyholing appears to affect the anticipated trends in melt pool length, further research is required

Measurement of Tissue Thermal Conductivity With Variable Thermal Dose During an Electrosurgical Joining Process Technical Publication. MSEC2017‐2944 Che‐Hao Yang, Samantha Kaonis, Washington State University, Pullman, WA, United States, Wei Li, Univ of Texas at Austin, Austin, TX, United States, Roland Chen, Washington State University, Pullman, WA, United States Electrosurgical vessel joining is commonly performed in surgical procedures to maintain hemostasis. This process requires elevated tem‐ perature to denature the tissue and while compression is applied, the tissue can be joined together. The elevated temperature can cause thermal damages to the surrounding tissues. In order to minimize these damages, it is critical to understand how the tissue properties change and how that affects the thermal spread. This study used porcine aorta arterial tissue to investigate tissue thermal conductivity with variable thermal dose. Seven joining times (0, 0.5, 1, 1.5, 2, 4, and 6 seconds) were used to create different amounts of thermal dose. A hybrid method that uses both experimental measurement and inverse heat transfer analysis was conducted to determine the thermal 59 conductivity of thin tissue samples. In general, the tissue thermal conductivity decreases when thermal dose increases. Accordingly, 36% decrease in tissue thermal conductivity was found when the thermal dose reaches the threshold for second‐degree burn (with 2‐second joining time). When thermal dose is beyond the threshold of third‐degree burn, the tissue thermal conductivity does not decrease signifi‐ cantly. A linear regression model was also developed and can be used to predict tissue thermal conductivity based on the thermal dose.

Additive Manufacturing (AM) of Flexible Electronic Devices: Online Monitoring of 3D Line Topology in Aerosol Jet Printing Process Using Shape‐From‐Shading (SfS) Image Analysis Technical Publication. MSEC2017‐2947 Roozbeh Salary, Jack P Lombardi, State University of New York at Binghamton, Binghamton, NY, United States, Prahalad Rao, University of Nebraska‐Lincoln, Lincoln, NE, United States, Mark Poliks, State University of New York at Binghamton, Binghamton, NY, United States The goal of this work is online quality monitoring of flexible electronic devices made using Aerosol jet printing (AJP) additive manufacturing (AM) process. In pursuit of this goal, the objective is to recover and quantify the 3D profile of AJP‐printed electronic traces (lines) through in situ images. The intent is to use the estimated 3D topology for online prediction of the device electrical performance characteristics. To realize this objective different shape‐from‐shading (SfS) techniques are tested to recover the 3D profile of lines from high resolution in situ 2D images. These images are obtained from a CCD camera installed on our experimental Optomec AJ300 AJP setup. White light interfer‐ ometry is used offline to verify the online experimental trends. Three types of SfS algorithms are tested, namely, minimization method, Pentland?s method, and Shah?s method. Tests with synthetic images and experimental data indicate that Shah?s method is more suitable. The correlation between online and offline estimates of the 3D profile thickness was ~80%.

Characterization of Material Behavior of the Fused Deposition Modeling Processed Parts Technical Publication. MSEC2017‐2949 Madhukar Somireddy, Aleksander Czekanski, York University, Toronto, ON, Canada In the present research, one of the additive manufacturing techniques, fused deposition modeling (FDM) fabricated parts are considered for investigation of their material behavior. The FDM process is a layer upon layer deposition of a material to build three dimensional parts and such parts behave as laminated composite structures. Each layer of the part acts as a unidirectional fiber reinforced lamina, which is treated as an orthotropic material. The mesostructure of a part fabricated via fused deposition modeling process is accounted for in the investigation of its mechanical behavior. The finite element (FE) procedure for characterization of a material constitutive law for the FDM processed parts is presented. In the analysis, the mesostructure of the part obtained via FDM process is replicated in the finite element models. Finite element models of tensile specimens are developed with mesostructure that would be obtained from FDM process, then uniaxial tensile test simulations are conducted. The elastic moduli of a lamina are calculated from the linear analysis and the strength pa‐ rameters are obtained from the nonlinear finite element analysis. The present work provides a FE methodology to find elastic moduli and strength parameters of a FDM processed part by accounting its mesostructure in the analysis.

Process Development for a Robotized Laser Wire Additive Manufacturing Technical Publication. MSEC2017‐2951 Meysam Akbari, Yaoyu Ding, Radovan Kovacevic, Southern Methodist University, Dallas, TX, United States Additive manufacturing has attracted the attention of industries such as aerospace and automotive as well as the medical technology sec‐ tors in recent years. Among all metal‐based additive techniques, laser metal wire deposition offers some advantages like shorter processing time, more efficient material usage, and a larger buildup envelop. It has been found that robotized laser/wire additive manufacturing (RLWAM) is a demanding process. A plethora of process parameters must be controlled compared to other laser‐based metal deposition processes. The influence of main process parameters such as laser power, stepover increment, wire feed speed, travel speed and z‐increment was investigated in this study to find the optimal values. Droplet formation, wire dripping, irregular deposition in the first layer, and deviation of the wire tip were also found to be the main obstacles throughout the process and practical solutions were proposed to deal with these issues. In this study, an 8‐axis robot (6‐axis arm robot with a 2‐axis positioner) and a 4 kW fiber laser along with a wire feeder were integrated to print the different geometrical shapes in 3D. In order to verify the geometrical accuracy of the as‐built part, the buildup was scanned using a portable 3D laser scanner. The 3D representation, the Standard Tessellation Language (STL) format obtained from the buildup, was compared with the original CAD model. The results show that RLWAM can be successfully applied in printing even

60 complicated geometries.

Enterprises in Cloud Manufacturing: A Preliminary Exploration Technical Publication. MSEC2017‐2952 Yongkui Liu, The University of Auckland, Auckland, New Zealand, Xun Xu, Ananth Srinivasan, University of Auckland, Auck‐ land, New Zealand, Lin Zhang, Beihang University, Beijing, China Cloud manufacturing is a new manufacturing paradigm in which manufacturing resources and capabilities offered by different enterprises are provided as cloud‐based services over the Internet. In addition to the cloud manufacturing platform, enterprises as resource providers are also essential part of a cloud manufacturing system as customer orders that are submitted to the cloud platform will ultimately need to be dispatched to enterprises’ production sites for execution. So far, however, issues concerning enterprises in cloud manufacturing has attracted little attention of researchers, and the most frequently mentioned issue in existing research that are concerned with enterprises is how to connect enterprises’ resources to the cloud infrastructure. This, to a large extent, hinders the development and implementation of cloud manufacturing as the lack of research on enterprises fails to uncover the requirements for enterprises in cloud manufacturing (i.e. Cloud Manufacturing Enterprises, CMEs), and thus enterprises have no reference for evaluating the changes that need to be made to adopt this new manufacturing paradigm. This paper focuses on this important issue and conducts a preliminary exploration on CMEs. We first analyze the requirements for CMEs, and then discuss some critical issues with CMEs in detail, including enterprise information systems, enterprise architecture, and enterprise modeling.

Parametric Topology Optimization Toward Rational Design and Efficient Prefabrication for Additive Manufacturing Technical Publication. MSEC2017‐2954 Long Jiang, Suny‐Stony Brook, Nesconset, NY, United States, Hang Ye, State University of New York at Buffalo, Amherst, NY, United States, Chi Zhou, University At Buffalo, Amherst, NY, United States, Shikui Chen, State University of New York at Stony Brook, Stony Brook, NY, United States, Wenyao Xu, State University of New York at Buffalo, Buffalo, NY, United States The significant advancement in the boosted fabrication speed and printing resolution of additive technology has greatly increased the ca‐ pability of achieving product design with high complexity. As a consequence, the prefabrication computation is increasingly significant and is becoming the bottleneck in the additive manufacturing process. In this paper, the authors investigate and devise an integrated computa‐ tional framework based on the parametric level set method and the DLP‐based SLA process for rational design and additive manufacturing of a broad range of multi‐scale, multi‐functional structures, and products by seamlessly synthesizing the innovation intelligence from to‐ pology optimization and additive manufacturing. A parametric level‐set based topology optimization framework has been implemented using Matlab programming language. The framework implemented the distance‐regularized RBF‐based parametric level set model and considered the prefabrication computation as the constraints. The output of the framework is the set of mask images which can be imme‐ diately used for the additive manufacturing process. The proposed approach seamlessly integrates the rational design and manufacturing to reduce the complexity of the computationally expensive prefabrication process. Two test cases including a freeform part and a mul‐ ti‐scale part are utilized to verify the effectiveness and efficiency of the proposed approach. Both the simulation and experimental results verified that the new rational design paradigm could significantly reduce the prefabrication computation cost without affecting the original design intent and losing original functionality.

Simulation Based On‐Line Evaluation of Singulation Plans to Handle Perception Uncertainty in Robotic Bin Picking Technical Publication. MSEC2017‐2955 Nithyananda Kumbla, University of Maryland, College Park, MD, United States, Shantanu Thakar, University of Southern Cal‐ ifornia, Los Angeles, CA, United States, Krishnanand Kaipa, Old Dominion University, Norflok, VA, United States, Jeremy Marvel, NIST, Gaithersburg, MD, United States, Satyandra Gupta, University of Southern California, Los Angeles, CA, United States Robotic bin picking requires using a perception system to estimate the posture of parts in the bin. The selected singulation plan should be robust with respect to perception uncertainties. If the estimated posture is significantly different from the actual posture, then the singula‐ tion plan may fail during execution. In such cases, the singulation process will need to be repeated. We are interested in selecting singula‐ tion plans that minimize the expected task completion time. In order to estimate the expected task completion time for a proposed singu‐ lation plan, we need to estimate the probability of success and the plan execution time. Robotic bin picking needs to be done in real‐time. Therefore candidate singulation plans need to be generated and evaluated in real‐time. This paper presents an approach for utilizing com‐ 61 putationally efficient simulations for on‐line evaluation of singulation plans. Results from physical experiments match well with predictions obtained from simulations

Predicting Sheet Forming Limit of Aluminum Alloys for Cold and Warm Forming by Developing a Ductile Failure Criterion Technical Publication. MSEC2017‐2956 Z.Q. Sheng, GM, Warren, MI, United States, Pankaj Mallick, University of Michigan ‐ Dearborn, Dearborn, MI, United States In this study, the forming limit of aluminum alloy sheet materials are predicted by developing a Ductile Failure Criterion (DFC). In the DFC, the damage growth is defined by Mclintock formula while the critical damage is defined by a so‐called effect function, which reflects the effect of strain path and initial sheet thickness. In the first part of this study, the DFC is used to predict Forming Limit Curves of six different aluminum sheet materials at room temperature. Then, the DFC is further developed for elevated temperature condition by introducing an improved Zener‐Hollomon parameter ( ), which is proposed to provide enhanced representation of the strain rate and temperature effect on limit strain. In warm forming condition, the improved DFC is used to predict the FLCs of Al5083‐O and failure in a rectangular cup warm draw process on Al5182+Mn. Comparison shows that all the prediction matches quite well with experimental measurement. Key words: Ductile failure criterion, elevated temperature, improved Zener‐Hollomon parameter, Forming limit

Evaluation of Environmental Sustainability for Additive Manufacturing Batch Production Technical Publication. MSEC2017‐2957 Yiran Yang, Lin Li, University of Illinois at Chicago, Chicago, IL, United States Additive manufacturing (AM), owning to the unique layer‐by‐layer manufacturing method and its associated advantages, has been imple‐ mented in a great number of industries. To further expand the AM applications, the current low throughput of AM system needs to be improved. Consequently, the batch production method, where multiple parts are fabricated in one batch, has gained increasing research interest. In the current state of literature, most research efforts assess the batch production approach based on its manufacturing cost saving potential. Nevertheless, environmental sustainability, serving as a critical part in AM development, is less explored. Environmental sustainability of AM batch production needs to be thoroughly investigated and assessed, due to the potential environmental impacts and human health risks that AM batch production activities might cause. This research aims to advance the state‐of‐the‐art on environmental sustainability evaluation for AM batch production, by experimentally comparing three main environmental sustainability aspects (i.e., en‐ ergy consumption, emission, and material waste) for batch production processes with different batch sizes. Based on the experimental results, the feasibility of batch production method for AM is discussed. The outcomes of this research will help evaluate the AM batch pro‐ duction method from an environmental sustainability standpoint, and facilitate the development of AM batch production.

Chip Adhesion and Tool Wear in Driven Rotary Cutting of Stainless Steel Technical Publication. MSEC2017‐2958 Hiroyuki Sasahara, Tokyo University of Agriculture and Technology, Fuchu, Tokyo, Japan, Masato Goto, Tokyo University of Agriculture and Technology, Tokyo, Tokyo, Japan, Wataru Takahashi, Mitsubishi Materials Corporation, Joso‐shi, Japan, Hi‐ romasa Yamamoto, Yamazaki Mazak Corporation, Aichi, Aichi, Japan, Toshiyuki Muraki, Yamazaki Mazak Corporation, Na‐ goya, Japan In driven rotary cutting of stainless steel, adhesions sometimes occur on the tool, causing increased wear. The type of coolant supplying methods and tool rotation speed affects largely on the adhesion because it depends on the temperature and lubricating performance. Re‐ sults showed that in a circumferential velocity ratio of 1.0, which means tangential component of tool peripheral speed is equal to work surface speed, there is no adhesion on the tool after cutting. In a circumferential velocity ratio of 2.0, adhesion occurred with overcooling of the flood coolant, and wear increased by adhesions to the rotating tool. It was found that the thermal cracks on the cutting edge was one of the factors of increased wear and chipping. Adhesives on the tool edge also accelerated the chipping.

Study of Microscale Three‐Dimensional Printing Using Near‐Field Melt Electrospinning Technical Publication. MSEC2017‐2960 Xiangyu You, Chengcong Ye, Ping Guo, The Chinese University of Hong Kong, Hong Kong, Hong Kong Three‐dimensional (3D) printing of microscale structures with high resolution (sub‐micron) and low cost is still a challenging work for the existing 3D printing techniques. Here we report a direct writing process via near‐field melt electrospinning to achieve microscale printing of 62 single filament wall structures. The process allows continuous direct writing due to the linear and stable jet trajectory in the electric near‐field. The layer‐by‐later stacking of fibers, or self‐assembly effect, is attributed to the attraction force from the molten deposited fi‐ bers and accumulated negative charges. We demonstrated successful printing of various 3D thin wall structures (freestanding single walls, double walls, annular walls, star‐shaped structures, and curved wall structures) with a minimal wall thickness less than 5 um. By optimizing the process parameters of near‐field melt electrospinning (electric field strength, collector moving speed, heating temperature, and nee‐ dle‐to‐collector distance), ultrafine poly (‐caprolactone) (PCL) fibers have been stably generated and precisely stacked and fused into 3D thin‐wall structures with an aspect ratio of more than 60. It is envisioned that the near‐field melt electrospinning can be transformed into a viable high‐resolution and low‐cost microscale 3D printing technology.

Patterned Microstructure Array Fabrication by Using a Novel Standing Surface Acoustic Wave Device Technical Publication. MSEC2017‐2962 Yancheng Wang, Dai Xue, Zhaoxin Deng, Deqing Mei, Zhejiang University, Hangzhou, Zhejiang, China This paper develops a novel standing surface acoustic wave (SAW) device with three‐pair of interdigital transducers (IDTs) to fabricate the patterned microstructure arrays with the assistant of ultraviolet (UV) polymerization. The working principle, structural design, and fabri‐ cation of the SAW device are presented. Then experimental setup was conducted to investigate the fabrication process and method of the patterned microstructure arrays on a thin liquid polymer surface. By adjusting the input wavelength and working voltage and selecting the pairs of IDTs, several types of patterned microstructure arrays, such as linear undulate and latticed undulate with different surface mor‐ phologies, could be fabricated. Results also demonstrated that the developed SAW device with the assistant of UV polymerization is an effective method to fabricate the patterned microstructure arrays, which may have great potential in the application of biomedical and microelectronic fields.

Study on Key Methods of On‐Machine Micro Milling Cutter Condition Inspection Based on Machine Vision Technical Publication. MSEC2017‐2965 XI ZHANG, Benzheng Zhang, Yuanyuan Shi, Bo Shang, Shanghai University, Shanghai, China In order to inspect the condition of micro milling cutter automatically and accurately in the on‐line process, a dedicated micro milling cutter condition inspection system was established in this paper, which includes an on‐machine inspection device and a controller. The key methods of the automatic dimension measurement and the cutting edge condition inspection for micro milling cutters are studied. The proposed methods can measure cutter diameter and clamping height, classify tool type as well as inspect cutting edge condition from both radial and axial direction. The experiments verify that the proposed methods and the developed inspection system can fulfill the needs of industrial applications.

Implementing the Digital Thread using Digital Twins Oral Presentation. MSEC2017‐2966 Martin Hardwick, STEP Tools, Inc., Troy, NY, United States On October 5th, the Digital Manufacturing working group of ISO TC184/SC4 gave a demonstration in which machining taking place at a plant 30 miles away was measured in real time in a web browser. The model included design requirements and process plan data. The ma‐ chining was tracked at a rate of 100 times a second (100 Hz). This compares to the 60 times a second that a typical computer screen is re‐ freshed. The real‐time was validated using a camera on the machine tool that showed the same machining movements as the simulation. Design requirements were communicated using the STEP AP242 protocol. Manufacturing solutions were communicated using the STEP‐NC AP238 protocol. The digital twin was built from an MTConnect stream delivered over the Internet from the machining system. It was meas‐ ured for conformance to its design requirements by real and virtual CMM’s. The measurement results were reported as QIF. This paper explains the architecture of the digital twin server and how it was able to update a solid model at (100 Hz).

Cradle‐to‐Grave Life Cycle Assessment of Solid‐State Perovskite Solar Cells Technical Publication. MSEC2017‐2970 Jingyi Zhang, Case Western Reserve University, Cleveland, OH, United States, Xianfeng Gao, Yelin Deng, Yuanchun Zha, Uni‐ versity of Wisconsin ‐ Milwaukee, Milwaukee, WI, United States, Chris Yuan, Case Western Reserve University, cleveland, OH, 63

United States With the advantages of low cost and high conversion efficiency, perovskite solar cell attracts enormous attention in recent years for re‐ search and development. However, the toxicity potential of lead used in perovskite solar cell manufacturing causes grave concern for its environmental performance. To understand and facilitate the sustainable development of perovskite solar cell, a comprehensive life cycle assessment has been conducted by using attributional life cycle assessment approach from cradle to grave, with manufacturing data from our lab experiments and literature. The results indicate that the major environmental problem is associated with system manufacturing, including cathode, organic solvent usage and recycling, and electricity utilization in component manufacturing process. Lead only con‐ tributes less than 1% of human toxicity and ecotoxicity potentials in the whole life cycle, which can be explained by the small amount usage of lead in perovskite dye preparation. More importantly, the uncertainties caused by life cycle inventory have been investigated in this study to show the importance of primary data source. In addition, a comparison of perovskite solar cell with conventional solar cells and other dye sensitized solar cells shows that perovskite solar cell could be a promising alternative technology for future clean power genera‐ tions.

Design of a Tip Based In‐Line Metrology System for Roll‐to‐Roll Manufactured Flexible Electronic Devices Technical Publication. MSEC2017‐2972 Liam G. Connolly, The University of Texas at Austin, Austin, TX, United States, Michael Cullinan, University of Texas at Austin, Austin, TX, United States The development of accurate, noncontact surface imaging is key to implementing an effective metrology strategy to manage defect detec‐ tion in high volume flexible electronic device fabrication. This paper presents the design of a compound, double parallelogram flex‐ ure‐hinge mechanism (DPFM) based nanopositioning system with stacked coarse‐fine adjustment DPFMs. In concert with novel Atomic Force Microscope (AFM)?on‐a‐chip technology, this coupled, multi‐flexure positioning system is proposed as a probe‐based metrology de‐ vice for roll‐to‐roll (R2R) electronics manufacturing [1], [2].

The structural parameters of this system have been designed to ensure the desired stiffness, range of motion, and resonant modes are achieved. The parametric design of this positioning system has been verified through Finite Element Analysis (FEA). The proposed system will achieve a scanning throughput of six, 60 ?m line scans every 0.15 seconds for a total throughput of over 75 ?m2/s at a lateral resolution nearing 50 nm and a vertical resolution of less than 20 nm. This will allow for the development of a statistical metrology framework to reli‐ ably measure and analyze nanofeatured, R2R manufactured, flexible electronics in a cost‐effective manner and provide fast, continuous defect identification.

Experimental Characterization of the Interaction Between Carbon Fiber Composite Prepregs During the Preforming Process Technical Publication. MSEC2017‐2973 Weizhao Zhang, Northwestern University, Evanston, IL, United States, zixuan zhang, northwestern unversity, Evanston, IL, United States, Jie Lu, Northwestern University, Evanston, IL, United States, Qian Wang, Northwestern Univ, Evanston, IL, United States, Xuming Su, Ford Motor Company, Dearborn, MI, United States, Danielle Zeng, Ford, Trenton, MI, United States, Mansour Mirdamadi, Dow Chemical Company, Auburn Hills, MI, United States, Jian Cao, Northwestern Univ, Evanston, IL, United States Carbon fiber composites have received growing attention because of their high performance. One economic method to manufacturing the composite parts is the sequence of forming followed by the compression molding process. In this sequence, the preforming procedure forms the prepreg, which is the composite with the uncured resin, to the product geometry while the molding process cures the resin. Slip between different prepreg layers is observed in the preforming step and this paper reports a method to characterize the properties of the interaction between different prepreg layers, which is critical to predictive modeling and design optimization. An experimental setup was established to evaluate the interactions at various industrial production conditions. The experimental results were analyzed for an in‐depth understanding about how the temperature, the relative sliding speed, and the fiber orientation affect the tangential interaction between two prepreg layers. The interaction factors measured from these experiments will be implemented in the computational preforming pro‐ gram.

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Modeling Particle Spray and Capture Efficiency for Direct Laser Deposition Using a Four Nozzle Powder Injection System Technical Publication. MSEC2017‐2974 Christopher Katinas, Weixiao Shang, Yung Shin, Jun Chen, Purdue University, West Lafayette, IN, United States Powder capture efficiency is indicative of the amount of material that is added to the substrate during laser additive manufacturing pro‐ cesses, and thus, being able to predict capture efficiency provides capability of predictive modeling during such processes. The focus of the work presented in this paper is to create a numerical model to understand particle trajectories and velocities, which in turn allows for the prediction of capture efficiency. To validate the numerical model, particle tracking velocimetry experiments at two powder flow rates were conducted on free stream particle spray to track individual particles such that particle concentration and velocity fields could be ob‐ tained. Results from the free stream comparison showed good agreement to the trends observed in experimental data and were subse‐ quently used in a direct laser deposition simulation to assess capture efficiency and temperature profile at steady‐state. The simulation was validated against a single track deposition experiment and showed proper correlation of the free surface geometry, molten pool boundary, heat affected zone boundary and capture efficiency.

Laser Sintering of Copper Nanoparticles: A Simplified Model for Fluence Estimation and Validation Technical Publication. MSEC2017‐2975 Nilabh Roy, The University of Texas at Austin, Austin, TX, United States, William Jou, Feng He, University of Texas at Austin, Austin, TX, United States, Jihoon Jeong, The University of Texas At Austin, Austin, TX, United States, Yaguo Wang, Michael Cullinan, University of Texas At Austin, Austin, TX, United States Copper (Cu) has already replaced aluminum as the primary material for interconnect fabrication due to its superior electrical and thermal conductivity. Low resistivity of Cu decreases the RC delay which in turn increases the integrated circuit(IC) speed. Copper nanoparticle (NP) inks can also serve as a promising replacement of NP inks in 2D printing applications on solid and flexible substrates. This paper pre‐ sents a simplified model to estimate optimum laser sintering parameters of Cu nanoparticles. The model is validated by the experimental sintering results using nanosecond and femtosecond pulsed . The predicted sintering thresholds agree well with sintering experi‐ ments.

Enhancing Mechanical Properties of Thin‐Walled Structures Using Non‐Planar Extrusion Based Additive Manufacturing Technical Publication. MSEC2017‐2978 Abdullah Alsharhan, Timotei Centea, Satyandra Gupta, University of Southern California, Los Angeles, CA, United States Traditional extrusion based additive manufacturing (AM) processes build parts by depositing material in planar layers. The development of processes that adopt a non‐planar approach is becoming a subject of significant interest in AM research. It is expected that such processes will impart superior mechanical strength to anisotropic and thin‐walled structures, and will especially be useful in exploiting continuous fiber reinforced composites in additive manufacturing. This paper presents an extrusion based non‐planar additive manufacturing process. The process allows for the deposition of material along 3‐dimensional paths, providing the capability to reorient deposition head, build objects on curved platforms, and create complete structures using one continuous strand. Two different parts are fabricated and tested in this paper. One is produced using the developed process, while the other is created using a commercial FDM 3D printer. The two specimens are then mechanically tested to examine their behavior in two different loading configurations, and to investigate the effect that the depo‐ sition method and orientation has on the failure mode.

Towards Identifying the Elements of a Minimum Information Model for Use in a Model‐Based Definition Technical Publication. MSEC2017‐2979 Alexander Miller, Purdue University, West Lafayette, IL, United States, Nathan Hartman, Purdue University‐ Computer Graphcis Technology, West Lafayette, IN, United States, Thomas Hedberg, National Institute of Standards and Technology, Gaithersburg, MD, United States, Jesse Zahner, Purdue University, West Lafayette, IN, United States, Allison Barnard Feeney, National Institute of Standards and Technology, Gaithersburg, MD, United States The concept of Model‐Based Definition (MBD) is being integrated into manufacturing companies in a variety of industries. Companies benefit from enhanced visualization, documentation, and communication capabilities offered by a 3D product representation when 2D drawings are replaced with 3D annotated models. In this transition, it is necessary that product information is not lost. A complication aris‐ es from the amount of product information defined implicitly in drawings. This presents a challenge when authoring and translating 3D 65 models through the product lifecycle. It requires a semantic understanding of the drawing to extract the implicit information. The capture of implicit and explicit information is critical to successfully transition to MBD. The research study described in this paper has yielded the term Minimum Information Model (MIM) to describe the minimum amount of information necessary in a given workflow, with the under‐ standing that any model‐based definition must be as rich in its implicit and explicit levels of information as drawings were historically. A survey was conducted across various industry sectors to identify the foundational elements of MIM in selected workflows. This study iden‐ tified the information used within the specific workflows, the capabilities of 3D CAD models to carry this information, and the implications for doing so.

Effect of Binder Content on Hybrid Magnetic Tool Behavior Technical Publication. MSEC2017‐2980 Max Stein, Hitomi Yamaguchi, University of Florida, Gainesville, FL, United States This paper proposes the use of a hybrid magnetic tool, consisting of magnetic particles bonded with water‐soluble glue, to improve both surface roughness and form accuracy of brittle materials such as ceramics. As the binder gradually dissolves into the lubricant, the bonded hybrid magnetic tool transforms to a particle brush in a magnetic field, increasing the deformability of the tool and its ability to conform to the target surface. This paper describes the effects of the tool transformation?from a bonded tool to a particle brush?on the characteristics of finished yttrium aluminum garnet (YAG) laser ceramics. The bonded tool removes material to flatten and smooth the target surface at the start of the process, gradually transitions to a particle brush (starting at the tool periphery), and finally smooths the surface as a flexible particle brush. The tool deformability and transition speed are adjustable by the binder content.

Interlaminar Toughening of GFRP: Part 1 ?Çö Improved Diffusion and Precipitation Technical Publication. MSEC2017‐2981 Dakai Bian, Columbia University, New York City, NY, United States, Bradley R. Beeksma, Columbia University, NY, NY, United States, Dong‐Jin Shim, Marshall Jones, GE Global Research, Niskayuna, NY, United States, Y Lawrence Yao, Columbia Univ, New York, NY, United States A low concentrated (PS) additive to epoxy is used since it is able to reduce the curing reaction rate but not at the cost of in‐ creasing viscosity and decreasing glass transition temperature of the curing epoxy. The modified epoxy is co‐cured with a compatible ther‐ moplastic interleaf during the vacuum assisted resin transfer molding (VARTM) to toughen the interlaminar of the composites. Using vis‐ cometry, the solubilities of thermoplastics polycarbonate (PC), polyetherimide (PEI), and polysulfone (PSU) are determined to predict their compatibility with epoxy. The diffusion and precipitation process between the most compatible polymer PSU and epoxy formed semi‐interpenetration networks (semi‐IPN). To optimize bonding adhesion, these diffusion and precipitation regions were studied via opti‐ cal microscopy under curing temperatures from 25?C to 120?C and PS additive concentrations to epoxy of 0% to 5%. Uniaxial tensile tests were performed to quantify the effects of diffusion and precipitation regions on composite delamination resistance and toughness. Crack paths were observed to characterize crack propagation and arrest mechanism. Fracture surfaces were examined by scanning electron mi‐ croscopy (SEM) to characterize the toughening mechanism of the thermoplastic interleaf reinforcements. The chemically etched interface between diffusion and precipitation region showed semi‐IPN morphology at different curing temperatures. Results revealed deeper diffu‐ sion and precipitation regions increases energy required to break semi‐IPN for crack propagation resulting in crack arrests and improved toughness.

Interlaminar Toughening of GFRP: Part 2 ?Çö Characterization and Numerical Simulation of Curing Kinetics Technical Publication. MSEC2017‐2982 Dakai Bian, Columbia University, New York City, NY, United States, Bradley R. Beeksma, Columbia University, NY, NY, United States, Dong‐Jin Shim, Marshall Jones, GE Global Research, Niskayuna, NY, United States, Y Lawrence Yao, Columbia Univ, New York, NY, United States Various methods of toughening the bonding between the interleaf and laminate reinforced polymer (GFRP) has been developed due to the increasing applications in industries. A polystyrene (PS) additive modified epoxy is used to improve the diffusion and precipita‐ tion region between polysulfone (PSU) interleaf and epoxy due to its influence on the curing kinetics without changing glass transition temperature and viscosity of the curing epoxy. The temperature dependent diffusivities of epoxy, amine hardener, and PSU are determined by using Attenuated Total Reflection‐ Fourier Transfer Infrared Spectroscopy (ATR‐FTIR) through monitoring the changing absorbance of 66 their characteristic peaks. Effects of PS additive on diffusivity in the epoxy system is investigated by comparing the diffusivity between non‐modified and PS modified epoxy. The consumption rate of the epoxide group in the curing epoxy reveals the curing reaction rate, and the influence of PS additive on the curing kinetics is also studied by determining the degree of curing with time. A diffusivity model coupled with curing kinetics is applied to simulate the diffusion and precipitation process between PSU and curing epoxy. The effect of geometry factor is considered to simulate the diffusion and precipitation process with and without the existence of fibers. The simulation results show the diffusion and precipitation depths which matches those observed in the experiments.

Dimensional Performance of As‐Built Assemblies in Polyjet Additive Manufacturing Process Technical Publication. MSEC2017‐2983 Azadeh Haghighi, Yiran Yang, Lin Li, University of Illinois at Chicago, Chicago, IL, United States The additive manufacturing (AM) technology provides a unique opportunity to realize as‐built assemblies, i.e., assemblies which can be fabricated as a whole in one build cycle. Some of the introduced challenges, however, are the design issues of these assembly structures and understanding the dimensional performance of the AM process to ensure proper mobility. While process improvement techniques have been proposed for dealing with individual additive components, it is also necessary to study the dimensional behavior of as‐built as‐ semblies compared to individual additive components. This paper studies and compares the dimensional performance of as‐built assem‐ blies with ordinary assemblies in which the components are fabricated individually and then assembled together. A design of experiment approach is applied to study the effect of assembly type and orientation on the final clearances. The results suggest that in addition to ori‐ entation factor, the type of assembly can also play an important role in the final clearance values. In addition, a different dimensional be‐ havior exists in the as‐built assembly structures compared to ordinary assemblies, i.e., clearances in as‐built assembly tend to be smaller and also more uniform along the clearance profile.

An Energy Saving Scheduling Method for Just in Time Material Handling in Mixed‐Model Assembly Line Technical Publication. MSEC2017‐2985 Liman Hu, Binghai Zhou, Yang Li, Tongji University, shanghai, shanghai, China Driven by the green logistics, automated guided vehicle (AGV) has been widely accepted as a new transportation tool for in‐house logistics, which enables a timely supply of parts to the designated workstations with less energy consumption. However, the existing scheduling methods for AGV scheduling are designed to minimize inventory or cost without explicitly considering energy saving. To fill the gap, this paper proposes an AGV scheduling model for energy saving in a mixed‐model assembly line, where AGVs can have variable travel speeds. A mixed‐integer model is constructed and an exact solution procedure is provided. Simulation studies are performed to investigate the main factors that determine the energy consumption and to demonstrate the effectiveness of the proposed method.

Product‐Service Family Enabled Product Configuration System for Cloud Manufacturing Technical Publication. MSEC2017‐2987 Shiqiang Yu, University of Auckland, Auckland, New Zealand, PAI ZHENG, The University of Auckland, Auckland, New Zealand, Chunyang Yu, Zhejiang University, Zhejiang, China, Xun Xu, University of Auckland, Auckland, New Zealand Rapid responsiveness to diverse customer needs is considered a competitive advantage in manufacturing business. To shrink the in‐ quiry‐to‐order process, manufacturing firms will benefit a lot from building a product configuration system (PCS) which is the enabler of mass customisation (MC). PCS has matured in consumer businesses for decades but in capital goods industries, typically operating in engi‐ neer‐to‐order (ETO) manner, things differ a lot. It is for the reason that conventional PCS is incapable of extending customisation from or‐ der‐delivery processes to the design/engineering phase. Cloud manufacturing, which is an emerging service‐oriented manufacturing para‐ digms enabled by cyber‐physical system, the Internet of Things and the Internet of Service, is promising to break the bottleneck of ?ETO PCS? by the provision of technical infrastructure for product, service and data customisation. With the introducing of manufactur‐ ing‐as‐a‐service (MaaS) concept, a product family is extended to a product‐service family (PSF) in this paper for implementing in‐depth product configuration process with scalable customisation depth (i.e., the degree of customisation freedom). Additionally, an approach of service delegation in product configuration process is proposed to support customer‐centric product customisation. At last, the methodol‐ ogy proposed in this paper is validated by a case study in which the product configuration process of a complex ETO product is performed.

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Effect of Needle Diameter on Scaffold Morphology and Strength in E‐Jetted Polycaprolactone Scaffolds Technical Publication. MSEC2017‐2989 Aishwarya Bhargav, National University of Singapore, Singapore, Singapore, Wen Feng Lu, Nat’l Univ Of Singapore, Singa‐ pore, Singapore, Vinicius Rosa, Jerry YH Fuh, National University of Singapore, Singapore, Singapore, Singapore Electro‐hydrodynamic Jetting or E‐Jetting is a process in which a polymer, dissolved in a solvent and extruded through a needle onto a sub‐ strate. This process is used to fabricate two dimensional scaffolds with porous mesh surfaces which act as a template for cell growth. As cells are very minute and are required to attach to the surface of the scaffold, it is essential to for the scaffold to have an adequate pore size that allows for nutrient transfer while preventing the penetration of cells through the scaffold. The fiber dimensions of the scaffold may be modified by varying the diameter of the needle through which the fiber is extruded. The change in fiber diameter subsequently results in the change in the bulk mechanical characteristics of the scaffold. It also causes a change in the net porosity of the scaffold. This paper aims to study the effect of the needle diameter on the bulk mechanical properties of the scaffold such as Young?s modulus, Tensile strength and Breaking Strength as well as morphological properties (porosity and pore size) of the scaffold. For this study, twelve scaffolds belonging to three study groups were synthesized using e‐jetting. By studying the effect of needle diameter on scaffold morphology and strength, we aim to develop a co‐relation between the scaffold parameters, which will ultimately help in the creation of a knowledge data‐ base. The purpose of creating this database is to choose a select needle for a selected biomedical application.

Vision‐Based Real‐Time Layer Error Quantification for Additive Manufacturing Technical Publication. MSEC2017‐2991 Haedong Jeong, Minsub Kim, Bumsoo Park, Seungchul Lee, UNIST, Ulsan, Korea (Republic) Quality assurance of Additive Manufacturing (AM) products has become an important issue as the AM technology is extending its applica‐ tion throughout the industry. However, with no definite measure to quantify the error of the product and monitor the manufacturing pro‐ cess, many attempts are made to propose an effective monitoring system for the quality assurance of AM products. In this research, a nov‐ el approach for quantifying the error in real‐time is presented through a closed‐loop vision‐based tracking method. As conventional AM processes are open‐loop processes, we focus on the implementation of real‐time error quantification of the products through the utiliza‐ tion of a closed‐loop process. Three test models are designed for the experiment, and the tracking data from the camera will be compared with the G‐code of the product to evaluate the geometrical errors. The results obtained from the camera analysis will then be validated through comparison of the results obtained from a 3D scanner.

The Development of a Novel Positioning System to Improve Pulmonary Outcomes in Critically Ill Patients Technical Publication. MSEC2017‐2992 Kalie Hennigan, Scott Miller, University of Hawaii at Manoa, Honolulu, HI, United States, Prakash Kabbur, Sheridan Healthcare, Coppell, TX, United States, Russell Woo, University of Hawaii at Manoa, Honolulu, HI, United States An automated inflatable repositioning device was created in this study for use in the developmentally supportive care of premature neo‐ nates. Inflatable air cells were used to achieve the safe positioning of these patients. The system is comprised of two pumps, four valves and four inflatable air cells that safely and slowly direct the air flow into the desired air cells by means of an Arduino Uno and a mul‐ ti‐directional control switch in order to obtain safe and proper positioning. Range of motion testing was conducted and it was discovered that this system is successful in achieving a sufficient range of motion in order to safely position the manikin. A pressure sensor was also connected to the system to measure the amount of pressure in the air cells over time during inflation. From this testing, it was found that the system is successful in inflating the air cells in a slow and controlled manner. Additionally, four NICU nurses from the Kapi?olani Medical Center for Women and Children tested the device and a survey was conducted to obtain feedback about the performance of the system. Overall, the device created was found to be successful in achieving positions in four directions in a safe, slow and controlled manner by means of an easy to use system that has the potential to be integrated into current neonatal health care technology.

Effect of Arc‐Current and Particle Morphology on Fracture Toughness of Plasma Sprayed Oxide Coating Technical Publication. MSEC2017‐2993 Simanchal Kar, Partha Pratim Bandyopadhyay, IIT Kharagpur, West Bengal, India, Kharagpur, West Bengal, India, Soumitra Paul, Indian Institute of Technology, Kharagpur, Kharagpur, West Bengal, India Alumina powder was sprayed on low carbon steel substrate using atmospheric plasma spray process. Two different powders namely 68 crushed and agglomerated powders were used and current was varied to study their effect on fracture toughness. Theoretically, with in‐ crease in arc current, melting of ceramic oxide shall increases and in turn dense coating should form. However, it was observed that if the arc power is too high and particle size of the powder being small (? 30 µm), the particles tend to fly away from the plasma core. Similarly, particle size distribution and powder morphology also affects the coating properties. Smaller particle should allow more melting resulting in dense coating and agglomerated powder allows flowability as well as better coating efficiency. Conversely, smaller particles tend to fly away from the plasma making the process difficult while the agglomerated particles showed a bimodal structure marked by presence of unmelted region in the splat core. All these factors lead to substantial variation in the fracture toughness of the coating. The present paper attempts to correlate plasma spraying parameters and microstructure of the coating with fracture toughness of the same.

Nonlinear Parameter Estimation in a Typical Industrial Air Handler Unit Technical Publication. MSEC2017‐2994 Lujia Feng, Pierluigi Pisu, Clemson University, Greenville, SC, United States, Laine Mears, Clemson University, Anderson, SC, United States, Jörg Schulte, BMW Manufacturing Co. LLC, Greer, SC, United States The energy usage inside of a manufacturing plant is mainly from two sources: energy demand from the production lines to support manu‐ facturing processes, and the plant building temperature control to maintain a comfortable working environment. It is reported that in the US, 14% of the primary energy and 32% of electricity is used by the industry and commercial building heating, ventilation and air condi‐ tioning (HVAC) system. As an important part of the HVAC system, the air handler unit (AHU) is a comprehensive air control system consist‐ ing of multiple sub‐units. Accurate modeling of the supply air temperature of AHU is important for later controller design and fault detec‐ tion, but it is also challenging because of the application of variable frequency drive (VFD) systems, overall degradation, and limited sensor information and meter data. Parameter estimation of the industry AHU is therefore worth studying. In this study, the authors intend to establish a deterministic physical model of AHU system, identify the unknown parameters based on the limited meter inputs, and compare the nonlinear parameter estimation results with the design parameters, in order to achieve the goal of improving the modeling accuracy without installing expensive metering systems.

Effects of Tool Nose Corner Radius and Main Cutting‐Edge Radius on Cutting Temperature in Micro‐Milling Inconel 718 Process Technical Publication. MSEC2017‐2997 XIAOHONG LU, Dalian University of Technology, Atlanta, GA, United States, Hua Wang, Dalian University of Technology, Da‐ lian, China, Zhenyuan Jia, Dailan University Of Technology, Dailan, Liaoning, China, Likun Si, Dalian University of Technology, Dalian, China, Steven Liang, Georgia Institute Of Technology, Atlanta, GA, United States Cutting temperature plays an important role in micro‐scale cutting process because the dimension of the micro‐milling cutter is relatively small and the wear of micro‐milling cutter is sensitive to temperature. Considering the sidewall of a groove is formed by main cutting edge of the tool, and the bottom of a groove is formed by tool tip and the edge on the end of the tool. Therefore, effects of tool nose corner radius and main cutting edge radius on cutting temperature in micro‐milling process cannot be ignored. However, few studies have been conducted on this issue. The effects of tool nose corner radius and main cutting edge radius on cutting temperature is investigated. A three‐dimensional micro‐milling Inconel718 model is established by using the software DEFORM3D. And the influence of tool nose corner radius and main cutting edge radius on the size and distribution of cutting temperature are studied by numerical simulation, which is veri‐ fied by experiments. The work provide reference for the control of the size and distribution of the cutting temperature during micro‐milling process.

A New Method for the Prediction of Micro‐Milling Tool Breakage Technical Publication. MSEC2017‐2999 XIAOHONG LU, Dalian University of Technology, Atlanta, GA, United States, Haixing Zhang, Dalian University of Technology, Dalian, China, Zhenyuan Jia, Dailan University Of Technology, Dailan, Liaoning, China, Yixuan Feng, Steven Liang, Georgia Institute of Technology, ATLANTA, GA, United States Micro‐milling tool breakage has become a bottleneck for the development of micro‐milling technology. A new method to predict mi‐ cro‐milling tool breakage based on theoretical model is presented in this paper. Based on the previously built micro‐milling force model, 69 the bending stress of the micro‐milling cutter caused by the distributed load along the spiral cutting edge is calculated; Then, the ultimate stress of carbide micro‐milling tool is obtained by experiments; Finally, the bending stress at the dangerous part of the micro‐milling tool is compared with the ultimate stress. Tool breakage curves are drawn with feed per tooth and axial cutting depth as horizontal and vertical axes respectively. The area above the curve is the tool breakage zone, and the area below the curve is the safety zone. The research pro‐ vides a new method for the prediction of micro‐milling tool breakage, and therefore guides the cutting parameters selection in mi‐ cro‐milling.

An Experimental Method of Needle Deflection and Prostate Movement Using the Anatomically Accurate Prostate Simula‐ tor and the Electromagnetic Tracking System Technical Publication. MSEC2017‐3000 Dian‐Ru Li, Jih‐Kai Yeh, Wei‐Chen Lin, University of Michigan, Ann Arbor, MI, United States, Jeffrey S. Montgomery, Universi‐ ty of Michigan Healthcare System, Ann Arbor, MI, United States, Albert Shih, University of Michigan, Ann Arbor, MI, United States This study develops an experimental method to measure the needle deflection and prostate movement using an anatomically accurate prostate simulator with the electromagnetic tracking (EMT) system. Accurate needle insertion is crucial for prostate biopsy to acquire the tissue samples from cancer sites identified by magnetic resonance imaging. False negatives or inability to diagnose are the clinical chal‐ lenges in the biopsy procedure. The main cause is that the needle tip missed the targeted cancer sites due to needle deflection and pros‐ tate movement. An anatomically accurate prostate simulator was developed to quantitatively and experimentally measure the deviation of needle tip from the ideal path and the movement of a target point in the prostate. The EMT system was utilized to simultaneously track the needle tip and target point positions in 3D space. Results show that the maximal needle deflection occurred at the first 60‐mm insertion with 6.7 and 0.7 mm in and perpendicular to the needle insertion plane, respectively. The corresponding target point movements were 6.5 mm and 2.4 mm in and perpendicular to the needle insertion plane, respectively. Differences between multiple insertions through the same path have also been quantified. This method can be utilized to study clinical prostate biopsy techniques, evaluate the accuracy of needle devices, and train clinicians for accurate prostate needle biopsy.

Simulation Model of Automated HVAC System Control Strategy With Thermal Comfort and Occupancy Considerations Technical Publication. MSEC2017‐3001 Bo Peng, Sheng‐Jen hsieh, Texas A&M University, College Station, TX, United States Currently, design and control of HVAC system in buildings rely heavily on simulation tools. However, the common tools available often fail to optimize occupants? comfort directly, nor do they consider real‐time variations in occupancy that affect comfort and energy perfor‐ mance. To address these limits, this research designed an occupancy‐based and thermal comfort‐driven building automation simulation model. A single‐space prototype lab room was co‐simulated using EnergyPlus and MATLAB with the help of BCVTB and MLE+ as middleware. Various climate scenarios from four cities in the U.S. in different seasons were examined. Results suggest that overall, compared to a conventional temperature‐driven control strategy baseline, the proposed system can minimize thermal comfort violation (in term of PMV model, |PMV|>>0.5 is considered as a violation) to 7% and reduce occupants? thermal discomfort by 62.5% on average. Meanwhile, energy con‐ sumption remains same or reduced (up to 2% reduction). Due to its simplicity, this strategy is relatively easy to implement in real‐world building automation systems with appropriate sensor placement in modern buildings.

Manufacturing and Computational Fluid Dynamics Modeling of a Patient‐Specific Fistula Model Technical Publication. MSEC2017‐3002 Zheng, John Pitre, University of Michigan, Ann Arbor, MI, United States, William Weitzel, VA Ann Arbor Health System, Ann Arbor, MI, United States, Joseph Bull, Albert Shih, University of Michigan, Ann Arbor, MI, United States Arteriovenous fistula is the joining of an artery to a vein to create vascular access for dialysis. The failure or maturation of fistula is affected by the vessel wall shear stress (WSS), which is difficult to measure in clinic. A computational fluid dynamics (CFD) model was built to esti‐ mate WSS of a patient‐specific fistula model. To validate this model, a silicone phantom was manufactured and used to carry out a particle imaging velocimetry (PIV) experiment. The flow field from the PIV experiment shows a good agreement with the CFD model. From the CFD model, the highest WSS (40 Pa) happens near the anastomosis. WSS in the vein is larger than that in the artery. WSS on the outer venous 70 wall is larger than that on the inner wall. The combined technique of additive manufacturing, silicone molding, and CFD is an effective tool to understand the maturation mechanism of a fistula.

Data‐Driven Thermal Comfort Prediction With Support Vector Machine Technical Publication. MSEC2017‐3003 Bo Peng, Sheng‐Jen hsieh, Texas A&M University, College Station, TX, United States Personal thermal comfort is a crucial yet often over‐simplified factor in building climate control. Traditional comfort models lack the adaptability to fit individuals? demand. Recent advances of machine learning and ubiquitous sensor networks enable the data‐driven ap‐ proach of thermal comfort. In this paper, we built a platform that can simulate occupants with different thermal sensations and used it to examine the performance of support vector machine (SVM) and compared with several other popular machine learning algorithms on thermal comfort prediction. We also proposed a hybrid SVM‐LDA thermal comfort classifier that can improve the efficiency of model training.

Implementation of a Knowledge‐Based Production Planning Including a Direct Manipulative Process Editor and a Mediator Architecture Technical Publication. MSEC2017‐3006 Benjamin Gernhardt, Matthias Hemmje, Tobias Vogel, University of Hagen, Hagen, North Rhine‐Westphalia, Germany, Lihui Wang, KTH, Royal Institute of Technology, Sweden, Stockholm, Select State/Province, Sweden Today, in the era of modern Intelligent Production Environments (IPE) and Industry 4.0, the manufacturing of a product takes place in vari‐ ous partial steps and these mostly in different locations, potentially distributed all over the world. The producing companies must assert in the global market and always find new ways to cut costs by saving tax, changing to the best providers, and by using the most efficient and fastest production processes. Furthermore, they must be inevitably based on a cloud‐based repository and distributed architectures to make data and information accessible everywhere as well as development processes and knowledge available for a worldwide cooperation. A so called Collaborative Adaptive (Production) Process Planning (CAPP) can be supported by semantic approaches for knowledge repre‐ sentation and management as well as knowledge sharing, access, and re‐use in a flexible and efficient way. In this way, to support CAPP scenarios, semantic representations of such knowledge integrated into a machine‐readable process formalization is a key enabling factor for sharing in cloud‐based knowledge repositories. This is especially required for, e.g., Small and Medium Enterprises (SMEs). When SMEs work together on a production planning for a joint product, they exchange component production and manufacturing change infor¬mation between different plan‐ning subsystems. These exchanges are mostly based on the already well‐established Standard for the Exchange of Product model data (STEP), not least to obtain a computer‐interpretable representation. Moreover, so‐called Function Block (FB) Domain Models could support these planning process. FBs serve as a high‐level planning‐process knowledge‐resource template and to the repre‐ sent¬ation of knowledge. Furthermore, metho¬dologies are required, which based on process‐oriented semantic knowledge‐representation, such as Process‐oriented Knowledge‐based In¬no¬vation Management (German: Wissens‐basiertes Prozess‐orientiertes Innovations Management, WPIM). WPIM is already a web‐ and cloud‐based tool suites and can represent such plan‐ ning processes and their knowledge resources and can therefore be used to support the integration and the management of distributed CAPP knowledge in Manufacturing Change Management (MCM), as well as its access and re‐use. That is also valid for Assembly‐, Logis‐ tics‐ and Layout Planning (ALLP). On the one hand, a collaborative planning in a machine‐readable and integrated representation will be possible as well as an optimization for mass production. On the other hand, within a cloud‐based semantic knowledge repository, that knowledge can be shared with all partners and contributors. To combine all these functionalities, in 2016 we have already introduced a method, called Knowledge‐based Production Planning (KPP). We outlined the theoretical advantages of integrating CAPP with Collaborative Manufacturing Change Manage¬ment (CMCM) in the last year at MSEC16. In this Paper, we will demonstrate our first implementations of the KPP application with an integrated visual direct manipulative process editor as well as a first prototype of our mediator architecture with a semantic integration including a query library based on the KPP ontology.

Characterization of Particle Emission From Fuse Deposition Modeling Printers Technical Publication. MSEC2017‐3007 Timothy Simon, Giovanny Aguilera, Fu Zhao, Purdue University, West Lafayette, IN, United States Throughout the past decade the popularity of additive manufacture (AM) has grown tremendously. Although AM has been deemed as an 71 environmentally friendly alternative to traditional processes, there have already been several studies done showing that AM processes can affect human health and the environment by emitting particles of a dynamic size range into its surrounding during a print. The objective of this paper is to look deeper into the issue of particle emissions from one of the most popular AM processes i.e. fused deposition model‐ ing (FDM). Particle emissions from a Makeblock 3‐D printer enclosed in a chamber and placed in a Class 1 cleanroom are measured using a high temporal resolution electrical low pressure impactor (ELPI) which takes close‐to‐real‐time measurements of particles in the range of 6‐200nm. A honeycomb cube with side length 1.25? and the NIST standard testing part are printed using acrylonitrile butadiene styrene (ABS) filament. Results show that particle emissions are closely related to the filament residence time in the extruder while less related to extruding speed. The initial spike of particle concentration right after printing starts is likely due to the long time needed to heat the ex‐ truder and the bed to the desired temperature. It is suggested that part geometry/features and build path could significantly affect particle emissions. TEM images suggest that particles may be formed through vapor condensation and coagulation of small particles.

Experimental Investigations on Surface Roughness, Cutting Forces and Tool Wear in Turning of Super Duplex Stainless Steel With Coated Carbide Inserts Technical Publication. MSEC2017‐3008 Shirish Kadam, Rohit Khake, Sadaiah Mudigonda, Dr Babasaheb Ambedkar Technological University, Lonere, Maharashtra, India This paper addresses experimental investigations of turning Super Duplex Stainless Steel (DSS) with uncoated and Physical Vapor Deposi‐ tion (PVD) coated carbide inserts under dry cutting condition. The parametric influence of cutting speed, feed and depth of cut on the sur‐ face finish and machinability aspects such as cutting force and tool wear are studied and conclusions are drawn. The turning parameters considered are cutting speed of 60 ‐ 360 m/min, feed of 0.05 ‐ 0.35 mm/rev and depth of cut of 0.5 ‐ 2 mm. Tool wear was analysed by using an optical microscope and scanning electron microscope. The study includes identification of tool wear mechanism occurring on the flank face. The characterization of the coating was made by Calo test for measurement of coating thickness and nanoindentation for hard‐ ness. Comparison of performance of PVD coatings TiAlSiN (3.3 ?m), AlTiN (3 ?m) and AlTiN (7 ?m) have been made in terms of tool life. The coatings were produced on P‐grade tungsten carbide inserts by using High Power Impulse Magnetron Sputtering (HiPIMS) technology. The findings of the study also provide the economic solution in case of dry turning of super DSS.

Experimental and Numerical Analysis of Burn Marks and Shrinkage Effect on Injection Molding Technical Publication. MSEC2017‐3009 Saeed Beheshtian Mesgaran, Islamic Azad University, Mashhad Branch Mashhad, Iran, Mashhad, Select State/Province, Iran, Seyyed Emad Seyyed Mousavi, Farzad Elhami Nik, Ferdowsi University Of Mashhad , Iran, Mashhad, Iran Injection Molding is among the most popular processes in plastic parts production. Through this process, burn marks and shrinkage play the most significant role in decreasing surface quality as well as increasing costs, especially when manufacturers use this method in order to produce thin‐walled plastic parts. In this paper, a new strategy to remove the defects caused by shrinkage and burn marks has been pro‐ posed for the injection molding process of a specific plastic part which is used to keep the doors of an automobiles open during the painting process. Burn marks caused by the trapped air inside thin walls of the part were first simulated in MOLDFLOW 2010 software. Next step is to compare the simulation results to results that are obtained from experimental analysis. Then, Burn marks and shrinkage effects were eliminated by optimization of the process which includes mold design revision by means of SOLIDWORKS software, modification of the simulation in MOLDFLOW and the mold modification in workshop environment by improvising some ejector pins in certain points. Fur‐ thermore, shrinkage amount of the part after cooling process was calculated by applying Finite Element Method (FEM) and obtained results were used to optimize the design of the mold. Results demonstrate that mold design optimization would be possible through designing flawless molds that contain certain points for trapped air discharge and calculating shrinkage amount by FEM for optimization of design procedure. Results consequently decrease costs as well as providing surface quality improvement.

Rapidly Deployable MTConnect‐Based Machine Tool Monitoring Systems Technical Publication. MSEC2017‐3012 Roby Lynn, Wafa Louhichi, Mahmoud Parto, Ethan Wescoat, Thomas Kurfess, Georgia Institute of Technology, Atlanta, GA, United States

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The amount of data that can be gathered from a machining process is often misunderstood, and even if these data are collected, they are frequently underutilized. Intelligent uses of data collected from a manufacturing operation can lead to increased productivity and lower costs. While some large‐scale manufacturers have developed custom solutions for data collection from their machine tools, small‐ and me‐ dium‐size enterprises need efficient and easily deployable methods for data collection and analysis. This paper presents three broad solu‐ tions to data collection from machine tools, all of which rely on the open‐source and royalty‐free MTConnect protocol: the first is a ma‐ chine monitoring dashboard based on Microsoft Excel; the second is an open source solution using Python and MTConnect; and the third is a cloud‐based system using Google Sheets. Time studies are performed on these systems to determine their capability to gather near re‐ al‐time data from a machining process.

Effect of Tempering Temperature on Hardness and Microstructure of Laser Surface Remelted AISI H13 Tool Steel Technical Publication. MSEC2017‐3014 Debapriya Patra Karmakar, GOPINATH MUVVALA, Indian Institute of Technology Kharagpur, Kharagpur, West Bengal, India, Ashish Kumar Nath, Indian Institute of Technology, Kharagpur, Kharagpur, West Bengal, India Surface hardening was performed by laser surface remelting of AISI H13 tool steel samples using a high power fiber laser. The surface hardened samples were exposed to different tempering temperature of 500ºC, 700 ºC and 900 ºC in a furnace for one hour and brought back to room temperature in still air and by water quenching. Changes of the laser remelted and hardened layer were investigated in terms of microstructure and hardness before and after exposure to different tempering temperatures. Laser remelting caused mainly dendritic microstructure at the top layer but the dendritic structure of the remelted layer got altered after tempering at high temperatures. Air and water quenching caused almost similar result during tempering of laser remelted layer. The microhardness variations along depth after tempering at different temperatures indicates that the surface hardening imparted by laser remelting remains almost intact up to 700 ºC but gets destroyed at 900 ºC. Although the experimental temperature limits gives approximate threshold values, but it provides a clear indication of a safe limit for laser surface hardened components in high temperature applications like hot‐forging dies and friction stir welding tool, etc.

Process Effect on Part Surface Roughness in Powder‐Bed Electron Beam Additive Manufacturing Technical Publication. MSEC2017‐3015 Subin Shrestha, University of Alabama, Tuscaloosa, AL, United States, Y. Kevin Chou, The University of Alabama, Tuscaloosa, AL, United States Surface roughness is an inherent attribute of parts fabricated by Powder‐Bed Electron Beam Additive Manufacturing (PB‐EBAM) process. The wide application of PB‐EBAM technology is affected by the part surface quality and therefore needs to be studied and optimized so as to establish PB‐EBAM process among other manufacturing processes. Therefore, in this study, the build surface of fabricated parts built with different speed function (SF) is analyzed using white light interferometry. The results show that, in general the build surface roughness along the beam moving direction slightly increases with the scanning speed. On the other hand, the hatch spacing noticeably affects the surface roughness in the transverse direction. The experimentally acquired average surface roughness increased with increasing speed function from about 3 µm for SF20 case to 11 µm for SF65 case. In addition, a 3D VOF model has been attempted to predict the surface formation during the PB‐EBAM process. Thus simulated SF36 case was able to predict different surface features and was in good agreement with experiment which shows that surface roughness analysis with numerical model may be a possible approach.

Preliminary Testing of Temperature Measurements in Selective Laser Melting Technical Publication. MSEC2017‐3016 Bo Cheng, University of Alabama, Tuscaloosa, AL, United States, Stephen Cooke, ASRC Federal Technical Services, Huntsville, AL, United States, Y. Kevin Chou, The University of Alabama, Tuscaloosa, AL, United States Selective laser melting (SLM) based on added‐material manufacturing method is one of the Additive Manufacturing (AM) technologies that can build full density metallic components. In this study, a thermal imager with about 670 nm wavelength was employed to collect build surface process temperature information during SLM fabrication using Monel K500 powder. The major findings are as follows. (1) At nomi‐ nal process conditions of 600 mm/s beam speed and 180 W beam power, the melt pool has a length of about 0.6 mm and a width of about 0.36 mm. (2) The obtained melt pool length/width ratio is about 1.5 for different build height. With the increase of build height, no clear trend was observed for melt pool length/width ratio and melt pool length value. (3) It is difficult to obtain true temperature in this study 73 but it is possible to estimate melt pool dimension with the identified radiant liquidus temperature.

Overhang Support Structure Design for Electron Beam Additive Manufacturing Technical Publication. MSEC2017‐3018 Bo Cheng, University of Alabama, Tuscaloosa, AL, United States, Y. Kevin Chou, The University of Alabama, Tuscaloosa, AL, United States Overhang structures are commonly found in Powder‐bed metal additive manufacturing (AM) such as electron beam additive manufacturing (EBAM) process. The EBAM is assumed to build overhang structure without support features since powder bed could provide support. However, heat dissipation difference by sintered powder and solid substrate for overhang feature actually causes severe part distortion and requires support structure. Current support generation methods usually used certain types of structure to cover the overhang space. They may overestimate the support volume or put a large amount of supports, which could not be necessary and increase the post process time. Thus, the object of this task is to enhance the performance and efficient usage of the EBAM technology through effective support structure designs. In this study, a combined heat support and support anchor design method has been proposed. Numerical model has been used to evaluate stress and deformation during the design process. The detailed design process has been presented for a typical overhang and the simulation results have indicated that overhang deformation can be greatly reduced using this new method.

Finite Element Analysis of the Friction Stir Forming Process Technical Publication. MSEC2017‐3019 Sladjan Lazarevic, Scott Miller, University of Hawaii at Manoa, Honolulu, HI, United States, Grant Kruger, University of Mich‐ igan, Ann Arbor, MI, United States, Theo van Niekerk, Nelson Mandella Metropolitan University, Port Elizabeth, South Africa, Blair Carlson, General Motors Corporation, Warren, MI, United States Friction stir forming utilizes a friction stirring action to soften and extrude a base material into a cavity in a substrate material thereby forming a joint. In this research, Abaqus software was used to model the process in order to understand the key joint features of interest and provide direction for experimental optimization. A three dimensional, thermo‐mechanical finite element model was developed and applied to simulate the process and obtain detailed stress and temperature distribution plots. Adaptive mesh and contact features were utilized for large deformation of the aluminum work material. It was found that the model accurately predicted the shape of the joint and flash extrusion during the process. The maximum temperature was found at the outer radius of the tool, but was much lower than tem‐ peratures in friction stir welding.

Investigation of Cellular Confinement in 3D Microscale Fibrous Substrates: Fabrication and Metrology Technical Publication. MSEC2017‐3020 Filippos Tourlomousis, William Boettcher, Stevens Institute of Technology, Hoboken, NJ, United States, Houzhu Ding, Stevens Institute of Technology, Jersey City, NJ, United States, Robert Chang, Stevens Institute of Technology, Hoboken, NJ, United States Engineered microenvironments along with robust quantitative models of cell shape metrology that can decouple the effect of various well‐defined cues on a stem cell?s phenotypic response would serve as an illuminating tool for testing mechanistic hypotheses on how stem cell fate is fundamentally regulated. As an experimental testbed to probe the effect of geometrical confinement on cell morphology, poly(?‐caprolactone) (PCL) layered fibrous meshes are fabricated with an in‐house melt electrospinning writing system. Gradual confine‐ ment states of fibroblasts are demonstrated by seeding primary fibroblasts on defined substrates, including a classical two‐dimensional (2D) petri dish and porous 3D fibrous substrates with microarchitectures tunable within a tight cellular dimensional scale window (1‐50 ?m). To characterize fibroblast confinement, a quantitative 3D confocal fluorescence imaging workflow for 3D cell shape representation is presented. The methodology advanced allows the extraction of cellular and subcellular morphometric features including the number, loca‐ tion, and 3D distance distribution metrics of the shape‐bearing focal adhesion proteins.

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Effects of Post Weld Heat Treatments (PWHT) on Friction Stir Welded AA2219‐T87 Joints Technical Publication. MSEC2017‐3021 Mohammad Dewan, Dhaka University of Engineering and Technology, Gazipur, Bangladesh, Muhammad Wahab, Louisiana State University, Baton Rouge, LA, United States, Khurshida Sharmin, Dhaka University of Engineering and Technology, Gazi‐ pur, Select State/Province, Bangladesh Friction Stir Welding (FSW) offers significantly better performance on aluminum alloy joints compared to the conventional fusion arc weld‐ ing techniques; however, plastic deformation, visco‐plastic flow of metals, and complex non‐uniform heating cycles during FSW processes, result in dissolution of alloying elements, intrinsic microstructural changes, and post‐weld residual stress development. As a consequence, about 30% reduction in ultimate strength (UTS) and 60% reduction in yield strength (YS) were observed in defect‐free, as‐welded AA2219‐T87 joints. PWHT is a common practice to refine grain‐coarsened microstructures which removes or redistributes post‐weld resid‐ ual stresses; and improves mechanical properties of heat‐treatable welded aluminum alloys by precipitation hardening. An extensive ex‐ perimental program was undertaken on PWHT of FS‐ welded AA2219‐T87 to obtain optimum PWHT conditions and improvement of the tensile properties. Artificial age‐hardening (AH) helped in the precipitation of supersaturated alloying elements produced around weld nugget area during the welding process. As a result, an average 20% improvement in YS and 5% improvements in UTS was observed in age‐ hardened (AH‐170°C‐18h) specimens as compared to AW specimens. To achieve full benefit of PWHT, solution‐treatment followed by age‐hardening (STAH) was performed on FS‐welded AA2219‐T87 specimens. Solution‐treatment (ST) helps in the grain refinement and formation of supersaturated precipitates in aluminum alloys. Age‐hardening of ST specimens help in the precipitation of alloying elements around grain boundaries and strengthen the specimens. Optimum aging period is important to achieve better mechanical properties. For FS‐ welded AA2219‐T87 peak aging time was 5 hours at 170°C. STAH‐170°C ‐5h treated specimens showed about 78% JE based on UTS, 61% JE based on yield strength, and 36% JE based on tensile toughness values of base metal.

Development of an Integrated Melt Modulation System to Manipulate Cold‐Runner Injection Molding Processing Parame‐ ters and Their Effects on Final Product Physical and Optical Properties Technical Publication. MSEC2017‐3022 Majed Alsarheed, Australian College of Kuwait, Emmaus, PA, United States Packing processing parameters, including packing pressure and packing time, have significant impact on the internal molecular orientations, mechanical properties and optical performance of injection molded polymeric products. One of the limitations of cold‐runner injection molding machines is the lack of real‐time control of packing processing parameters during an injection molding cycle. As a result, a new melt modulation device has been developed and experimentally validated to control melt flow and manipulate processing parameters dur‐ ing cold‐runner manufacturing. The use of the integrated melt modulation device has shown enhancement of physical properties and optical performance of injection molded polymeric products. Numerical simulations and experimental results of common thermoplastic optical polymers, such as PMMA, PC, and GPPS have been conducted and briefly demonstrated herein.

Development of Laser Polishing As an Auxiliary Post‐Process to Improve Surface Quality in Fused Deposition Modeling Parts Technical Publication. MSEC2017‐3024 Mario Perez‐Dewey, Durul Ulutan, Bucknell University, Lewisburg, PA, United States Laser polishing is a highly effective surface treatment process mainly used on metals and optical components, but it can also be used on plastic parts. It requires no manual labor, can be applied on parts of any size, and produces no hazardous or polluting substances on many plastic parts. Fused deposition modeling (FDM) is an additive manufacturing process in which parts are built by extruding thin layers of hot material through a nozzle. It has the advantage of producing complicated part geometries, and the possibility to change a design with no additional cost. This study investigates the use of laser polishing as an auxiliary post‐process on Polylactic Acid (PLA) parts produced with FDM to improve the surface quality of final products. Although YAG lasers are commonly used in assisting metal machining processes, a CO2 laser was utilized in this study to post‐process 3D‐printed parts in order to reduce the staircase appearance. The main purpose of this study is to demonstrate that instead of reducing step size in 3D printing processes, it is possible to use bigger step sizes and laser treat the surface quickly afterwards to decrease the total process time while not compromising from surface quality. Laser speeds of 43‐180 mm/s and laser powers of 0.75‐3.75 W were tested on blocks of 3D‐printed PLA with a parallelogram prism shape at 0.3 mm layer height. By var‐ ying laser speed and power, roughness reductions of up to 97% were achieved resulting in a uniform average surface roughness of 2.02 µm. This presents a fast, automatable, and inexpensive auxiliary post‐process to FDM. 75

Bending Mechanism Analysis for Laser Forming of Metal Foam Technical Publication. MSEC2017‐3026 Tizian Bucher, Adelaide Young, Columbia University, New York, NY, United States, Min Zhang, Chang Jun Chen, School of Mechanical and Electrical Engineering, Laser Processing Research Cente, Suzhou, China, Y Lawrence Yao, Columbia Univ, New York, NY, United States To date, the industrial production of metal foam components has remained challenging, since few methods exist to manufacture metal foam into the shapes required in engineering applications. Laser forming is currently the only method with a high geometrical flexibility that is able to shape arbitrarily sized parts. What prevents the industrial implementation of the method, however, is that no detailed ex‐ perimental analysis has been done of the metal foam strain response during laser forming, and hence the existing numerical models have been insufficiently validated. Moreover, current understanding of the laser forming process is poor, and it has been assumed, without ex‐ perimental proof, that the temperature gradient mechanism (TGM) from sheet metal forming is the governing mechanism for metal foam. In this study, these issues were addressed by using digital image correlation (DIC) to obtain in‐process and post‐process strain data that was then used to validate a numerical model. Additionally, metal foam laser forming was compared with metal foam 4‐point bending and sheet metal laser forming to explain why metal foam can be bent despite its high bending stiffness, and to evaluate whether TGM is valid for metal foam. The strain measurements revealed that tensile stretching is only a small contributor to foam bending, with the major con‐ tributor being compression‐induced shortening. Unlike in sheet metal laser forming, this shortening is achieved through cell wall bending, as opposed to plastic compressive strains. Based on this important difference with traditional TGM, a modified temperature gradient mechanism (MTGM) was proposed.

Empirical Modeling of Material Removal Considering Tool Condition in Chemical Mechanical Planarization Process Technical Publication. MSEC2017‐3027 Zhenhua Wu, Virginia State University, Petersburg, VA, United States The key performance indicators in Chemical Mechanical Planarization (CMP) processes are usually assessed by measuring the material re‐ moval rate (MRR) and Within‐Wafer‐Nonuniformity (WIWNU), which are vitally dependent on the processing variables including down pressure, rotation of wafer and rotation of polishing pad, slurry flow, and the condition of the polishing pad etc. MRR is critical to the WIWNU since MRR will infer the end‐point in the polishing process. In this study, empirical approaches were conducted to model the MRR with the production CMP settings. With the collected data from real semiconductor manufacturing processes, correlation and principle component analysis (PCA) were conducted to select the features mostly related to the CMP process, then neural network (NN) and adap‐ tive neuro fuzzy inference system (ANFIS) based models were proposed to understand process parameters in CMP process and estimate the MRR. The NN and ANFIS models were compared on the performance metrics of 1) mean square error (MSE), and determination coeffi‐ cient (R2) based on bootstrap. The bootstrap based evaluation shows that NN achieved a MSE of 9.68e03 with the R2 value of 0.81 in the training stage and MSE of 9.59e3 with the R2 value of 0.81 in the validation stage; ANFIS achieved a MSE of 126.24 with the R2 value of 0.9102 in the training stage and MSE of 6.17e4 with the R2 value of 0.3133 in the validation stage. The empirical model is promising to be integrated with the data‐driven based control of CMP processes.

Modeling of Absolute Distance Meter Shift Inside a Laser Tracker Technical Publication. MSEC2017‐3028 He Li, Missouri University of Science and Technology, Rolla, MO, United States, Robert Landers, Missouri Univ Of Sci & Tech, Rolla, MO, United States, Douglas Bristow, Missouri University of Science and Technology, Rolla, MO, United States In the measurement of machine tool and robot geometric errors, one of the most extensively used instruments is the Laser Tracker (LT). Errors in the LT measurements will decrease the effectiveness of the error modeling and compensation methods that utilize these meas‐ urements. When the LT?s Absolute Distance Meter (ADM) is used without frequent referencing to a home position, large and long‐term shifts occur. The ADM shift directly introduces errors in the radial component of every measurement in spherical coordinates, which will result in measurement errors in the Cartesian coordinates. Although the ADM shift is addressed in newer LT designs using internal refer‐ encing hardware, this paper presents a pragmatic and efficient software solution to ADM shift for LTs in which the internal referencing hardware is not embedded. The LT was measured for 22 hr in a temperature‐constant room to examine the ADM shift effects on meas‐ urements. An ADM shift model was then proposed by assuming that the ADM shift equally affects radial components of all measurements wherever the target is, as long as it is within the measurement range. Another experiment was then performed to test the validity of the

76 proposed model. After the model was identified and errors were corrected, the maximum temporal variation in the radial distance meas‐ urement is reduced by 80‐86%.

Material Flow Analysis for the Incremental Sheet‐Bulk Gearing by Rotating Tools Technical Publication. MSEC2017‐3029 Sebastian Wernicke, Institute of Forming Technology and Lightweight Construction TU Dortmund University, Dortmund, NRW, Germany, Peter Sieczkarek, Institute of Forming Technology and Lightweight Construction / TU Dortmund University, Dort‐ mund, NRW, Germany, Joshua Grodotzki, Soeren Gies, Institute of Forming Technology and Lightweight Construction TU Dortmund University, Dortmund, NRW, Germany, Nooman Ben Khalifa, Institute of Forming Technology and Lightweight Construction, TU Dortmund University, Dortmund, Germany, A. Erman Tekkaya, Institute of Forming Technology and Light‐ weight Construction / TU Dortmund University, Dortmund, Germany The manufacturing of gear‐elements by forming offers advantages regarding the resulting mechanical properties of the functional compo‐ nents. One possible approach is offered by the incremental sheet‐bulk metal forming of gears, which is highly flexible but economically not efficient regarding the high process time. This paper presents a new sheet‐bulk gear forming process using rotating tools to speed up the manufacturing of load‐adapted gears. Here, different concepts with non‐synchronized and synchronized rotating tools are investigated to form high‐strength gears in bainitic steel BS600. The focus is on the analysis of the occurring material flow which is examined by means of finite element analysis and microstructural investigations to ensure the manufacture of fully functional geared components by sheet‐bulk metal forming

Cutting Simulation in Drilling on Cylinder Surface in Turning Center Operation Technical Publication. MSEC2017‐3030 Takashi Matsumura, Tokyo Denki University, Tokyo, Tokyo, Japan, Shoichi Tamura, Tochigi Industrial Technology Center, Utsunomiya, Tochigi, Japan Drillings and millings of cylinders are performed in operations on turning centers. Then, the drill holes are machined on the cylinder surfac‐ es with offsets of the cutting positions from the workpiece axis. The paper presents an analytical model to predict the cutting force in drill‐ ing of cylinders. Three dimensional chip flow is interpreted as a piling of the orthogonal cuttings in the planes containing the cutting veloci‐ ties and the chip flow velocities. In drilling, the chip flow models are made on the chisel and the lips. The chip flow directions are deter‐ mined to minimize the cutting energies on the chisel and the lips. The workpiece model on the cylinder is defined by the cutting point with respect to the cylinder shape. The cutting force in drilling of a cylinder is compared with that in drilling of a plate. Then, the effect of the offset cutting points on the cutting force is discussed in terms of the resultant cutting force, which induces the machining error and the tool breakage.

Multi‐Scale Stereolithography Using Shaped Beams Technical Publication. MSEC2017‐3031 Yong Chen, Huachao Mao, Yuen‐Shan Leung, Yuanrui Li, Pan Hu, Wei Wu, University Of Southern California, Los Angeles, CA, United States Current Stereolithography (SL) can fabricate three‐dimensional (3D) objects in a single scale level, e.g. printing macro‐scale or micro‐scale objects. However, it is difficult for the SL printers to fabricate a 3D macro‐scale object with micro‐scale features. In the paper a novel SL‐based multi‐scale fabrication method is presented to address such a problem. The developed SL process can fabricate multi‐scale fea‐ tures by dynamically changing the shape and size of a laser beam. Different shaped beams are realized by switching apertures with differ‐ ent micro‐patterns. The laser beam without using any micro‐patterns is used to fabricate the macro‐scale features, while the shaped laser beams with smaller sizes are used to fabricate micro‐patterned features. Accordingly, the tool path planning method for the multi‐scale fabrication process are developed so that macro‐scale and micro‐scale features can be built by using different layer thicknesses, laser ex‐ posure time, and scanning paths. Compared with the conventional SL process based on a fixed laser beam size, our process can fabricate multi‐scale features in a 3D object. It also has fast fabrication speed and good surface quality.

77

Structure of Electrospray Printed Deposits for Short Spray Times Technical Publication. MSEC2017‐3032 Nicholas Brown, Yaqun Zhu, Ao Li, Mingfei Zhao, Xin Yong, SUNY Binghamton, Binghamton, NY, United States, Paul R. Chiarot, State University of New York At Binghamton, Binghamton, NY, United States In electrospray printing, a plume of highly charged droplets is created from a conductive ink. Printing occurs by positioning a target sub‐ strate in the path of the emitted material. Here, the ink used is a colloidal dispersion consisting of nanoparticles suspended in a volatile solvent. The selection of a volatile solvent allows for rapid evaporation of the droplets in‐flight to produce dry nanoparticles. Electrospray imparts excess electric charge onto the emitted particles. The interaction of this charge with the global electric field and with other charged particles/droplets governs the particles’ trajectory and ultimately determines the microstructure of the printed deposit. In this study, we characterized the structure of nanoparticle deposits printed using electrospray after short spray times. Electrospray printing is capable of exerting much finer control over microstructure compared to traditional printing techniques. This has significant implications in the manu‐ facturing of thin‐films

Simulations of Microstructure Evolution During Friction Stir Blind Riveting Using a Cellular Automaton Method Technical Publication. MSEC2017‐3034 Avik Samanta, Ninggang Shen, Haipeng Ji, University of Iowa, Iowa City, IA, United States, Weiming Wang, University of Hawaii at Manoa, Honolulu, HI, United States, Hongtao Ding, The University of Iowa, Iowa City, IA, United States, Jingjing Li, The Pennsylvania State University, University Park, PA, United States Friction stir blind riveting (FSBR) is a novel and highly efficient joining technique for lightweight metal materials, such as aluminum alloys. The FSBR process induced large gradients of plastic deformation near the rivet hole surface and resulted in a distinctive gradient micro‐ structure in this domain. In this study, microstructural analysis is conducted to analyze the final microstructure after the FSBR process. Dy‐ namic recrystallization (DRX) is determined as the dominant microstructure evolution mechanism due to the significant heat generation during the process. To better understand the FSBR process, a two‐dimensional Cellular Automaton (CA) model is developed to simulate the microstructure evolution near the rivet hole surface by considering the FSBR process loading condition. To model the significant micro‐ structure change near the rivet hole surface, spatial distributed temporal thermal and mechanical loading conditions are applied to simu‐ late the effect of the large gradient plastic deformation near the hole surface. The distribution grain topography and recrystallization frac‐ tion are obtained through the simulations, which agree well with the experimental data. This study presents a reliable numerical ap‐ proach to model and simulate microstructure evolution governed by DRX under the large plastic deformation gradient in FSBR

Laser Surface Engineering of Hierarchy Hydroxyapatite Aerogel for Bone Tissue Engineering Technical Publication. MSEC2017‐3035 Pedram Parandoush, Hanxiong Fan, Xiaolei Song, Dong Lin, Kansas State University, Manhattan, IL, United States Bioceramics with porous microstructure has attracted intense attention in tissue engineering due to tissue growth facilitation in the human body. In the present work, a novel manufacturing process for producing hydroxyapatite (HA) aerogels with a high density shell inspired by human bone microstructure is proposed for bone tissue engineering applications. This method combines laser processing and traditional freeze casting in which HA aerogel is prepared by freeze casting and aqueous suspension prior to laser processing of the aerogel surface with a focused CO2 laser beam that forms a dense layer on top of the porous microstructure. Using the proposed method, HA aerogel with dense shell was successfully prepared with a microstructure similar to human bone. The effect of laser process parameters on surface and cross‐sectional morphology and microstructure was investigated in order to obtain optimum parameters and have a better understanding of the process. Low laser energy resulted in fragile surface with defects and cracks due to low temperature and inability of laser to fully melt the surface while high laser energy caused thermal damage both to surface and microstructure. The range of 40‐45 W laser power, 5 mm/s scanning speed, spot size of 1 mmm and 50 % overlap in laser scanning the surface yielded the best surface morphology and micro structure in our experiments.

The Effect of Multi‐Point Electrical Paths on Global Springback Elimination in Single Point Incremental Forming Technical Publication. MSEC2017‐3036 Jacklyn Niebauer, Derek Shaffer, Penn State Erie, The Behrend College, Erie, PA, United States, Ihab Ragai, Penn State University, Erie, PA, United States, John Roth, Penn State Erie, The Behrend College, Erie, PA, United States 78

Automotive and aerospace industries are interested in implementing die‐less forming processes in order to reduce part costs and the re‐ quired forming energy. One method of die‐less forming is incremental forming, in which a sheet metal part is formed; typically with a hem‐ ispherical tool that deforms material as it pushes into the material and passes along the surface to create the desired part geometry. One problem with incremental forming is global springback, which occurs after the part has been formed and is released from the forming fix‐ ture. This effect is caused by residual stresses that are created during part deformation and result in geometric inaccuracies after the clamping force has been released. In this paper, the effect of post‐deformation applied direct current on the springback of pre‐formed sheet metal will be investigated. This is a process is a type of electrically assisted manufacturing (EAM). This paper is a continuation of pre‐ vious works presented at MSEC 2015‐2016. The initial feasibility study described herein already achieves a springback reduction of 26.3% and is dependent on the regions of high stress concentration as well as current density. Future work will extend this reduction through further testing of complex configurations.

The Effects of Polarity and Current Path in Electrically Assisted Single Point Incremental Forming of 2024‐T3 Aluminum Technical Publication. MSEC2017‐3037 Tyler Grimm, Penn State University, Erie, Beaver, PA, United States, Ihab Ragai, Penn State University, Erie, PA, United States, John Roth, Penn State Erie, The Behrend College, Erie, PA, United States Electrically assisted incremental sheet forming (EAIF) is a novel addition to the incremental forming (IF) method. One variation of this ap‐ proach applies direct electrical current during forming. Many improvements over tradition IF can be seen by utilizing this method, to in‐ clude greater part accuracy, reduced forming force, and greater formability. In order to maximize the effects of electrically assisted incremental forming, all parameters of the method must be investigated, including the polarity of the current passing through the part and the path that the applied current takes. The effects of altering these two parame‐ ters is the primary investigation in this research. It was determined that, in order to optimize springback reduction and formability during electrically assisted single point incremental forming, the tool should be assigned the positive electrode and the center of the workpiece should be assigned the negative electrode. Additionally, the mechanism behind the spalling effect inherent to EAIF is discussed.

Interoperability in Cloud Manufacturing and Practice on Private Cloud Structure for SMEs Technical Publication. MSEC2017‐3038 Xi Vincent Wang, Lihui Wang, KTH, Royal Institute of Technology, Sweden, Stockholm, Sweden In recent years, Cloud manufacturing has become a new research trend in manufacturing systems leading to the next generation of produc‐ tion paradigm. However, the interoperability issue still requires more research due to the heterogeneous environment caused by multiple Cloud services and applications developed in different platforms and languages. Therefore, this research aims to combat the interoperabil‐ ity issue in Cloud Manufacturing System. During implementation, the industrial users, especially Small‐ and Medium‐sized Enterprises (SMEs), are normally short of budget for hardware and software investment due to financial stresses, but they are facing multiple chal‐ lenges required by customers at the same time including security requirements, safety regulations. Therefore in this research work, the proposed Cloud manufacturing system is specifically tailored for SMEs.

The Effect of Polyethylene (Glycol) Diacrylate Post‐Fabrication Rest Time on Compressive Properties Analysis of Cryogeni‐ cally Treated Sheet 6/6 Technical Publication. MSEC2017‐3039 Derek Shaffer, Cody Reinstadtler, John Roth, Penn State Erie, The Behrend College, Erie, PA, United States, Ihab Ragai, Penn State University, Erie, PA, United States When manufacturing polymer and rubber products, the parts are frequently exposed to cryogenic temperatures after molding or forming in order to improve the ability to remove excess material and flash. However, there has been very little investigation into the effect that cryogenic temperatures may have on polymers. As such, the goal of the research described herein is to examine the effect of this type of treatment on the properties of one such polymer, Nylon 6/6. More specifically, the temperature of the environment surrounding Nylon 6/6 is decreased at two different rates into the cryogenic temperature range, allowed to soak, and then returned to ambient. Whereupon the material properties of the treated Nylon are compared to baseline. This testing demonstrates that the exposure to the cold environment

79 resulted in a decrease in the yield and ultimate tensile strength of the Nylon while leaving the area reduction and strain after necking roughly unchanged. Examination of the surface condition of the treated specimens did not bring to light corresponding cracking from the treatments, thereby indicated that the resultant change in mechanical behavior is likely caused by structural changes within the Nylon. Additional testing of the Nylon, with respect to frequency response, further demonstrated that exposure to cryogenic temperatures re‐ sulted in decreases in the Nylon?s natural response at the structure?s dominate mode. These initial findings indicate that the conven‐ tional technique of lowering a part’s temperature to enhance the ability to remove flash does, in fact, result in measurable changes in the mechanical behavior of the Nylon product.

FEM Investigation of the Effects of Impact Speed and Angle of Impacts of Abrasive in the Vibration Assisted Nano Impact Machining by Loose Abrasives Technical Publication. MSEC2017‐3043 Nick Duong, Jianfeng Ma, Saint Louis University, Saint Louis, MO, United States, Shuting Lei, Kansas State Univ, Manhattan, KS, United States In this paper, the commercial FEM software package Abaqus is employed to model the novel nanomachining process, Vibration Assisted Nano Impact machining by Loose Abrasives (VANILA), which combines the principles of vibration‐assisted abrasive machining and tip‐based nanomachining to conduct nano abrasive machining of hard and brittle materials. In this novel nanomachining process, an atomic force microscope (AFM) is used as a platform and the nano abrasives injected in slurry between the workpiece and the vibrating AFM probe im‐ pact the workpiece and result in nanoscale material removal. Diamond particles are used as the loose abrasives. The effects of impact speed, angle of impacts, and the frictional coefficient between the workpiece and abrasives are investigated using Abaqus. It is found that the impact speed, impact angle, and frictional coefficient between the silicon workpiece and nanoabrasives have big influence on the nanocavity?s size and depth.

Experimental Investigation of Key Process Parameters During Continuous‐Bending‐Under‐Tension of AA6022‐T4 Technical Publication. MSEC2017‐3045 Timothy Roemer, Kimball Union Academy, Bow, NH, United States, Brad Kinsey, Yannis Korkolis, Edward Momanyi, Univer‐ sity of New Hampshire, Durham, NH, United States Continuous‐Bending‐Under‐Tension (CBT) is an experimental technique that has been shown to increase elongation‐to‐fracture by over 100% in aluminum alloys and over 300% in steel as compared to uniaxial tensile tests [1]. This procedure is a modified form of a tensile test in which a specimen experiences 3 point plastic bending, induced by traversing 3 rollers back and forth over the gauge length, while simul‐ taneously being pulled in tension. This process is able to delay the occurrence of necking in pure tension by suppressing the instability. Thus, significantly more elongation is achieved in the specimen prior to fracture. In this paper, an experimental investigation of key process parameters, i.e., bending depth and pulling speed, during CBT testing of AA6022‐T4 is presented. The load cycle during a CBT test will also be discussed along with the strain induced throughout the gauge length.

Electrically Assisted Drilling of Usibor 1500 Boron Steel and its Implications for Electrically Assisted Machining Technical Publication. MSEC2017‐3046 Nived Govind Karumatt, Clemson University International Center for Automotive Research, Greenville, SC, United States, Brandt Ruszkiewicz, Clemson University, International Center for Automotive Research, Greenville, SC, United States, Laine Mears, Clemson University, Anderson, SC, United States With the increasing demands in the automotive industry for passenger safety and higher structural strength and stiffness, the automotive industry is using more advanced high strength steels. The ability to reduce tool wear and drilling forces in post forming drilling of high strength steel parts is of high importance to the automotive industry. Electrically assisted drilling is a process in which electric current is passed through the drill bit to the workpiece resulting in local softening, and allowing for a reduction in cutting forces and potential in‐ crease in tool life. In this paper, tungsten carbide (WC)‐tipped drill bits are used to study the effect of varying electrical current on 1500 Usibor® steel work pieces. The effects of current on the drilling process of high strength steel are investigated in this research by studying the maximum temperature during drilling, the dependence of chip formation, tool wear and the axial force during the drilling operation. It was found that the magnitude of current passed through the workpiece directly influences the axial force that the tool experiences, and thus the tool wear. This effect is modeled through Joule heating, leading to elevated temperature and thermal softening. 80

Integrate Manufacturing Planning to Cloud Manufacturing Framework Technical Publication. MSEC2017‐3047 Xiangyun Li, Southwestern Jiaotong University, Chengdu, China, luping Zhang, Southwestern University of Finance and Eco‐ nomics, Chengdu, China, chunxia Yu, China University of Petroleum‐Beijing, Beijing, China We provide a cloud manufacturing based manufacturing planning framework for small and medium‐sized enterprises. Manufacturing plan‐ ning is conducted by separate units in the cloud instead of in corporations or manufacturing platforms. Disorders can be removed by the adoption of our newly‐introduced units. To retain the workability of our new framework, three assumptions are imposed. A concrete case on process planning and scheduling is used for illustration of the necessity of our assumptions and operational mechanism of our design. Finally, a preliminary discuss on how intellect resources as well as small and medium‐sized enterprises are involved to create a sustainable environment for small and medium‐sized enterprises is placed. Keywords: manufacturing planning; cloud manufacturing; sustainable manufacturing; intellect resources.

Development of a New Laser‐Assisted Additive Manufacturing Technology for Hybrid Functionally Graded Material Composites Technical Publication. MSEC2017‐3048 Jung Sub Kim, Young Chang Kim, Sang Won Lee, Sungkyunkwan University, Suwon, Korea (Republic), Jeonghan Ko, Ajou University, Suwon, Korea (Republic), Haseung Chung, University of Michigan, Ann Arbor, MI, United States This paper investigates a new technology to create functionally graded material (FGM) by additive manufacturing (AM). In particular, this paper focuses on creating graphene‐polymer composite FGM by laser‐based sintering processes. Graphene‐polymer composites have re‐ ceived high attention in AM due to their excellent electrical conductivity, thermal stability and mechanical strength. However, AM of the graphene‐polymer composites has a huge challenge to overcome. The heterogeneous materials should be mixed properly, and it is not easy to achieve the desired composite characteristics solely by changing the mass ratio of graphene. This paper shows a newly developed la‐ ser‐assisted AM system for the graphene‐polymer composite FGM by laser‐based sintering processes. The paper also describes two meth‐ ods of material integration: mixing graphene and polyethylene powders before sintering, and depositing the different material powders separately and sintering them. This study identified that the two method led to different mechanical and electrical properties of the creat‐ ed parts. Thus this paper demonstrates the possibility to create quite useful hybrid (mechanically and electrically) FGM composites.

Turning Force Prediction of AISI 4130 Considering Dynamic Recrystallization Technical Publication. MSEC2017‐3049 Zhipeng Pan, Yixuan Feng, Georgia Institute of Technology, ATLANTA, GA, United States, Xia Ji, Donghua University, Shang‐ hai, China, Steven Liang, Georgia Institute Of Technology, Atlanta, GA, United States Thermal mechanical loadings in machining process would promote material microstructure changes. The material microstructure evolution, such as grain size evolution and phase transformation could significantly influence the material flow stress behavior, which will directly affect the machining forces. An analytical model is proposed to predict cutting forces during the turning of AISI 4130 steel. The material dynamic recrystallization is considered through Johnson‐Mehl‐Avrami‐Kolmogorov (JMAK) model. The explicit calculation of average grain size is provided in an analytical model. The grain size effect on the material flow stress is considered by introducing the Hall‐Petch relation into a modified Johnson‐Cook model. The cutting forces prediction are based on Oxley?s contact mechanics with consideration of mechan‐ ical and thermal loads. The model is validated by comparing the predicted machining forces with experimental measurements.

Study of Layer Formation During Droplet‐Based 3D Printing of Gel Structures Technical Publication. MSEC2017‐3050 Kyle Christensen, Yong Huang, University of Florida, Gainesville, FL, United States Additive manufacturing, also known as three‐dimensional (3D) printing, is an approach in which a structure may be fabricated layer by lay‐ er. For 3D inkjet printing, droplets are ejected from a nozzle and each layer is formed droplet by droplet. Inkjet printing has been widely applied for the fabrication of 3D biological gel structures, but the knowledge of the microscale interactions between printed droplets is still 81 largely elusive. This study aims to elucidate the alginate layer formation process during drop‐on‐demand inkjet printing using high speed imaging and particle image velocimetry. Droplets are found to impact, spread, and coalesce within a fluid region at the deposition site, forming coherent printed lines within a layer. Interfaces are found to form between printed lines within a layer depending on printing con‐ ditions and printing path orientation. The effects of printing conditions on the behavior of droplets during layer formation are discussed and modeled based on gelation dynamics, and recommendations are presented to enable controllable and reliable fabrication of gel struc‐ tures.

A Desktop Application for Sustainability Performance Assessment of Composed Unit‐Based Manufacturing Systems Technical Publication. MSEC2017‐3051 Matteo M. Smullin, Zahra Iman, Karl Haapala, Oregon State University, Corvallis, OR, United States Life cycle assessment software packages such as SimaPro, GaBi, and Umberto have in past years become well established tools for con‐ ducting environmental impact analysis. However, applications for broader sustainability assessment are limited. Recent research has de‐ veloped an information modeling framework to compose unit manufacturing models for sustainable assessment and has led to the defini‐ tion of unit manufacturing process information modeling concepts. An engineer can use the framework to generate a manufacturing sys‐ tem sustainability assessment by composing unit manufacturing process models. The results can aid engineers in selecting the superior manufacturing system for a given product. To demonstrate usefulness of the information framework, a prototype desktop application was developed. The application was implemented in Windows Project Foundation (WPF) using C# as the coding language to create a graphical user interface. Mathworks MATLAB serves as the calculation engine. Unit manufacturing process models are written following the frame‐ work and then read by the application, which then produces a sustainability assessment for the manufacturing system. An automobile‐like metal product manufacturing system acts as the case study demonstrating the use of the application.

Study of Chip Morphology and Chip Formation Mechanism During Machining of Magnesium‐Based Metal Matrix Composites Technical Publication. MSEC2017‐3052 Brian Davis, David Dabrow, University of Florida, Gainesville, FL, United States, Licheng Ju, Florida State University, Tallahas‐ see, FL, United States, Anhai Li, University of Florida, Gainesville, FL, United States, Chengying Xu, Florida State Univ, Talla‐ hassee, FL, United States, Yong Huang, University of Florida, Gainesville, FL, United States Magnesium (Mg) and its alloys are among the lightest metallic structural materials, making them very attractive for use in the aerospace and automotive industries. Recently, Mg has been used in metal matrix composites (MMCs), demonstrating significant improvements in mechanical performance. However, the machinability of Mg‐based MMCs is still largely elusive. In this study, Mg‐based MMCs are ma‐ chined using a wide range of cutting speeds in order to elucidate both the chip morphology and chip formation mechanism. Cutting speed is found to have the most significant influence on both the chip morphology and chip formation mechanism, with the propensity of discon‐ tinuous, particle‐type chip formation increasing as the cutting speed increases. Saw‐tooth chips are found to be the primary chip morphol‐ ogy at low cutting speeds (lower than 0.5 m/s), while discontinuous, particle‐type chips prevail at high cutting speeds (higher than 1.0 m/s). Using in situ high speed imaging, the formation of the saw‐tooth chip morphology is found to be due to crack initiation at the free surface. However, as the cutting speed (and strain rate) increases, the formation of the discontinuous, particle‐type chip morphology is found to be due to crack initiation at the tool tip. In addition, the influences of tool rake angle, particle size, and particle volume fracture are investi‐ gated and found to have little effect on the chip morphology and chip formation mechanism.

Chatter Suppression in Parallel Turning With Unequal Pitch Using Observer Based Cutting Force Estimation Technical Publication. MSEC2017‐3054 Shinya Sakata, Takashi Kadota, Yuki Yamada, Keio University, Yokohama, Japan, Kenichi Nakanishi, Nakamura‐Tome Preci‐ sion Industry Co, Kanazawa, Japan, Hayato Yoshioka, Tokyo institute of technology, Tokyo, Japan, Norikazu Suzuki, Nagoya University, Nagoya, Aichi, Japan, Yasuhiro Kakinuma, Keio University, Yokohama, Select State/Province, Japan Parallel turning attracts attention as one of the important technologies for the multi‐tasking machine tools. This is because there is a po‐ tential to enhance the stability limits compared to turning operation using single tool when cutting conditions are properly selected. Alt‐ hough stability prediction models for parallel turning have been developed in recent years, in‐process monitoring technique of chatter is 82 almost out of focus. In this study, to suppress chatter vibration, unequal pitch turning method was proposed. In this method, the upper tool was properly con‐ trolled based on optimum pitch angle calculated from spindle speed and chatter frequency. Chatter frequency was identified from esti‐ mated cutting force by disturbance observer. From the result of parallel turning test, it is clear that chatter vibration can be suppressed by controlling the upper tool based on optimum pitch angle.

Efficient Prediction of Contact Behavior in a 6‐High Rolling Mill With Continuously Variable Crown Intermediate Rolls Technical Publication. MSEC2017‐3058 Feng Zhang, Arif Malik, University of Texas at Dallas, Richardson, TX, United States Continuously Variable Crown (CVC) shifting mechanisms represent a control technology with wide range of capability to influence the thickness profile and flatness (shape) of metal strip and sheet in rolling‐type manufacturing processes. Further, because of the efficiency and extensive control capability to operate on thin‐gauge, high‐strength ferrous alloys, the 6‐high mill with CVC profiles machined onto the intermediate rolls (IR) represents a popular mill configuration because of the large control range for the strip thickness profile that results from lateral shifting of the intermediate rolls. However, together with this efficiency and capability comes very complex contact behaviors between the rolls and strip, including highly non‐linear contact force distribution, loss of contact, asymmetric roll wear, unwanted strip wedge profiles, and need to apply corrective roll tilting. Therefore, for most effective industry use of 6‐high mills with intermediate roll CVC shifting, a rapid and accurate mathematical rolling model is needed to predict and account for these complex contact behaviors. This paper introduces an efficient roll‐stack model capable of modeling such rolling mills under steady‐state conditions. The model formulation applies the simplified mixed finite element method (SMFEM), which is adapted to simulate asymmetric 6‐high CVC mill contact behaviors. Results for a specific case study compare favorably to those obtained from a large‐scale commercial finite element simulation, yet require a small fraction of the associated computational time and effort.

Graphene Growth on and Transfer From Platinum Thin Films Technical Publication. MSEC2017‐3059 Joon Hyong Cho, The University of Texas at Austin, Austin, TX, United States, Michael Cullinan, University of Texas at Austin, Austin, TX, United States This paper presents graphene growth on Pt deposited on four different adhesion layers such as Ti, Cr, Ta, and Ni. During the graphene growth at 1000 oC using conventional Chemical Vapor Deposition method, these adhesion layers diffuse into and alloy with Pt layer result‐ ing graphene to grow on different alloys. Therefore, Pt layer on different adhesion layers induces different quality and number of layer(s) of graphene grown on the film. Monolayer graphene was produced on majority of metal layers except on Pt/Ta layer where bilayer graphene is observed. The lowest defects were found on graphene grown on Pt/Ni film where slightly higher number of wrinkles are observed com‐ pared to other alloys. We characterized graphene using SEM images of transferred graphene, of Pt grains after the growth of graphene, and of in‐depth profiles of thin film via TOF‐SIMS. Our paper states feasibility of graphene growth on Pt thin film on various adhesion layers and obstacles to overcome to enhance graphene transfer from Pt thin film. We address one of the major difficulties of graphene growth and transfer to implement graphene in NEMS/MEMS devices.

Coolant Channel and Flow Characteristics of MQL Drill Bits: Experimental and Numerical Analyses Technical Publication. MSEC2017‐3060 Yi‐Tang Kao, Behrouz Takabi, Mozheng Hu, Bruce Tai, Texas A&M University, College Station, TX, United States In minimum quantity lubrication (MQL) machining, mist flow plays a critical role in both lubrication and cooling. This paper aims to observe and understand the mist flow structure of different coolant channel designs for internal MQL drilling. Two different channel geometries (circular and triangular cross‐section) and two sizes of each channel were selected for both experimental and computational analyses. The flow structure was captured by a high‐speed camera and explained using computational fluid dynamics (CFD). The results showed that, for all the channel geometries, higher oil concentration was found close to the drill center. Specifically, in the triangular channel, the flow tends to accumulate at three corners. This study also measured the airspeed, which increased with the hydraulic diameter of the channel. This paper has demonstrated the effects of channel geometry and the feasibility of CFD in mist flow analysis.

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Dynamic Response of 3D‐Printed Bi‐Material Structure Using Drop Weight Impact Test Technical Publication. MSEC2017‐3061 Anish Ravindra Amin, Texas A&M Univeristy, College Station, TX, United States, Yi‐Tang Kao, Bruce Tai, Texas A&M University, College Station, TX, United States, Jyhwen Wang, Texas A&m Univ, College Station, TX, United States Additive manufacturing has led to increasing number of applications that require complex geometries and multiple materials. This paper presented a bi‐material structure (BMS) composed of a cushion matrix held by a 3D printed frame structure for an improved impact re‐ sistance. The study mainly focused on understanding the effects of structural topology and matrix material. Two matrix materials, silicone elastomer and polyurethane (PU) foam, were selected to impregnate into two different PLA frame structures. Drop weight impact test was carried out to measure the impact force and energy absorption. The results showed that a more significant improvement was achieved by the structure that can provide an interlocking mechanism with the matrix material and thus avoid delamination and crack propagation. The selected PU foam led more energy absorption and force bearing capacity of the structure than the silicone elastomer.

Bending‐Additive‐Machining Hybrid Manufacturing of Sheet Metal Structures Technical Publication. MSEC2017‐3062 Ye Li, Raghavendra Kalyan Rapthadu, Bradley University, Peoria, IL, United States The ever‐increasing industry innovation demands a paradigm of manufacturing process that is capable of accomplishing multiple tasks on a single component. Majority of structural parts require bending of metal sheets with high degree of accuracy. In many applications bent parts with additional features are sought out for various special purposes. Clearly there is a need calling for the integration of different manufacturing processes to reach a synergistic effect. Traditionally a combination of additive manufacturing and machining is used to alle‐ viate the constraints set forth by machining alone. However this hybrid approach is still constrained by both the limited cutter accessibility and gravity‐imposed deposition direction. This paper presents a new Hybrid Manufacturing configuration by combining bending, deposi‐ tion and machining processes. The major advantage of this new approach hinges on the deliberate use of bending process by providing additional accessibility that is not available on traditional additive ? machining setup. Essentially the accessibility issue is overcome by in‐ troducing an intermediate bending step so that both metal deposition and removal can be conducted in the process‐required orientation. As bending is part of this new hybrid process, springback is also inherent to this new hybrid manufacturing approach. This research incor‐ porates the consideration of both springback compensation and cold hardening effect in the selection of intermediate bending step. Exam‐ ples are also provided to show the efficacy of this new hybrid manufacturing approach

A Modified Dynamic Programming Model in Condition‐Based Maintenance Optimization Technical Publication. MSEC2017‐3065 Mengkai Xu, Md. Noor E Alam, Sagar Kamarthi, Northeastern University, Boston, MA, United States In condition‐based maintenance, preventive replacement threshold and inspection scheme play important roles in maintenance perfor‐ mance. Major research considers cost as the main objective for measuring maintenance performance; here the average cost per unit time is used as the only objective in a single‐unit system. The intention of this study was to investigate that how the average cost per unit time varies through changing replacement threshold and inspection scheme, the aim is to simultaneously determine an optimal replacement threshold and inspection scheme. The heterogeneity of hazard rate over stages of the equipment entails less frequent inspections when the equipment is at a healthy condition and more frequent inspections when the equipment is at a progressively deteriorated condition. Therefore the proposed condition‐based inspection in the present work is non‐periodic. A method based on dynamic programming is de‐ veloped in order to implement a condition‐based inspection scheme; furthermore the threshold for preventive replacement and the in‐ spection scheme are simultaneously determined and then the optimal average maintenance cost is obtained.

Cutting Process Monitoring System Using Audible Sound Signals and Machine Learning Techniques: An Application to End Milling Technical Publication. MSEC2017‐3069 Achyuth Kothuru, Sai Prasad Nooka, Rui Liu, Rochester Institute of Technology, Rochester, NY, United States In a fully automated manufacturing system, tool condition monitoring system is essential to detect the failure in advance and minimize the manufacturing loses with the increase in productivity. To look for a reliable, simple and cheap solution, this paper proposes a new tool 84 wear monitoring model to detect the tool wear progression and early detection of tool failure in end milling using audible sound signals. In this study, cutting tools are classified into six classes based on different flank wear ranges. A series of end milling experiments are operated with a broad range of cutting conditions for each class to collect sound signals. A machine learning algorithm that incorporates support vector machine (SVM) approach coupled with the application of time and frequency domain analysis is developed to correlate observed sound signals? signatures to tool wear conditions. The performance evaluation results of the proposed algorithm have shown accurate predictions in detecting tool wear conditions from the sound signals. In addition, the proposed machine learning approach has shown the fastest response rate, which provides the good solution for on‐line cutting tool monitoring.

Tribological Properties of Textured Cemented Carbide Surfaces of Different Wettability Produced by Pulse Laser Technical Publication. MSEC2017‐3072 Xiuqing Hao, Xiaolu Song, Nanjing University of Aeronautics & Astronautics, Nanjing, China, Liang Li, Ning He, Nanjing Uni‐ versity of Aeronautics and Astronautics, Nanjing, Jiangsu, China The micro/nano textured cemented carbide surface of different wettability was produced by laser scanning and fluorinated treatment. The tribological properties of the un‐textured, oleophobic and oleophilic micro/nano textured surface were investigated experimentally includ‐ ing the effects of crank speed and contact pressure by a reciprocating friction and a wear tester. For all tested surfaces, the friction coeffi‐ cient of the surface decreased as both the increasing crank speed and contact pressure increased. Compared to the un‐textured surface, the friction coefficient of the micro/nano textured surface was significantly decreased, being sensitive to the wettability of the surface. Besides, the tribological properties of the oleophobic micro/nano textured surface were superior to the oleophilic micro/nano textured surface under the same experimental conditions. The improvement in tribological properties of the oleophobic micro/nano textured sur‐ face could be attributed to the low wettability, which was beneficial to rapid accumulation of the lubricating oil on the surface.

Investigation of the Correlation Between Micro‐Scale Particle Distribution in 3D Printing and Macroscopic Composite Per‐ formance Technical Publication. MSEC2017‐3074 Lu Lu, University of Illinois at Chicago, Schaumburg, IL, United States, Erina Baynojir Joyee, Yayue Pan, University of Illinois at Chicago, Chicago, IL, United States To date, various multi‐material and multi‐functional Additive Manufacturing technologies have been developed for the production of mul‐ ti‐functional smart structures. Those technologies are capable of controlling the local distributions of materials, hence achieving gradient or heterogeneous properties and functions. Such multi‐material and multi‐functional manufacturing capability opens up new applications in many fields. However, it is still largely unknown that how to design the localized material distribution to achieve the desired product prop‐ erties and functionalities. To address this challenge, the correlation between the micro‐scale material distribution and the macroscopic composite performance needs to be established. In our previous work, a novel Magnetic‐field‐assisted Stereolithography (M‐PSL) process has been developed, for fabricating magnetic particle‐polymer composites. Hence, in this work, we focus on the study of magnet‐ ic‐field‐responsive particle‐polymer composite design, with the aim of developing some guidelines for predicting the magnet‐ ic‐field‐responsive properties of the composite fabricated by M‐PSL process. Micro‐scale particle distribution parameters, including particle loading fraction, particle magnetization, and distribution patterns, are investigated. Their influences on the properties of particle‐polymer liquid suspensions, and the properties of the 3D printed composites, are characterized. By utilizing the magnetic anisotropy properties of the printed composites, different motions of the printed parts could be triggered at different relative positions under the applied magnetic field. Physical models are established, to predict the particle‐polymer liquid suspension properties and the trigger conditions of fabricated parts. Experiments are performed to verify the physical models. The predicted results agree well with the experimental measurements, indicating the effectiveness of predicting the macroscopic composite performance using micro‐scale distribution data, and the feasibility of using the physical models for guiding the multi‐material and multi‐functional composite design.

Polarization Effect on Out of Plane Configured Nanoparticle Packing Technical Publication. MSEC2017‐3075 Anil Yuksel, Michael Cullinan, University of Texas at Austin, Austin, TX, United States, Jayathi Murthy, University of California at Los Angeles, Los Angeles, CA, United States

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Surface plasmon polaritons are associated with the light‐nanoparticle interaction and results in high enhancement in the gap between the particles. Indeed, this is affected by particle size, spacing, interlayer distance and light source properties. Polarization effect on three‐dimensional (3D) and out of plane nanoparticle packings are presented herein to understand the out of plane configuration effect by using 532 nm plane wave light. This analysis gives insight on the particle interactions between the adjacent layers for multilayer nanoparti‐ cle packings. It has been seen that the electric field enhancement is up to 400 folds for TM (Transverse Tmagnetic)M ( or X‐polarized.) polarization light and 26 folds for TE (Transverse electric) or (Y‐polarized .) polarization llight. Thermo‐optical properties change nonline‐ arly between 0 and 10 nm gap spacing due to the strong and non‐local near‐field interaction between the particles for the TM polarized light; however, this is linear for TE polarized light. This will give insight on the micro/nano heat transport for the interlayer particles for 100 nm diameter of Cu nanoparticle packings under 532 nm light under different polarization for 3‐D interconnect (IC) manufacturing.

Fabrication and Characterization of a Biocompatible Coating Formed on a Heat‐Treated Magnesium Alloy Using Micro‐Arc Oxidation Technical Publication. MSEC2017‐3080 Hamdy Ibrahim, The University of Toledo, Toledo, OH, United States, Mohammad Elahinia, The University of Toledo, Sylvania, OH, United States The fast corrosion rate of magnesium (Mg) alloys is the main problem associated with the use of such biocompatible alloys for bone fixation applications. The corrosion resistance of Mg alloys can be improved by different post‐fabrication processes such as heat treatment and coating. We have heat‐treated a biocompatible Mg‐1.2Zn‐0.5Ca (wt.%) alloy at optimized heat treatment parameters to achieve the high‐ est mechanical strength and corrosion resistance. Afterwards, the heat‐treated alloy was coated with a ceramic layer using micro arc oxida‐ tion (MAO) process to further enhance the corrosion resistance. The microstructure of the prepared samples was investigated using optical microscopy and scanning electron microscopy (SEM). The corro‐ sion characteristics were determined by conducting in vitro electrochemical and immersion corrosion tests. The results showed that the heat treatment process successfully improved the mechanical and corrosion properties of the Mg‐1.2Zn‐0.5Mn (wt.%) alloy. Both the in vitro electrochemical and immersion corrosion tests showed that the MAO‐coated samples have a significantly higher corrosion resistance which results in a significantly lower corrosion rate. This study indicated that the biocompatible coating pro‐ duced by MAO process may be suitable for providing heat‐treated Mg‐Zn‐Ca‐based alloys with protection from corrosion towards synthe‐ sizing bone fixation materials in clinical application.

Investigation on burr height control and chip morphology in dry drilling of Titanium alloys Oral Presentation. MSEC2017‐3084 Shaochun Sui, AVIC Cheng Du Aircraft Industrial (Group) Co.,Ltd., Chengdu, China, Xiaohua Li, Chao Sun, AVIC Cheng Du Air‐ craft Industrial (Group) Co.,Ltd, Chengdu, China Drilling of titanium alloy is being widely used during in aerospace assembly. Burr at the exit surface and long chips tangling along the drill body bring lots of process problems. The burr at the exit surface should be deburred. Otherwise, it will need reassembling operation, which is time‐consuming. Also, the formation of coil continuous chips, different with the segmented chips, leads to the reduction of hole quality and tool breaking. To solve these problems, burrs and chip formation during dry drilling of Ti‐6Al‐4V alloy with solid carbide tools were examined. Dynamic cutting forces were recorded under different cutting speeds and feed rates. The relationship between the burr height and the point angle of the drill was studied through finite element method. The burrs heights were measured by a laser triangulation sys‐ tem. Multi view characterization of both continuous and chips were analyzed by scanning electron microscope (SEM) which includes the cross‐section of top surface, free surface and back surface. It was found that the increase in feed rates significantly affects the burr height and chip morphology, while the influence of cutting speed is little. The burr height decreased from 1259.245um to 47.385um with the in‐ crease of feed rate from 0.03mm/r to 0.27mm/r at the same cutting speeds 35m/min, which change little with the cutting speed increasing from 15m/min to 35m/min. The burr height decreases with the increase of tool point angle. The free surface and cross‐section of the chips were changed obviously with the increase of feed rate. The length of chips decreased with increasing feed rate. This research demonstrates that the control of burr height and breaking chips can be achieved by the proper setting of feed rate and drill point angle. In this study the proper feed rate value is 0.21mm/r and the proper drill point angle is 138°.

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QIF And The Landscape Of Digital Metrology Oral Presentation. MSEC2017‐3090 Edward Morse, UNC Charlotte, Concord, NC, United States Modern metrology systems consist of a patchwork of various individual software packages, each of which produce and/or consume mas‐ sive amounts of data. The efficacy of these software systems is severely encumbered by the lack of interoperability between its compo‐ nents. Transferring data between software packages is costly both in terms of the time required of the human expert to manually process the data, and in terms of the errors involved in the manual transcription.

This paper will describe the Quality Information Framework (QIF) and will explain how it can provide the information format necessary to master the challenge of interoperability. QIF is an XML‐based ontology for manufacturing data, all built on semantic links to 3D model data. This solution arose organically via a body of industry experts ranging from manufacturers (end users), software vendors, research organiza‐ tions, and National Measurement Institutes, all coordinated by the Dimensional Metrology Standards Consortium (DMSC).

Various workflows that use QIF will be described, all of which leverage the benefit of the large quantity of information that first‐class in‐ teroperability can beget: automation, optimization, data analytics, and traceability across multiple domains.

Dynamic Electrical Impedance in Bipolar Tissue Welding Technical Publication. MSEC2017‐3091 Xiaoran Li, Russell Borduin, The University of Texas at Austin, Austin, TX, United States, Roland Chen, Washington State Uni‐ versity, Pullman, WA, United States, Wei Li, Univ of Texas at Austin, Austin, TX, United States Bipolar tissue welding is a material joining process where high frequency alternating current is applied to biological tissue in medical pro‐ cedures such as wound closure and blood vessel sealing. The process is often performed with a set of laparoscopic forceps in a minimal invasive surgery to achieve less bleeding and shorter recovery time. However, problems such as tissue sticking, thermal damage, and joint failure often occur and need to be solved before the process can be reliably used in more surgical procedures. In this study, experiments were conducted to investigate dynamic behavior of the tissue welding process through electrical impedance measurements. Both scis‐ sor‐type and parallel electrodes were used with various compression and power settings in the experiment. It was found that the electrical impedance of tissue was lower when parallel electrodes were used. It can be used to understand the results and dynamic behavior of the tissue welding process, including the size of heat affected zone, tissue sticking, and the compression force effect.

Investigation on the Effects of Process Parameters on Defect Formation in Friction Stir Welded Samples via Predictive Nu‐ merical Modeling and Experiments Technical Publication. MSEC2017‐3092 Abhishek Ajri, Purdue Univeristy, West Lafayette, IN, United States, Yung Shin, Purdue University, West Lafayette, IN, United States Setting optimum process parameters is very critical in achieving a sound friction stir weld joint. Understanding the formation of defects and developing techniques to minimize them can help in improving the overall weld strength. The most common defects in friction stir welding are tunnel defects, cavities and excess flash formation which are caused due to incorrect tool rotational or advancing speed. In this paper, the formation of these defects is explained with the help of an experimentally verified 3D finite element model. It was observed that the asymmetricity in temperature distribution varies for different types of defects formed during friction stir welding. The location of the defect also changes based on the shoulder induced flow and pin induced flow during friction stir welding. Besides formation of defects like excess flash, cavity defects, tunnel/wormhole defects, two types of groove like defects are also discussed in this paper. By studying the different types of defects formed, a methodology is proposed to recognize these defects and counter them by modifying the process parameters to achieve a sound joint for a displacement based friction stir welding process.

Interoperability for Feedback Loops from Dimensional Metrology in Digital Manufacturing Invited Presentation. MSEC2017‐3093 Robert Brown, Mitutoyo America Corporation, Aurora, IL, United States 87

Interoperability in feedback loops is a very old problem within the digital thread and is an underserved aspect of the contemporary stand‐ ards community and R&D initiatives in general. While downstream information data flows have received much attention, and have ma‐ tured significantly over the last decade, this presentation will highlight many potential opportunities for interoperability standards such as MTConnect and the Quality Information Framework (QIF) to provide a transport mechanism for many use cases in digital manufacturing that require feedback loops. This presentation will contrast the current state of the art with downstream digital data flows to the various feedback loops possible with a focus on dimensional metrology results and statistical analysis as a data source. In addition to a discussion of standard machine tool wear feedback, this presentation will describe the potential for sampling plan feedback, statistical algorithm feed‐ back, and control chart feedback. Possibilities for execution to plan and plan to design workflows will also be discussed.

State of the Art: A Review of Electrically‐Assisted Manufacturing with Emphasis on Modeling and Understanding of the Electroplastic Effect Oral Presentation. MSEC2017‐3098 Brandt Ruszkiewicz, Clemson University, International Center for Automotive Research, Greenville, SC, United States, Tyler Grimm, Penn State University, Erie, Beaver, PA, United States, Ihab Ragai, Penn State University, Erie, PA, United States, Laine Mears, Clemson University, Anderson, SC, United States, John Roth, Penn State Erie, The Behrend College, Erie, PA, United States Increasingly strict fuel efficiency standards have driven the aerospace and automotive industries to improve the fuel economy of their fleets. A key method for feasibly improving the fuel economy is by decreasing the weight, which requires the introduction of materials with high strength to weight ratios into airplane and vehicle designs. Many of these materials are not as formable or machinable as conventional low carbon steels, making production difficult when using traditional forming and machining strategies and capital. Electrical augmentation offers a potential solution to this dilemma through enhancing process capabilities, and allowing for continued use of existing equipment. The use of electricity to aid in deformation of metallic materials is termed Electrically‐Assisted Manufacturing. The direct effect of electrici‐ ty on the deformation of metallic materials is termed the electroplastic effect. This paper presents a summary of the current state of the art in using electric current to augment existing manufacturing processes for processing of higher‐strength materials. Advantages of this pro‐ cess include: flow stress and forming force reduction, increased formability, decreased elastic recovery, fracture mode transformation from brittle to ductile, decreased overall process energy, and decreased cutting forces in machining. There is currently a lack of agreement as to the underlying mechanisms of the electroplastic effect. Therefore, this paper presents the four main existing theories and the experimental understanding of these theories, along with modeling approaches for understanding and predicting the electroplastic effect.

Process and Operations Control in Modern Manufacturing Technical Publication. MSEC2017‐3104 Dragan Djurdjanovic, The University of Texas At Austin, Austin, TX, United States, Lin Li, University of Illinois at Chicago, Chi‐ cago, IL, United States, Laine Mears, Clemson University, Anderson, SC, United States, Farbod Akhavan Niaki, Clemson Uni‐ versity, Greenville, SC, United States, Asad Ul Haq, University of Texas at Austin, Austin, TX, United States Dramatic advancements and adoption of computing capabilities, communication technologies, and advanced, pervasive sensing have im‐ pacted every aspect of modern manufacturing. Furthermore, the very character of manufacturing is changing fast, with new, complex pro‐ cesses and new products appearing in both the industries and academe. As for traditional manufacturing processes, they are also undergo‐ ing transformations in the sense that they face everincreasing requirements in terms of quality, reliability and productivity. Finally, across all manufacturing we see the need to understand and control interactions between various stages of any given process, as well as interac‐ tions between multiple products produced in a manufacturing system. All these factors have motivated tremendous advancements in methodologies and applications of control theory in all aspects of manufacturing: at process and equipment level, manufacturing systems level and operations level. Motivated by these factors, the purpose of this paper is to give a high‐level overview of latest progress in pro‐ cess and operations control in modern manufacturing. Such a review of relevant work at various scales of manufacturing is aimed not only to offer interested readers information about state‐of‐the art in control methods and applications in manufacturing, but also to give re‐ searchers and practitioners a vision about where the direction of future research may be, especially in light of opportunities that lay as one concurrently looks at the process, system and operation levels of manufacturing.

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Measurement Science for Metal‐Based Additive Manufacturing Invited Presentation. MSEC2017‐3119 Jarred Heigel, National Institute of Standards and Technology, Gaithersburg, MD, United States The mission of the National Institute of Standards and Technology (NIST) is to promote U.S. innovation and industrial competitiveness by advancing measurement science, standards, and technology in ways that enhance economic security and improve our quality of life. Spe‐ cifically in Additive Manufacturing (AM), NIST?s Engineering Laboratory aims to provide measurement science solutions to problems that hinder the progress of metal‐based AM. The Measurement Science for AM program was created to develop and deploy measurement sci‐ ence that will enable rapid design‐to‐product transformation through advances in; material characterization; in‐process sensing, monitor‐ ing, and model‐based optimal control; performance qualification of materials, processes and parts; and end‐to‐end digital implementation of Additive Manufacturing processes and systems. The objective of this talk is to present the current research activities to meet these goals.

Wear of Cutting Tools in Modulation‐Assisted Machining of Structural Metals Invited Presentation. MSEC2017‐3147 James Mann, M4 Sciences LLC, West Lafayette, IN, United States The application of a controlled superimposed oscillation to machining ? modulation‐assisted machining (MAM) ‐ has demonstrated unique changes in the mechanics of the cutting process. In particular, modulation of the tool‐feed or undeformed chip thickness (feed‐modulation) has demonstrated controlled chip formation, important changes in the nature of tool‐work engagement, and potential for increased mate‐ rial removal rates (MRR) compared to conventional machining. The intermittent separation of the tool‐work contact in MAM reduces the contact time and enhances the effectiveness of cutting fluids, leading to reduced cutting tool wear. The effects of low‐frequency, feed‐modulation (MAM) on chip formation and tool wear in machining of structural alloys will be discussed. Using case studies involving machining of structural metal systems, e.g., compacted graphite iron (CGI), stainless steels, and Ti alloys, MAM is quite effective in reducing the wear of cutting tools in turning and drilling processes. For example, when machining compacted graphite iron at high machining speeds (>> 500 m/min), the CBN tool life with MAM is at least one order of magnitude greater than in conventional machining. The improvement in wear performance is a consequence of a reduction in the severity of the tool‐work contact conditions in MAM: formation of discrete chips, reduction in intimacy of the contact, and enhanced fluid action and lower cutting temperatures. The modulation‐assisted machining configuration with feed‐direction modulation is feasible for implementation at high speeds and offers a potential solution to a challenging class of industrial machining applications.

The Development and Prospects for Additive Manufacturing Invited Presentation. MSEC2017‐3162 Dave Bourell, Univ Of Texas Austin, Austin, TX, United States Modern Additive Manufacturing (AM) is proposed to have begun in 1988 with the first transfer of a commercial AM machine, the SLA‐1 by 3D Systems. However, the concept of layered additive manufacturing significantly predates the computer. The author divides devel‐ opments in AM into three historical categories with illustrations that draw from US patents. Earliest is AM prehistory, dating back almost 150 years and associated with the period before the advent of computers. Second are AM precursors. Covering the period from about 1960 to 1984, these inventions embodied all the salient aspects of modern AM, but none were commercialized. It is speculated that a contributing factor was the limited knowledge and general utilization difficulty of modern distributed computing. Finally, modern AM exploded onto the commercial sector starting in the mid‐1980s with most current processes being invented in a ~10‐year period from 1985‐1995. The presentation will close with a brief analysis of recent developments, a future outlook and identification of some current challenges to advancement of AM technologies.

Design of a Continuous‐Tension‐Compression Machine for Sheet Metal Oral Presentation. MSEC2017‐3163 Jacqueline McNally, University of New Hampshire, Rochester, NH, United States As the demand for lighter vehicles increase, so does the demand for using lighter materials. Most of the components that need to be light‐ ened stem from the overall body of vehicle which is typically formed out of steel. Steel sheet typically has a low springback which makes it perfect for forming the car body whereas other sheet metals range in the amount of springback they have. The springback in advanced 89 high‐strength steels and other alloys (Aluminum, Magnesium) has not been studied as much as low‐carbon steel since the need for its properties haven?t been required up until now. This springback characteristic is the main driving factor for the machine that was developed in this project.

Invisibell Oral Presentation. MSEC2017‐3164 Swetha Sriram, Rensselaer Polytechnic Institute, Troy, NY, United States In Manufacturing Processes and Systems Laboratory (MPS), the primary purpose of the class is for each student to learn, by experience, how to build and execute an efficient cost‐effective manufacturing system that produces a useful, high quality, and economical product. Team C?s product, the Invisi‐Bell, is one of the two products that was selected to continue into the production phase of MPS?s second se‐ mester. The Invisi‐Bell is a unique bicycle bell that provides several innovative components while maintaining complete functionality. The processes and operations involved in producing the Invisi‐Bell are varied and advanced, testing the creativity and innovation of the mem‐ bers of the Invisi‐Bell team. While challenging, the production of the Invisi‐Bell and the refinement of the manufacturing processes involved is within the scope of the materials on hand, the team?s budget, the relatively short time frame, and machines available in the Manufac‐ turing Innovation Learning Lab.

Design and Fabrication of Cost‐Effective Flexible Thin‐Film Solar Cells using Additive Manufacturing Oral Presentation. MSEC2017‐3165 Rinkesh Contractor, California State University, Fullerton, CA, United States Today, most solar cell industries use crystalline silicon (c‐Si) as the preferred photovoltaic material. While c‐Si solar cells delivers efficiencies in the range of 15% to 25%, have been very expensive in terms of manufacturing. Recently, thin‐film solar cells (TFSC) made of simple and inexpensive materials are used as an alternative to c‐Si solar cells. Even though TFSC have lower efficiency, they are mostly flexible, easier to handle and are less susceptible to damage compared to c‐Si solar cells. TFSC is composed of thin layers of photovoltaic materials sand‐ wiched between transparent conductive oxide and a back conductive contact. TFSC can be manufactured in small quantities using relatively inexpensive solution‐phase techniques such as roll‐to‐roll processing and screen printing technology. However, scaling‐up the TFSC manu‐ facturing from small scale laboratory tests to large industrial production requires better and efficient manufacturing processes. This re‐ search project explores the possibility of using additive manufacturing process to fabricate thin‐film solar cells (TFSC) efficiently and rapidly. The study focusses on fabrication of Dye‐Sensitized Solar Cells (DSSC) which are one of the most common type of TFSC. In this project, three successive layers of TFSC are fabricated using a 3D printer at different thicknesses. The efficiencies of each cell are evaluated and compared for various combinations of raw materials. The results of this study would enable 3D printing towards rapid commercialization of TFSC technology because it is an excellent choice of indoor application as they perform better under diverse light condition.

The Dream Machine: A Multi‐Tool Additive Manufacturing System Oral Presentation. MSEC2017‐3166 Lindsey Bass, VirginiaTech, Blacksburg, VA, United States The goal of this project is to design, build, and evaluate a single AM system that allows users to print with a combination of five technolo‐ gies: binder jetting, material jetting, vat photopolymerization, filament extrusion, and paste extrusion. As a research printer, an open‐architecture approach has been employed that provides users with full control to adjust parameters. This senior design project at Virginia Tech started in the fall when the team designed the system and assembled a prototype demonstrating functionality. Now that the entire system has been manufactured, the current goal is to focus on testing and advance the system to use 3 multiple AM technologies within a single build. Performance evaluation of both hardware and software will guide the direction for future system improvements so that a successful product will be presented by May 2017.

Mind in the Machine Oral Presentation. MSEC2017‐3167 Freddy Wang, Rensselaer Polytechnic Institute, Troy, NY, United States

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The Manufacturing Processes and Systems class is designed to allow students to learn about manufacturing and have hands on experience in producing products. Students use the Manufacturing Innovation Learning Lab to learn how to design, produce and budget a project while working on a team. The team was given the project after another team worked on the project in a previous semester. This year?s team has the responsibility of producing 400 products from the Technical Data Package/other work that the previous team has done and updating the work as the team progresses. The Mind in the Machine product is a product that is designed to show off RPI spirit as well as be a piece that is different from other products on the market today. The product showcases a gear system that is not found in many products in the market.

Circulator Packaging Robot Oral Presentation. MSEC2017‐3168 Jamie Gravell, University of Texas at Dallas, Richardson, TX, United States Raytheon has challenged our team to design an end effector (henceforth interchangeably called the product) that can automate the trans‐ fer of circulators from a magnetic hardboat to a wafflepack. This automation will not only cut labor costs but also eliminate damage inflict‐ ed on circulators by human error, and any subsequent need for rework. Since use of the tape boat will be discontinued by Raytheon, our project is required to be compatible only with the hardboat. This project is exceptionally challenging because documentation regarding automated handling of highly magnetic parts is not readily accessible. The end effector is unique and has been fabricated by the team for this project alone. A gantry robot was purchased to show proof of concept to Raytheon and at our school?s senior design expo. 3D printing was provided by Raytheon. Machining was completed at Turnamatic Machine Inc., where our student team leader is employed.

Design and Manufacture of a Compliant Joint for Mitigating Quadrant Glitches Oral Presentation. MSEC2017‐3169 Xingjian Liu, University of Michigan, Ann Arbor, MI, United States Mechanical bearings (i.e., sliding and, especially, rolling bearings) are widely used in precision motion stages because of their low cost, large motion range, high off‐axis stiffness and ruggedness. They are also finding increasing use in ultra‐precision motion stages. However, the use of mechanical bearings usually results in quadrant glitches, which are position errors, that occur as the stage tries to overcome the highly nonlinear pre‐motion friction during motion reversals. Quadrant glitches can only be partially suppressed by feedback control, because a feedback controller must wait for errors to develop before it takes corrective actions. Therefore, feedforward compensation is most often used to suppress quadrant glitches beyond what is achievable using feedback control. However, the feedforward compensation requires complex friction model and accurate parameters to predict the friction accurately. Thus, they need frequent re‐calibration or adaptation to maintain their effectiveness. In this project, we want to find a way that quadrant glitches can be accurately compensated using simple models of premotion friction.

Survival Wallet Team Oral Presentation. MSEC2017‐3170 Sam Chiappone, Rensselaer Polytechnic Institute, Troy, NY, United States A Technical Data Package (TDP) was created for the Manufacturing Processes and Systems Lab I (MPS) class and contains all relevant in‐ formation that is required to manufacture, assemble, and package the Survival Wallet in the Manufacturing Innovation and Learning Lab (MILL). This document is a short summary of the TDP created for the class. The idea for the Survival Wallet developed from a plastic wallet design submitted by high school students in the Preface summer program run by the Dean of Students.

A New Kind of Thinking: Revolutionizing Design and Manufacturing Invited Presentation. MSEC2017‐3171 William Regli, Defense Advanced Research Projects Agency (DARPA), Arlington, VA, United States The revolution underway in manufacturing is the product of a diverse set of disciplines that have reached a level of maturity to offer radi‐ cally new tools and capabilities. Because of these simultaneous advances in materials science, process control, robotics—‐and especially computation, data and machine intelligence—‐we can begin to envision design and production as an information‐centric and algorithmic

91 process. Somewhat surprisingly, however, many of our most advanced approaches to design and fabrication remain firmly grounded in methodologies and processes that literally go back centuries. As we enter this era of computation, data and machine intelligence, we are offered the opportunity to reframe, tabula rasa, the system of design and production. We will discuss the need (and opportunities) for a paradigm shift in design and manufacturing and provide several examples of what the new scientific questions might be like. Ultimately, for each of these questions, the challenge is how to integrate human creativity and insight with computing machinery in order to have the machines not just as our tools—‐but as our partners.

Emerging Trends in Nanotribology, and their Implications for Manufacturing Invited Presentation. MSEC2017‐3172 Robert Carpick, Univ Of Pennsylvania, Philadelphia, PA, United States Advanced manufacturing methods are continually progressing to smaller scales in multiple ways, including manufactured component fea‐ ture size, finished surface roughness, and desired dimensional accuracy. At small length scales, the high surface‐to‐volume ratio ensures that surface interactions such as friction, adhesion, and wear, become critically important in controlling the manufacturing process, and must also be accounted for in designing small‐scale devices that will function properly. Unfortunately, a lack of fundamental understanding of such tribological interactions has prevented the rational design of small‐scale manufacturing processes. In this talk, I will review chal‐ lenges and opportunities in micro‐ and nano‐manufacturing, and will highlight tribology problems and the solutions that exist for address‐ ing them which have been developed through basic research in tribology. Examples will include: the successful development of nanocrys‐ talline diamond tool coatings to enable the dry micro‐milling of aluminum; the development of nanostructured diamond atomic force mi‐ croscope probes for tip‐based nanomanufacturing; new insights into the fundamental origins of wear at the nanoscale enabled by in situ electron microscopy studies of contact, sliding, and wear; and a novel, early‐stage nanoscale additive manufacturing process we call ?na‐ notribological printing?.

Sustainable Manufacturing Analysis of Atomic Layer Deposition of Al2O3 thin film Oral Presentation. MSEC2017‐3174 Chris Yuan, Case western reserve university, cleveland, OH, United States Atomic layer deposition (ALD), as the most accurate thin film coating technology, has found a wide range of applications across semicon‐ ductors, solar cells, medical devices, optics, etc. However, the sustainability issues of ALD technology are significant, including: large amount of toxic chemicals usage, high energy consumption, and novel nanoparticle emissions. This presentation is on ALD sustainable manufacturing with a case study on Al2O3 thin film as high‐k dielectric gate for semiconductor application. The material and energy con‐ sumptions, process and nanoparticle emissions are systematically investigated in this study.

A System and Architecture of Fused Deposition Modeling ‐ Unit Manufacturing Process Oral Presentation. MSEC2017‐3175 Rong Pan, , Tempe, AZ, United States In today?s competitive world economy, the manufacturing and design engineers face the challenge of manufacturing components rapidly to meet customer requirements and achieve competitive edge. Additive manufacturing provides an efficient method to build complex products or prototypes to minimize the design and cycle time. Fused Deposition Modeling (FDM) is an additive manufacturing process used to build prototypes using variety of materials. The build and support materials are extruded as a semi‐molten filament through the extru‐ sion head and deposited layer by layer to construct prototypes directly from 3D CAD model [2]. This technology is increasingly used for customized products, conceptual models and finds its applications in many fields of engineering and industry like aerospace, automotive products, dentistry and medical implants etc.

Manual Grinding Operation Oral Presentation. MSEC2017‐3177 Jayanti Das, UC Davis, Davis, CA, United States Manual grinding operations are prominently used in repair, construction, foundries, welding to cut, remove burrs, improve surface quality, 92 remove slag, etc. Compared to the automated grinding process, manual grinding operations are critically dependent on worker?s posture, motion, gripping forces, process knowledge and personal skill level. Moreover, accidents with power tools account for 2/3 of accidents with grinding machines and cause severe health issues with irreversible medical effects (Odum et al., 2014). In addition, poor control of the ma‐ chining process may influence the geometrical and physical properties of the machined surfaces, especially under dry cutting condition.

Milling Efficiency Investigation Oral Presentation. MSEC2017‐3178 Evan Brooke, Stony Brook University, Glen Rock, NJ, United States In response to increasing public pressure to reduce carbon dioxide emissions and savings associated with the reduction of total energy in a given manufacturing process, it is of interest to the industry how energy and emissions could be minimized. Important factors to the total cost and emissions of the production of a given part include but are not limited to the machine selection, the spindle speed, and basic power. Therefore, by investigating the cost and emissions per part for a given geometry in a milling process, we can obtain valuable infor‐ mation on the minimization of carbon emissions and cost per part and generalize for commercial use.

Rough Machining of Impellers UMP Oral Presentation. MSEC2017‐3179 Zhenhua Wu, Virginia State University, Petersburg, VA, United States Impellers are advanced mechanical products that are commonly associated with being used in turbo‐machineries. Impellers are composed of multiple equivalently manufactured blades that revolve on a hub surface at 360 degrees. The current practice for manufacturing impel‐ lers is through machining, measuring and finalizing the product initiated from an original workpiece. Due to the complex design of impel‐ lers, the proposed research was to achieve an integrated solution of digital design and manufacturing of impellers. This would ultimately be achieved by using product lifecycle management (PLM) software together with 2‐axis, and 3‐axis CNC machining. This research tested the original hypothesis of how machining parameters influence the energy consumption while using Computer Numerical Control (CNC) ma‐ chining of impellers, under the ASTM Standard Guide for Characterizing Environmental Aspects of Manufacturing Processes (ASTM E60.13 E3012‐16). Such machining parameters include cutting depth, spindle speed, feed rate, and machine codes.

Machining of Prismatic Parts Oral Presentation. MSEC2017‐3180 Dusan Sormaz, Ohio Univ, Athens, OH, United States Today?s smart factories need accurate and rapid estimation and analysis of production process for not only optimizing production line but also ensuring sustainability by minimizing environmental impact [1] [2]. The estimations of resource, cost, products, by?products, waste, and environmental impact of a complete production process need to be computed at unit manufacturing process (UMP) level for greater accuracy. Current production management systems suffer from inflexibility in two different ways: some systems, able to capture complexi‐ ty of manufacturing planning, are often too monolithic to be used in modeling unit operations or flexibly compose them to represent com‐ plex systems; others are simple computational tools, which fail to capture inter?relations of various aspect of integrated manufacturing. Particularly, very few UMP modeling tools take into account the complete set of geometry, dimensions and tolerance (GD&T), associated with the part designs. As a result of this disconnection from part design, the estimation and prognosis cannot capture the delta when part design is changed. As a remedy of these shortcomings, computational models need to be built for different UMPs, which should consider the GD&T specification of part design for accurately computing various metrics for UMP, and capture the transformation of the work?piece through the production. Furthermore, these models should use standardized schemas and mappings to be easily disseminated and com‐ posed to model complex manufacturing systems.

Fuse Diffuser‐Drill, Mill, Turn Oral Presentation. MSEC2017‐3181 Liam Klein, Stony Brook University, Stony Brook, NJ, United States Manufacturing is defined by a variety of intricate machining processes that, when combined and optimized, can result in an efficient, eco‐

93 nomical, and feasible method of production. These methods can prove quite complex and thus require an in‐depth analysis and computa‐ tional reasoning to develop a refined procedure that can be referenced and recycled as a guideline for future production. Taking these fac‐ tors into account, a full chain of processes were modeled with the implementation of G‐code programming for CNC machining and the use of transformation equations programmed in MATLAB to estimate efficiency prior to operation. This model was illustrated by selecting an object to be theoretically manufactured and utilized such programming and mathematical algorithms to follow its development through turning, boring, milling, drilling and threading. When analyzed, many outputs governing the effectiveness of a machining process can be digitally determined before investing the time and resources to actually commit to a physical endeavor.

Modelling for Fused Filament Fabrication Additive Manufacturing Process Oral Presentation. MSEC2017‐3182 Vittal Prabhu, Penn State University, University Park, PA, United States Fused Deposition Modelling (FDM) is a type of additive manufacturing process in which a 3D object is directly manufactured from a 3D CAD data, layer by layer, by extruding a semi‐liquid thermoplastic from a fine orifice. FDM was developed by Stratasys founder Scott Crump in late 1980s. FDM is now a popular technology used for building concept models, functional prototypes and end‐use production parts. The part is produced by extruding fine strings of molten material to form layers as the material hardens immediately after extrusion from the nozzle.

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Paper Number Page Paper Number Page Paper Number Page ICMP2017‐4303 96 ICMP2017‐4368 111 ICMP2017‐4435 127 ICMP2017‐4304 96 ICMP2017‐4369 112 ICMP2017‐4436 128 ICMP2017‐4308 96 ICMP2017‐4370 112 ICMP2017‐4437 128 ICMP2017‐4309 97 ICMP2017‐4371 113 ICMP2017‐4439 128 ICMP2017‐4311 97 ICMP2017‐4372 113 ICMP2017‐4440 128 ICMP2017‐4312 97 ICMP2017‐4373 114 ICMP2017‐4441 129 ICMP2017‐4315 98 ICMP2017‐4374 114 ICMP2017‐4445 129 ICMP2017‐4316 98 ICMP2017‐4376 114 ICMP2017‐4447 130 ICMP2017‐4317 98 ICMP2017‐4379 115 ICMP2017‐4448 130 ICMP2017‐4319 99 ICMP2017‐4380 115 ICMP2017‐4320 99 ICMP2017‐4381 115 ICMP2017‐4321 100 ICMP2017‐4383 116 ICMP2017‐4323 100 ICMP2017‐4384 116 ICMP2017‐4325 101 ICMP2017‐4385 117 ICMP2017‐4327 101 ICMP2017‐4386 117 ICMP2017‐4328 102 ICMP2017‐4388 118 ICMP2017‐4330 102 ICMP2017‐4389 118 ICMP2017‐4332 102 ICMP2017‐4390 118 ICMP2017‐4333 103 ICMP2017‐4391 118 ICMP2017‐4334 103 ICMP2017‐4392 119 ICMP2017‐4335 103 ICMP2017‐4393 119 ICMP2017‐4336 103 ICMP2017‐4394 119 ICMP2017‐4341 104 ICMP2017‐4396 120 ICMP2017‐4342 104 ICMP2017‐4400 120 ICMP2017‐4343 104 ICMP2017‐4401 120 ICMP2017‐4344 105 ICMP2017‐4404 121 ICMP2017‐4346 105 ICMP2017‐4405 121 ICMP2017‐4347 106 ICMP2017‐4406 122 ICMP2017‐4348 106 ICMP2017‐4409 122 ICMP2017‐4349 106 ICMP2017‐4411 122 ICMP2017‐4351 107 ICMP2017‐4413 122 ICMP2017‐4352 107 ICMP2017‐4414 123 ICMP2017‐4353 107 ICMP2017‐4418 123 ICMP2017‐4354 108 ICMP2017‐4419 123 ICMP2017‐4357 108 ICMP2017‐4421 124 ICMP2017‐4358 109 ICMP2017‐4423 124 ICMP2017‐4359 109 ICMP2017‐4424 124 ICMP2017‐4360 109 ICMP2017‐4425 125 ICMP2017‐4361 110 ICMP2017‐4426 125 ICMP2017‐4363 110 ICMP2017‐4427 126 ICMP2017‐4364 110 ICMP2017‐4430 126 ICMP2017‐4365 111 ICMP2017‐4431 127 ICMP2017‐4366 111 ICMP2017‐4433 127

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Estimation of Stress and Displacement Around Nick Zone of Zipper Pull Tab Formed on Paperboard Technical Publication. ICMP2017‐4303 Shigeru Nagasawa, Nagaoka Univ Of Tech, Nagaoka, Niigata, Japan, Masahiro Uehara, Nagaoka University of Technology, Nagaoka, Niigata, Japan, Chiharu Matsumoto, Taiyo Package Corp., Tateyama‐machi, Toyama, Japan, Haruya Kambe, We‐ erayut Jina, Nagaoka University of Technology, Nagaoka, Niigata, Japan Various paperboard based boxes for packaging confectionery such as candy are processed by using a form‐cutting press machine and fold‐ er‐gluer machine. Such the packaging boxes are often sealed by a paperboard based cap and also processed so as to have a zipper pull tab structure near the cap. The zipper pull tab structure is used for opening the cap by tearing the zipper dash lines which are cut off by using a repeatedly nicked wedge blade. Such a zipper pull tab structure is empirically designed and then there are many various patterns with re‐ spect to the geometrical features. In order to arrange and classify those various patterns of zipper pull tab,we need to reveal the tearing characteristics of those pull tab structure when changing some representative parameters, such as the pitches of nick, the profile of entry guide part. The authors are experimentally investigating the tearing patterns of zipper pull tab, and collecting some breaking patterns. However, since such the breaking and/or tearing mode occur at the complicated notched zone under three dimensional deformation, it is not easy to predict its breaking patterns without observing the distribution of stress concentration when varying the geometric parameters and the grain direction of paperboard. In this work, therefore, an FEM simulation model has been developed for seeing the effect of ani‐ sotropic properties of paperboard. Using an orthotropic elastic model, the stress distribution abound the notched zone of zipper pull tab structure is discussed and compared with some experimental teared modes.

Mechanical Behavior and Failure of Easily‐Decomposable Dissimilar‐Materials‐Joint Fabricated by Friction Stir Forming Technical Publication. ICMP2017‐4304 Takahiro Ohashi, Hamed Mofidi Tabatabaei, Tadashi Nishihara, Kokushikan University, Tokyo, Japan In this paper, the authors discuss about the dissimilar materials joining structures that were fabricated by friction stir forming (FSF) and are easily decomposable. Dissimilar‐materials‐joining has been successfully studied as a key for new generation light weight parts; however, it can be a barrier against recycling in future. The authors have suggested the concept of easily‐decomposable joining of dissimilar materials with employing friction stir forming (FSF). A joined plate having a key hole was prepared and put it on the mold having the cavity of a hook. An aluminum alloy plate was put on them and conducted friction stirring on its back surface. Due to massive heat and compression force generated by the friction stirring, a hook‐like joint was successfully generated. Opposite hooks generated by the above approach join dis‐ similar materials tightly, but the materials are able to be decomposed smoothly after cutting them between the hooks. The authors evalu‐ ated the joints by tensile and shear tests and discuss about their mechanical behavior and failure.

A Study on the Sand Mold Collapsibility for Multi‐Cavity Casting Process of Aluminum Technical Publication. ICMP2017‐4308 Yoshio FUKUSHIMA, Saitama Institute of Technology, Fukaya, Saitama, Japan, Tomoaki SAKATA, Gunma Industrial Technol‐ ogy Center, Maebashi, Japan, Akiko SAKAMOTO, Saitama Institute of Technology, Fukaya, Saitama, Japan, Takashi SUDA, Gunma Industrial Technology Center, Maebashi, Japan, Jun OZAWA, Naigai co.,ltd., Takasaki, Japan Recently, with limitations on resources and environmental constraints growing, the needs for aluminum and its manufacturing method are increasing as the key of the making many kinds of parts lighter. The tilting gravity casting method is a typical technique to manufacture aluminum casting parts. The metal mold casting is insufficient to manufacture the part with complicated shapes such as the nest of boxes structure, like the turbo charger parts of the automobile engine. On the other hand, the sand mold casting is effective way to manufacture the parts with complicated shapes. In this study, we focused on ?H‐Process?, which is the sand mold casting process and able to manufac‐ ture many parts at the same time. This method can manufacture plural products at the same time by only one sprue. The “H‐process” method leads to reduce the cycle time for casting. Furthermore, this method can realize the reduction of the production time in compari‐ son with the tilting gravity casting method. Therefore, it can reduce the manufacturing costs. It has been reported that there is the practical use of ?H‐Process? in the field of cast iron, but there has been no study in the aluminum casting field because of the problem about the collapsibility property of sand mold for the aluminum casting. The problem, which we have to consider in the case of the aluminum casting, is that the collapsibility of sand mold is inferior to that of iron casting. The resin included in the sand mold with the iron casting is decom‐ posed and burned down completely because the casting temperature reaches approximately 1500 degrees Celsius. On the other hand, the resin included in the sand mold in aluminum casting is not burned down because the melting point is approximately 700 degrees Celsius.

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The resin included in the sand exerts the adverse effect on the collapsibility of the sand mold. The adverse effect causes the sand remaining in the cast product after casting. Therefore, we investigated the temperature in the sand mold during casting and the bending strength of sand mold after casting by using several kinds of sand. This paper is intended as the practical application of the H‐Process method of alu‐ minum casting.

On the Transduction of Ultrasound Through a Polymer Film Oral Presentation. ICMP2017‐4309 Hironori Tohmyoh, Tohoku Univ, Sendai 980‐8579, Japan A technique to transmit and receive the ultrasound into/from a solid sample via a layer has been reported, and this has been used to visu‐ alize inside the sample without getting the sample wet. In this ultrasonic transmission system, the waveform of the echo reflected back from the sample is modulated by the layer if the thickness of the layer is sufficiently thin compared with the wavelength of the ultrasound. This is because the echo transmittance among the water, the layer and the sample shows the frequency dependent. In this paper, a theo‐ retical model to predict the waveform of the echo reflected back from the sample through a layer is presented, and the validity of the model is verified by conducting the experiments where the ultrasound is transmitted into a metallic plate via a polymer film and the echo reflected at the back of the plate is received again via the film. The waveforms predicted by the developed theoretical model were in good agreement with those obtained by the experiments. It is noted that the present model was confirmed experimentally to be applicable for predicting the waveforms obtained by the focused ultrasonic transducer although the present model was based on the plane wave theory. Theoretical model developed was also useful for characterizing various kinds of thin films.

Effect of Crack Closure on Small Crack Propagation in a Polycrystalline Ni‐Base Superalloy Under TMF Condition Technical Publication. ICMP2017‐4311 Yasuhiro Yamazaki, Niigata Institute of Technology, Kashiwazaki, Japan In this work, the initiation and propagation behaviors of naturally initiated small crack in a polycrystalline Ni‐base superalloy, IN738LC, un‐ der the several kinds of TMF conditions. The experimental results revealed that the propagation behavior of the naturally initiated crack was affected by thermo‐mechanical loading condition. The small crack growth rate as well as oxidation behavior around the crack was also affected with the TMF conditions. However, when the small crack propagation rates were correlated with the effective fatigue J integral range based on the continuum fracture mechanics taking the crack‐opening‐closing behavior into consideration, they could be expressed with a unique curve regardless of the difference in TMF condition.

The Measuring Technique Of The Temperature In A Specimen During The Rotating Bending Fatigue Test Oral Presentation. ICMP2017‐4312 Taizoh Yamamoto, Benning Lian, Yamamoto Metal Technos Co., Ltd., Osaka, Osaka, Japan, Koji Gotoh, Kyushu University, Fukuoka, Fukuoka, Japan One of difficulties in fatigue tests for structural materials is to take a long time to perform the fatigue test. Fatigue tests are usually con‐ ducted toward the loading cycles of N=107, but the fatigue property in gigacycle regime is also focused as an important subject in recent years. In such a long‐life region, a tremendous long period is required to perform fatigue tests. If the fatigue test is performed at the load‐ ing frequency of 50Hz, it takes more than 200 days to reach 109 cycles of the load application. It means that it takes very long term for us to obtain one S‐N curve. If the high loading frequency such as ultrasonic fatigue test was accepted to save the testing time, temperature raising of the specimen due to the internal friction would take place and some cooling system or intermittent loading system should be furnished to examine the original fatigue property. Thus, the acceleration fatigue test by ultrasonic technology would cause new difficult subjects as the fatigue testing method to obtain the fatigue property at the usual frequency. In order to overcome these difficulties, au‐ thors have developed special types of fatigue testing machines in rotating bending, in which four specimens can be tested simultaneously. Thus, a series of fatigue tests even in gigacycle regime can be carried out within a reasonable time period, even if it is used with various environment options. It is already known that the fatigue dates are matched with many experimental dates in the past, though the dates of an ultrasonic fatigue testing machine are unclear. Accordingly, this machine is useful to file up a number of fatigue test data in gigacycle regime for various kinds of metallic materials, and such databases can provide the fundamental design data for mechanical structures in the wide variety of the engineering application. However, the temperature gradient of the specimen always becomes a major issue when researchers perform the rotating bending fatigue test at high and low temperature even if they use this type of machine, because it is very 97 difficult to measure the temperature gradient of a specimen precisely during the rotating bending fatigue test. In this time, the novelty measuring technique of the temperature near the fracture portion in a specimen during the rotating bending fatigue test of cantilever type is proposed, and the measured temperature gradient of the specimen is discussed in this study.

Development of Clamp Force Detection Wrench for Bolt/Nut Assemblies Technical Publication. ICMP2017‐4315 Shinji Hashimura, Yujiro Sekido, Shibaura Institute of Technology, Tokyo, Japan, Kyoichi Komatsu, Tohnichi Manufacturing Works Co., Ltd., Tokyo, Japan In bolted joints to use for assembling machines and so on, clamp force is very important parameter to secure these reliability. Hence to avoid accidents, we must check whether the bolted joint have enough the clamp force at maintenance. However it is not easy not only to control the clamp force in the tightening process but also to measure the clamp force. A method to easily detect clamp force of a bolt/nut assembly had been proposed in our previous study. In a detection process of the method, the protruding bolt thread portion from the nut is applied tensile force. When the tensile force have reached at clamp force, the relationship between the tensile force and the displacement at the loading point changes. The proposed method detect the tensile force, at which the relationship changes, as the clamp force of the bolt/nut assembly. In this study, we have developed a wrench to detect the clamp force of a bolt/nut assembly based on the proposed method. We have estimated the detection accuracy of the detection wrench. And we have also investigated influences of amount of the clamp force of the bolt/nut assembly on the detection accuracy. Results showed that the developed wrench could detect the clamp force of the bolt/nut assembly within about ±5 %. It was also seen that the detection error was not greatly influenced by the grip length and the set clamp force.

In Situ Estimation of Support Reaction on Thin Sheet Subjected to Local Compression Using Data Assimilation Technical Publication. ICMP2017‐4316 Yoshinao Kishimoto, Yukiyoshi Kobayashi, Toshihisa Ohtsuka, Shin Yamagata, Tokyo City University, Setagaya‐ku, Tokyo, Japan A thin sheet subjected to an external local compression is deformed at relatively low load. Although the local compression induces serious incidents such as large deformation and fracture in solid structures, the local compression enables sheet metal forming represented by bending and deep drawing. On the other hand, the support reaction occurs on the sheet subjected to the local compression, and the esti‐ mation of the support reaction is also important for the incident inquiry and the proper plastic working. The finite element method (FEM) is one of the useful approaches to analyze the mechanical behavior in the elastic‐plastic deformation. However, the conventional FEM pro‐ vides the deterministic solution based on the material constants and the boundary conditions set in advance. It is difficult for the FEM to solve bifurcation problems including the estimation of the load distribution on the thin sheet with wrinkling in deep drawing in real time. This study has developed a novel technique to estimate the support reaction on the thin sheet subjected to the local compression using the data assimilation. In the proposed method, the FEM based on the strain increment theory is applied to derive the observation equation that describes the direct relationship between the support reaction and the deformed shape of the thin sheet. Then the support reaction when the residual sum of square of the observation equation is minimized is calculated by using the measured data of the deformed shape. If the deformed shape is measured in real time, the support reaction can be estimated in situ. In order to demonstrate the validity of the proposed method, numerical simulations and actual measurements have been performed. In the numerical simulations, the several sup‐ port conditions of the thin sheet were given in advance. Then the conventional FEM was applied to obtain the correct support reaction and the deformed shape of the thin sheet. In the actual measurements, the indentation tests by using sandwich panels whose core layers were composed of cylindrical cell walls were carried out and the support reaction by the cell walls were measured by the strain gages attached to the cell walls. The proposed method was applied on the deformed data in the numerical simulations and the actual measurements to esti‐ mate the support reaction. The results show that the support reactions estimated by the proposed method have good agreement with the correct values in both of the validation approaches.

Evaluation of Local Strain Fluctuation of Structures by Sensing Layers With Built‐In Rayleigh Scattering‐Based Distributed Fiber‐Optic Sensors Technical Publication. ICMP2017‐4317

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Tatsuro Kosaka, Yuki Handa, Kazuhiro Kusukawa, Kochi University of Technology, Kami, Kochi, Japan, Masayuki Kitamura, Hokuriku Fiber Glass, Co. Ltd., Komatsu, Ishikawa, Japan It is well known that multi‐site cracks occurring around fastener holes are very dangerous damage modes for structures, especially aircraft. In order to avoid final fracture, it is important to develop a nondestructive monitoring technique of damage distribution. Our idea is to de‐ velop a sensing layer using a non‐crimp fabric (NCF) and sensors. Since a NCF has straight warp fiber bundles, it is easy to weave optical fiber sensors in the fabric by a weaving machine. On the other hand, a Rayleigh scattering‐based distributed fiber‐optic sen‐ sor has high sensitivity of strain (several micro‐strains) and high spatial resolution (1 mm is minimum). Therefore, the sensor can be thought to have a potential to measure local strain fluctuation caused by a crack. The distributed sensor records distribution of Rayleigh scattering and then strain distribution is calculated from a frequency shift of spatial spectrum in a gauge section. Therefore, it can be considered that the gauge length affect sensitivity of local strain distribution. In the present study, the sensing performance of local strain fluctuation was investigated. A glass NCF with the embedded distributed sensors was developed as a sensing layer preform. Then, the NCF laminates and the NCF/Plain woven cloths laminates were manufactured in order to investigate feasibility of measurement of local strain fluctuation gen‐ erated by uneven structure of plain woven layers. Tensile tests were conducted while measuring strain by the sensing layers and strain gauges. Strain distribution was calculated with 1 mm gauge length. The results showed that the high‐frequency fluctuation was observed in the strain distribution of the both NSF and NSF/Plain laminates. In order to evaluate the local strain fluctuation quantitatively, high‐frequency components were taken by high‐pass filtering. Then, the cross‐correlation coefficient with the base data and RSM ampli‐ tude were calculated. From the results, it appeared that the local strain fluctuation of NSF/Plain laminates showed high correlation while loading and the amplitude was in proportion to load. On the other hand, the amplitude of fluctuation of NSF laminates was out of propor‐ tion to load and the value was around 30 micro strains. From the above results, it can be concluded that the sensing layer can measure local strain fluctuation of a structure by analyzing with short gauge length and noise of 30 micro strains is included in the local strain distri‐ bution.

Characteristics of Laminated Spark Plasma Sintered Compacts Composed of Alumina‐Particle‐Dispersed Magnesium and Magnesium Oral Presentation. ICMP2017‐4319 Shigehiro Kawamori, Tamagawa University, Tokyo, Japan, Hiroshi Fujiwara, Shizuoka Institute of Science and Technology, Shizuoka, Japan, Yukio Kasuga, Tamagawa University, Tokyo, Japan To reduce the weight of 20 vol% Al2O3‐particle‐dispersed Mg (Al2O3/Mg) compacts produced by spark plasma sintering (SPS), which are much harder than practical high strength AZ91 Mg alloys, 20/0/20 vol% laminated SPS compacts sandwiching a lightweight 0 vol% Al2O3/Mg (0 vol%) layer between two 20 vol% Al2O3/Mg (20 vol%) layers were fabricated by a mechanical milling/SPS process, and their microstructures and mechanical properties were investigated. The density of the 20/0/20 vol% laminated SPS compacts was 1.88 Mg∙m‐3, and they could be lightened to approximately 80% of the weight of equivalent 20 vol% SPS compacts. The 20/0/20 vol% laminated SPS compacts had a slightly higher hardness than the 20 vol% SPS compacts and a much higher hardness than AZ91 alloys. The bending strength of the 20/0/20 vol% laminated SPS compacts was almost the same as that of the 20 vol% SPS compacts, and was higher than the value calculated from those of the 20 and 0 vol% SPS compacts using the rule of mixtures. A new phase appeared at the flat interface be‐ tween the 20 and 0 vol% layers with excellent adhesion to the adjoining layers, so this phase probably had a strong effect on the bending strength of the 20/0/20 vol% laminated SPS compacts. The new phase generated a monotonically decreasing hardness gradient from the 20 vol% layer to the 0 vol% layer and was formed by diffusion of Al and O from the 20 vol% layer and diffusion of Mg from the 0 vol% layer. The new phase most likely consisted of ?Mg, MgO, and Mg17Al12, and the concentrations of Al in the ?Mg, MgO, and Mg17Al12 compo‐ nents of this phase were considered to decrease from the 20 vol% layer to the 0 vol% layer.

Effect of Microstructure of Metal‐Core Piezoelectric Fiber/Aluminum Composite on its Output Voltage Characteristic Technical Publication. ICMP2017‐4320 Tetsuro Yanaseko, Kogakuin University, Hachioji, Tokyo, Tokyo, Japan, Hiroshi Sato, National Institute of Advanced Industrial Science and Technology, Tsukuba, ibaraki, Japan, Isao Kuboki, Kogakuin University, Hachioji, Tokyo, Japan, Hiroshi Asanuma, Chiba University, Chiba, Chiba, Japan This research investigated the effect of microstructure of metal‐core piezoelectric fiber/aluminum composite on its output voltage charac‐ teristics. The metal‐core piezoelectric fiber/aluminum composite has been developed in order to overcome the problems that piezoelectric

99 ceramics has poor mechanical properties and reliability; brittleness and low fracture strain. This composite is aluminum which is embedded piezoelectric fiber by using interphase forming/bonding method, and fracture strain of the metal‐core piezoelectric fiber was significantly improved by embedding in aluminum. This composite is expected to long‐term available high reliability sensor devices and energy harvest‐ er by using its features. However, it was confirmed that the output voltage variation caused by the residual Al‐Cu eutectic alloy that ap‐ pears in the embedding process and the eccentricity of the core, and that interferes practical use of this composite. In this research, the influence of the composite microstructure, such as residual eutectic alloy and eccentricity of the metal‐core on the output voltage charac‐ teristic is evaluated by using finite element analysis. According to the results, it was found that following, 1) decreasing of the output volt‐ age caused by impediment of stress transmission between the piezoelectric fiber and aluminum matrix, and this impediment occurred from high Young’s modulus and low Poisson’s ration of the residual eutectic alloy compare to the aluminum matrix and the piezoelectric fiber, 2) the eccentricity of the metal‐core increases the region of the piezoelectric fiber that polarized in low electric field in the polarization pro‐ cess and reduces the piezoelectric constant, therefore, decreasing of the output voltage due to the eccentricity of the core occurs.

Fabrication of Metal Matrix Piezoelectric Composite Using Surface Oxidized Metal Fiber as Internal Electrode Technical Publication. ICMP2017‐4321 Kazuki Horikiri, Kogakuin University, Hachiouji‐shi, Tokyo, Japan, Tetsuro Yanaseko, Kogakuin University, Hachioji, Tokyo, Tokyo, Japan, Isao Kuboki, Kogakuin University, Hachioji, Tokyo, Japan, Hiroshi Sato, National Institute of Advanced Industrial Science and Technology, Tsukuba, ibaraki, Japan, Hiroshi Asanuma, Chiba University, Chiba, Chiba, Japan This document describes fabrication of metal matrix piezoelectric composite using surface oxidized metal fiber as internal electrode. As metal matrix piezoelectric composite, metal‐core piezoelectric fiber/aluminum composite has been developed in previous research. This composite realized higher fracture strain of embedded piezoelectric fiber than commercial piezoelectric ceramics. However, there are two problems that the electrode structure is determined when using metal‐core piezoelectric fiber, it is impossible to design the output voltage characteristic to required characteristics, and the piezoelectric fiber is exposed from the matrix ends, the exposed portion is vulnerable. In order to solve the problems, metal matrix using piezoelectric composite using surface oxidized metal fiber as internal electrode. Oxide layer insulates between matrix and metal fiber and protects chemical reaction between piezoelectric ceramics and metal fiber in sintering and embedding process. In this research, nickel and titanium fiber was used as metal fiber, and oxidized by heating in the Air. And lead zir‐ conate titanate plate was sintered around their fiber as piezoelectric ceramics, after that, lead zirconate titante plates and surface oxidized metal fibers embedded in aluminum matrix using interphase forming/bonding method. As results, piezoelectric ceramics and metal oxide could be embedded in aluminum matrix without loss of piezoelectric function, fabrication of new metal matrix piezoelectric composite was succeeded.

Characterization of Contact Condition in a Flange Connection by Longitudinal Waves Technical Publication. ICMP2017‐4323 Hideo Cho, Aoyama Gakuin University, Shibuya‐ku, Tokyo, Japan, Kanami Yamamoto, Kojiro Nishimiya, Aoyama Gakuin Uni‐ versity, sagamihara, kanagawa, Japan, Hiroaki Ito, Kindai unversity, Higashi hiroshima, Hiroshima, Japan, Junya Shimizu, Aoyama Gakuin University, sagamihara, Kanagawa, Japan A flange connection is a one of the portion where the integrity should be assured. An ultrasonic method for characterizing the condition in the flange connection would be a powerful tool and many researchers have already proposed interesting approaches for it such as ampli‐ tude and/or velocity measurements. In this study, to characterize surface pressure on a flange connection, frequency response and instan‐ taneous frequency of longitudinal waves reflected or transmitting metal/gasket/metal system which simulated a flange connection was evaluated under various surface pressures. Frequency response of the reflected wave was calculated by de‐convoluting the reflected wave with the wave reflected at back surface of the top metal substrate without a gasket. Several dips in amplitude on the response was clearly observed and shifted to high frequency with the pressure. The frequencies corresponding to the dips can be predicted based on reflectivity on three layered plate as a function of thickness of the interphase layer. The thickness of the gasket under the pressure can be estimated by matching the measured dip frequencies with calculated ones and rapidly decrease with the pressure in low surface pressure region and showed gradually linear decrease in high surface pressure region. The change in relation between the pressure and thickness reduction would indicated contact stiffness of the interface between the metal and the gasket. The instantaneous frequency was calculated by the phase of the wave after complex continuous wavelet transform with a gabor function as a mother wavelet. The calculated instanta‐ neous frequency of the transmitted wave takes a maximum in initial portion of the wave. The maximum frequency in low pressure rapidly increased with the pressure and in high pressure region gradually increase. Those instantaneous frequency change would originated from 100 interference between direct transmitted wave and multiple echoes in the gasket and/or phase shift at the interface between metal/gasket. Since both frequency response of the reflected waves and instantaneous frequency of the transmitted wave are independence of the am‐ plitude of the wave, the results in this study would showed intrinsic contact condition of the contact portion. The both parameters would be good clues for charactering the integrity of the flange connection.

Deployable Renewable Energy Devices for Disaster Mitigation With Smart Nanogrid Technical Publication. ICMP2017‐4325 Mehrdad Ghasemi Nejhad, Univ Of Hawaii, Honolulu, HI, United States, Brenden Minei, Caton Gabrick, Matsu Thornton, Reza Ghorbani, University of Hawaii ‐ Department of Mechanical Engineering, Honolulu, HI, United States This paper explains the development of Deployable Disaster Devices (D3) for disaster mitigation with smart nanogrid, where wind turbines and solar panels are developed in modular forms, which can be tied together depending on the needed power. The D3 units can be used: (1) as a standalone unit in case of a disaster where no source of power is available, (2) for a remote location such as a farm, camp site, or desert (3) for a community that converts energy usage from fossil fuels to renewable energy sources, or (4) in a community system as a source of renewable energy for grid‐tie or off‐grid operation. Smart D3 system delivers power to the network when the smart D3 nano‐grid is tied to the network and when the power generation is larger than consumption & storage recharge needs, or draws power from the network when the smart D3 nano‐grid is tied to the network and when the power generation is less than consumption & storage recharge needs. The power generated by the D3 system is routed through high efficiency inverters for proper DC to DC or DC to AC for final use or grid‐tie operations. The power delivery from the D3 is 220v AC, 110v AC and 12v DC provide proper power for most electrical and electronic devices worldwide. The power supply is scalable, using a modular system that connects multiple units together, employing devices such as external Input‐Output or I/O ports. The primary unit is the brain of the system allowing for smart switching and load bal‐ ancing of power input and smart regulation of power output. The Smart D3 systems are protected by ruggedized weather proof casings allowing for operation in a variety of extreme environments and can be parachuted into the needed locations. The Smart Nanogrid Sys‐ tems will have sensors that will sense the environmental conditions for the wind turbines and solar panels for maximum energy harvesting as well as identifying the appliances in use. These signals will be sent to a control system to send signal to the energy harvester actuators to maximize the power generation and regulate the power, i.e., either send the power to the appliances and consumer devices or send the power to the batteries and capacitors for energy storage, if the power is being generated but there are no consumer appliances in use, making it a ?deployable renewable energy devices system with smart nanogrid.?

Night Time Sensors for Rapid Detection of Areas Impacted by Disasters Technical Publication. ICMP2017‐4327 Cristian Vendittozzi,, Giancarlo Santilli, Universidade de Brasilia, Brasília, Distrito Federal, Brazil, Paolo Gessini, Univerisdade de Brasilia, Brasilia, Distrito Federal, Brazil Nowadays, disaster management is organized in a well‐defined structure that refers to four different phases: prevention, preparedness, relief, and reconstruction (Disaster Management Cycle, DMC). Satellite remote sensing (SRS) is the ideal tool for disaster management, covering many tasks over all the phases of the DMC. An important aspect to emphasize is the opportunity to collect information over large areas, in short time intervals, at a safe distance and with a resolution that can increase depending on the level of required detail. This paper focuses on the third point of the DMC, the relief phase, and is aimed at the characterization of performances and limits of applicability of night‐time satellite images, for the detection and occupancy monitoring of human settlements and for a prompt assessment of damages. This way, SRS allows rapid and targeted intervention, allowing the mitigation of the effect of disasters of natural or anthropic origin. Pres‐ ently, few sensors operating at night are available for this purpose in the visible/near infrared part of the spectrum (DMSP/OLS, SACC/HSTC). However, in the case of DMSP/OLS, the availability of a constellation of satellites and the width of the sensor?s swath allow Earth coverage twice over one night. This can result useful in the aftermath of a natural disaster such as earthquakes, floods, conflicts, etc when first responders providing relief action need to know the location and the extent of the areas of damages, the potential amount of population involved and the place where survivors are concentrated. Naturally, after this prompt detection of the areas interested by the event, the corresponding Very High Spatial Resolution (VHSR) satellite images can be acquired to obtain an accurate overview of the actual damages. In fact, the availability of a preliminary fast estimate of the impacted areas can support a suitable selection of the VHSR images acquisition time since these sensors are characterized by a very small frame size that makes unpractical a blind acquisition of the whole region. This way to proceed is also compatible with the longer time usually needed to obtain a VHSR image of a given area of interest, due the orbital 101 and observation geometry constraints. Even if high, the OLS sensor?s sensitivity could be not sufficient to detect settlements with reduced artificial lights, as often happens in rural or less developed regions of interest, however this methodology represents an excellent tool for the first rapid assessments of disaster areas in most cases. Nevertheless, a couple of examples of the results obtainable using night‐time images in these scenarios are provided.

Technology evaluation on paper tubes manufacture by comparing between expert and non‐expert Oral Presentation. ICMP2017‐4328 Mitsunori Suda, Daisankogyo Co., Ltd, Kashiwara, OO, Japan, Takanori Kitamura, Kyoto Institute of Technology, Kyoto, OO, Japan, Zhiyuan Zhang, Daiwa Itagami Co Ltd, Osaka, Japan, Hiroyuki Hamada, Kyoto Institute of Technology Kyoto Institute of Technology, Kyoto, Kyoto, Japan Many kinds of paper tubes are used as core of toilet paper craft tapes, print paper and film etc. Paper tubes are also used for subsidiary material, display and packing part, a part of an exhibition stand and its structure. In 1950s, the paper tubes were firstly produced in Japan. From then on, the technical innovation for machine structure to produce paper tubes is rarely seen except the NC control. Paper tubes are usually produced by expert workers who are trained for experience. The manufacture technology can also be developed by this empirical rule. Paperboards for paper tubes production are not stable and the paper tubes fabrication is different with the mass‐produced goods that are produced in a certain size and shape, it belongs to the class of high‐mix low‐volume production. Even many orders are received with a short delivery time, it is also a career that the technology is inherited in the daily working. The so‐called expert is non‐expert person who is trained in the daily working and improve the technology by himself. It is a task for middle and small‐sized enterprises in how to train the workers in a short time effectively. This is not only for paper tubes production, but also for a small factory on how to inherit its technology in a short time effectively. The objective of this is to analyze the motion for paper tubes fabricating by observe difference between expert and non‐expert at work site as one of ?Great master?s work? in middle and small‐sized enterprises.

Microstructural Evolution in Aluminum Alloys Caused by High Speed Deformation Technical Publication. ICMP2017‐4330 Keitaro Horikawa, Ken‐ichi Tanigaki, Hidetoshi Kobayashi, Osaka University, Toyonaka, Osaka, Japan In the present study, we investigated the effect of high‐speed deformation on the formation of lattice defects and aging precipitates in 6061 and 7075 aluminum alloys. When the aluminum alloys after the solution heat treatment was previously deformed with high‐speed deformation more than 1000 s‐1, the following aging performance was highly enhanced. High resolution TEM observation revealed that the aggregation of point defect clusters were densely introduced by the high speed deformation. The point defect clusters were assumed to be a type of stacking fault tetrahedron (SFT). The enhanced aging performance was thus believed to be brought about by the interaction be‐ tween solute elements and SFT.

Casting of Aluminum Alloy Clad Strip by Twin Roll Caster Technical Publication. ICMP2017‐4332 Toshio Haga, Osaka Institute of Technology, Osaka, Japan Casting of an aluminum alloy clad strip with 400 mm width was tried using an unequal diameter equipped with a scraper. This caster was consisted by a lower large roll of 1000 mm diameter, an upper small roll of 300 mm diameter and a scraper. The width of the rolls was 400 mm, and the rolls were made from mild steel. The rolls were cooled from inside by the flowing water. The upper roll was set at 15 degree of inclination angle from the top of the lower roll. The scraper was mounted on the lower roll. The acts of the scraper was to prevent the mixture of the two kinds of molten metals. The first strip could be drawn from the gap between the lower roll and the scraper without the leak of the molten metal. The scraper was moveable depend on the thickness of the first strip. The molten metal of the second layer was poured on the first layer, and the molten metal was solidified by the cooling from the upper roll and the first layer. An aluminum alloy used for the sliding bearing, which was made from Al‐40%Sn‐1%Cu and 1070 aluminum alloy, were cast into the clad strip. The 1070 was first layer and the Al‐40%Sn‐1%Cu was second layer. This was decided by the solidification temperature. The solidification temperature of the 1070 is higher than Al‐40%Sn‐1%Cu. Therefore, Al‐40%Sn‐1%Cu was cast as the second layer to prevent the melting of the Al‐40%Sn‐1%Cu. The casting roll speed was 10 m/min, roll load was 20 kN and the scraper load was 16 kN. This roll speed was more than five times higher than that of the conventional twin roll caster for aluminum alloy. This roll load was less than one‐hundredth than that of the conventional twin roll caster for aluminum alloy. This small roll load means that the two strips were not bonded by the load from the 102 roll. The 400 mm width clad strip could be cast continuously ty this twin roll caster. The as‐cast clad strip could be cold rolled down to 1 mm without peeling at the bonding interface. The bonding interface was clear. The Sn, which was element of the Al‐40%Sn‐1%Cu, did not dif‐ fuse in to the 1070. This means that two molten metals were not mixed, and the 1070 was not melted by the molten metal of the Al‐40%Sn‐1%Cu.

Viscoplastic Behavior in Angle‐Ply CFRP Laminates Oral Presentation. ICMP2017‐4333 Shinji Ogihara, Tokyo University of Science, Noda, Chiba, Japan Experimental evaluation of mechanical behavior in angle‐ply CFRP laminate is conducted. Based on the experimental results, analytical modeling of viscoplastic constitutive relation is considered.

Investigation of the Quality of Autoclaved Composite Plates Through Working Process Technical Publication. ICMP2017‐4334 Norimichi Nanami, Nihon University, Chiyoda, Tokyo, Japan, Toshikazu Uchida, Yosuke Watanabe, Katsuyuki Hara, UCHIDA Co., Ltd., Iruma‐Gun, Saitama, Japan, Koji Kuroda, Hiroyuki HAMADA, Kyoto Institute of Technology, Kyoto, Kyoto, Japan, Akihiko GOTO, Osaka Sangyo University, Osaka, Japan, Hayato NAKATANI, Osaka City University, Osaka, Osaka, Japan Carbon fiber reinforced polymer (CFRP) products are utilized in the aerospace industry to provide high specific stiffness/strength. It is nec‐ essary to assure of the quality of CFRP products such as strength, stiffness. Defects in the products are caused by the skill of the working people, leading to the unexpected damage and failure of the products. Herein, we investigate the influence of the worked surface quality to the open hole tensile strength and interlaminar shear strength of CFRP plates. The results revealed that the quality of the machined sur‐ face of the plate in the hole making process altered its tensile strength. However, a further testing method to estimate the interlaminar shear strength of the plate is required to understand the influence of its surface quality in working process to its interlaminar shear strength.

Stiffness Reduction due to Matrix Cracking in Angle‐Ply Composite Laminates Oral Presentation. ICMP2017‐4335 Shinji Ogihara, Mohammad Fikry Mohammad Jelani, Ryuta Kitamura, Tokyo University of Science, Noda, Chiba, Japan Stiffness reduction due to matrix cracking in both GFRP and CFRP angle‐ply laminates is experimentally evaluated. Both variational analysis and finite element methods are conducted to compare with the experimental results.

Molten Polymer Monitoring During Solidification by Ultrasonic Pulse‐Echo Method Using Polygonal Buffer Rod Technical Publication. ICMP2017‐4336 Masanori ABE, Ikuo Ihara, Nagaoka Univ of Tech, Nagaoka 940‐2188, Japan Polymers such as polyethylene, polystyrene and polyurethane, because of their excellent moldability and inexpensiveness, have widely been used as an indispensable material for various industrial products such as aircrafts and automobiles. In general, the mechanical prop‐ erties of polymers strongly depend on the orientation of polymer chain that is also related to its manufacturing process. Therefore, it is necessary to monitor and characterize the real state of polymer resin during solidification process, to assure the quality and reliability of polymer products. In particular, a noninvasive technique for monitoring such molten polymer are greatly desired for some practical appli‐ cation in industries as well as academia. However, there have been little technique to meet such requirements. Ultrasound is expected to be an effective means for such monitoring of molten polymer because of its capability to probe the interior of materials and its high sensitivity to material properties. The advantages of ultrasonic measurements such as non‐invasiveness and faster response are also quite attractive. In this work, an ultrasonic pulse‐echo measurements are applied to molten polymer monitoring during heating and cooling processes. The polygonal buffer rod made of a polyimide has been used for the monitoring so that appropriate pulse‐echo measurements with a high signal to noise (S/N) ratio are successfully performed. It should be noted that the polygonal buffer rod is effective for reducing trailing noise echoes accompanying with the main pulse echo during the measurements and the polyimide rod provides a better acoustic impedance matching between the rod and polymer resin. A low density polyethylene (LDPE) is employed as a 103 polymer specimen. The tip of polygonal buffer rod of 115 mm length is immersed into molten LDPE at a temperature around 470 K and pulse‐echo measurements in the molten LDPE are permed at a frequency around 1 MHz. Ultrasonic velocity and attenuation of the LDPE at molten and solid states have been measured. It has been found that the velocity in solid state decreases significantly with the increase in temperature, whereas the velocity in liquid state decreases slightly. On the other hand, the attenuation in liquid state increases significant‐ ly with temperature. In addition, the development of the ultrasonic echo from a solid‐liquid interface has been observed when the bottom surface of the molten polymer is being cooled adequately. Thus, it has been demonstrated that the present ultrasonic buffer rod could be a useful tool to monitor the molten polymer during heating and cooling processes.

Microstructures and Mechanical Property of Intermetallic Compounds Reinforced Composites Technical Publication. ICMP2017‐4341 Yongbum Choi, Hiroshima university, Higashi‐Hiroshima, Hiroshima, Japan, Zhefeng Xu, Kazuhiro Matsugi, Hiroshima univer‐ sity, Higashi hiroshima, Hiroshima, Japan, Kenjiro Sugio, Gen Sasaki, Hiroshima University, Higashi‐Hiroshima, Hiroshima, Japan Recently, the conversion to aluminum alloy from cast iron materials has been increasing. And advanced features of the aluminum alloy are demanded. Metal matrix composites (MMC) which are strengthened with ceramic particles dispersed aluminum composite are developed. It is applied in practical for brake disk and piston in mobile parts in the industrial field. However, development of a simple manufacturing process is needed to expand an application of MMC. Therefore, a new process is proposed to fabricate an Al3Ni, intermetallic compounds particles reinforced metal matrix composite by Infiltration and reaction method in this study. In order to fabricated fine intermetallic com‐ pounds, it was investigated the optimum conditions for fine intermetallic compounds dispersion inside the matrix by different reaction time, 60s, 300s and 600s at molten alloy temperature of 973K, applied pressure of 0.1MPa and specific surface areas (>> 5800 m2/m3) of nickel porous. Counts, area fraction and aspect ratio of the intermetallic compounds inside matrix are investigated. In finally, three point bending strength of intermetallic compounds reinforced matrix composites was evaluated.

Energy Harvesting From Temperature Change by Piezoelectric/CNT‐Based Polymer Composite Laminates Technical Publication. ICMP2017‐4342 Marina Fox, University of California, Berkeley, Berkeley, CA, United States, Kotaro Mori, Ibaraki University, Hitachi, Ibaraki, Japan, Fumio Narita, Tohoku Univ, Sendai 980‐8579, Japan Energy harvesting is a process that captures unused ambient energy. The ambient energy comes in the form of vibration, sun, heat, etc. Piezoelectric ceramics have been widely recognized for their potential utility in energy harvesting applications. Recently, Shindo and Narita [1] studied the electromechanical response of S‐shaped piezoelectric energy harvesters under vibration both numerically and experimen‐ tally. They showed that when the S‐shaped harvester is operated near the first and second resonant frequencies, the output voltages be‐ come high during bending and torsional modes, respectively. They also found that the stress near the clamped end in the S‐shaped har‐ vester is lower than that in the straight harvester for the same output voltage. Narita et al. [2] studied the electromechanical behavior of polymer‐carbon nanotube (CNT)/piezoelectric laminates under cyclic bending. The objectives of this study are to report the potential of piezoelectric ceramics for thermal energy harvesting and to evaluate the output voltage and power as we rapidly shift the temperature from room temperature to high temperature (60 oC). Composite bimorph devices capable of demonstrating piezoelectric behavior under temperature change were constructed using lead zirconate titanate (PZT) plate and polycarbonate integrated with varying weight fractions of CNT (0, 0.8, 1.0, 2.5 and 5.0 wt%). The device was connected in parallel to a voltmeter and a selected value of resistance. The device was then inserted into a 60 oC oven. The resulting output voltages were recorded until the device reached a settle‐down stage where output voltages decreased consistently. The output power was then calculated by the equation W = V2/R, where W is power in watts, V is voltage in volts, and R is resistance in ohms. The effect of weight percentages of CNT within the polycarbonate on the output voltage and power versus resistance curves was discussed in detail.

References [1] Y. Shindo and F. Narita, Dynamic Bending/Torsion and Output Power of S‐Shaped Piezoelectric Energy Harvesters, International Journal of Mechanics and Materials in Design, 10 (2014) 305‐311. [2] F. Narita, S. Okura, Y. Shindo and T. Takeda, Electromechanical Response of Polycarbonate‐CNT/PZT Laminates Subjected to Cyclic Bending, International Journal of Materials and Product Technology, 52 (2016) 276‐285.

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AE Characterization of Microfracture Process During Bending Tests of Silica‐Particle‐Filled‐Epoxy Resin Technical Publication. ICMP2017‐4343 Ryosuke FUJIMOTO, Fumito MATSUOKA, Shuichi WAKAYAMA, Tokyo Metropolitan University, Hachioji‐shi, Tokyo, Japan, Yasuo KARASAWA, Meidensha Corporation, Numazu‐shi, Shizuoka, Japan, Naoto KAMEDA, Takashi ABE, Meidensha Corpo‐ ration, Shinagawa‐ku, Tokyo, Japan Epoxy resin has been used for the insulator of switchgear because of its excellent high electrical resistance. However, thermal stress is initi‐ ated because linear expansion coefficient of copper used as conductor is lower than that of epoxy resin. In order to suppress the thermal stress, silica particles with much lower linear expansion coefficient are filled. In this paper, the microfracture process during four‐point bending tests of silica‐particle‐filled epoxy resin was characterized by acoustic emission (AE) technique. Specimens with different weight fraction of silica particles were prepared in order to investigate the effects of the content of silica particles on microfracture process. Specimens with 25 wt.% and 60 wt.% of silica particle were used and AE measurement was performed during the bending test. The two AE sensors were attached to both the ends of the specimen in order to identify AE source locations. Rapid increasing point of cumulative AE energy was observed before final fracture in both specimens. AE source location at this point corresponded to the location of final fracture. It was then suggested that the maincrack was formed at this point and propagated to the final fracture. From those results, the critical stress for maincrack formation and the final fracture strength were defined as C and B, respectively. The average value of C was almost the same in both specimens, while the average value of B of 60 wt% was higher than that of 25 wt%. It was then suggested that crack growth resistance increased with the increase in content of silica particles. Consequently, the critical stress, ?C, would be more available as the conservative design parameter than the final fracture strength because the microfracture process of silica‐particle‐filled epoxy resin is the maincrack formation followed by its propagation to unstable fracture.

Experimental and Numerical Characterization of Nanofluid Minimum Quantity Lubrication End‐Milling Process According to Mist Spraying Condition Technical Publication. ICMP2017‐4344 Jin Woo Kim, Young Chang Kim, Jung Sub Kim, Sangwon Lee, Sungkyunkwan University, Suwon, Korea (Republic) In this research, a computational fluid dynamics (CFD) analysis is conducted to investigate the mist flow characteristics in the case of nanofluid minimum quantity lubrication (MQL) for the conventional end‐milling process of a titanium alloy. The nanofluid contains hexag‐ onal boron nitride (hBN) particles, which are injected to the cutting region with various spraying angles during the end‐milling experiments. After a series of experiments, the cutting forces are measured and it is found that the spraying angle of 90o results in the smallest cutting forces. Afterwards, the CFD analysis is carried out by building 2‐dimensional model having both triangle and quadrangle elements. In this model, the droplet spraying, turbulent behavior of mist and tool rotation are realized by using a discrete phase model, a realizable k‐model and a moving reference frame, respectively. Then, a PISO algorithm is introduced for analyzing the model. The results from the CFD analysis show that more droplets can be penetrated into the tool surface in the case of the spraying angle of 90, which could result in significant reduction in the cutting forces.

Effects of Friction Welding Conditions on Tensile Strength of Friction Welded Joint Between 5052 Al Alloy and Pure Copper Technical Publication. ICMP2017‐4346 Masaaki Kimura, University of Hyogo, Himeji, Hyogo, Japan, Yuusuke Inui, University of Hyogo (Present: Toyo Tire & Rubber Co., LTD), Himeji, Hyogo, Japan, Masahiro Kusaka, Koichi Kaizu, University of Hyogo, Himeji, Hyogo, Japan This paper described the effects of friction welding conditions on tensile strength of friction welded joint between Al‐Mg alloy (AA5052) and pure copper (OFC). The joining phenomena during the friction process and the effects of friction pressure, friction time and forge pressure on the joint strength have been investigated, and the metallurgical characteristics of joints have been also observed and analyzed. The adjacent region of the weld interface at the AA5052 side was upset during the friction process, although that of the OFC side was hard‐ ly upset. However, when the joint was made with a friction pressure of 30 MPa, all joints fractured at the weld interface because those joints had the not‐joined region at this portion. All joints did not have a joint efficiency of 100% (same tensile strength as the AA5052 base metal) and the fracture on the AA5052 base metal without crack at the weld interface, although the joint efficiency increased with increas‐ ing forge pressure. It was showed that the joint had the mechanically mixed layer as the lamellar structures of AA5052 and OFC on the ad‐ jacent region of the weld interface at the AA5052 side, and that layer influenced to the fractured point of the joint. The mechanically mixed layer decreased with decreasing friction time and friction pressure after the initial peak. Then, the joint, which had the same tensile

105 strength as the AA5052 base metal, the fracture on the AA5052 base metal with no crack at the weld interface, and less mechanically mixed layer with no the intermetallic compound (IMC) interlayer on the weld interface, could be successfully achieved. In conclusion, it was suggested that the joint should be made with low friction pressures such as 20 MPa to prevent generating of the mechanically mixed layer, opportune friction time such as 6.0 s to not generate the IMC interlayer, and with high forge pressure such as 240 MPa in order to achieve completely joining of the weld interface.

Orientation Behavior of Plate‐Like Ceramic Particles by Differential Speed Powder Rolling Technical Publication. ICMP2017‐4347 Kazunari Shinagawa, Kyushu University, Fukuoka, Japan, Qi Feng, Kagawa University, Takamatsu, Japan Powder rolling is a possible way to produce grain‐orientated ceramic materials with using plate‐like powder particles. Orientation behav‐ ior of ceramic particles, plate‐like alumina as a model material, during differential speed rolling was examined to seek the optimum condi‐ tion of rolling. Powder particles were kneaded with an organic binder to plasticize, and slab specimens were formed in dies. The speci‐ mens, without any sheath, were rolled with changing the difference in rolling speeds of two roll. The average of the orientation angle and the standard deviation of the angle distribution obtained by image analysis for each plate‐like particle were evacuated as the degree of orientation. The degree of orientation became higher as the ratio of roll speeds was increased.

Numerical Simulation for Longitudinal Compression of a Unidirectional Carbon Fiber Reinforced Plastic Constructed by X‐Ray Computed Tomography Technical Publication. ICMP2017‐4348 Keisuke Iizuka, Nihon University, Chiyoda‐ku, Tokyo, Japan, Masahito Ueda, Nihon University, Chiyoda, Tokyo, Japan, Takuya Takahashi, Nihon University, Chiyoda‐ku, Tokyo, Japan, Akinori Yoshimura, Masahiro Nakayama, Japan Aerospace Explora‐ tion Agency, Mitaka, OO, Japan Fiber waviness in a unidirectional carbon fiber reinforced plastic (CFRP) is developed during processing. Compressive strength of the unidi‐ rectional CFRP decreases due to fiber waviness. However, fiber waviness in the unidirectional CFRP has not been well understood, and the effect on the compressive strength has not clarified. In this study, a compression test of a unidirectional carbon fiber reinforced plastic (CFRP) was performed in an X‐ray computed tomography (CT) system. Internal compressive failure of the CFRP was observed during load‐ ing. In‐phase fiber micro buckling was occurred at the early stage of failure, and fiber fracture initiated at a location. Fiber fracture propa‐ gated through the whole cross section as a result of the fiber micro buckling. The scenario of compressive failure due to fiber kinking in a unidirectional CFRP under longitudinal compressive loading was revealed. Then, three dimensional finite element model of the CFRP was constructed using sliced images taken by the X‐ray CT system. In the finite element model, actual fiber random waviness was modeled. Compressive behavior of the CFRP was numerically simulated to study the effect of random fiber waviness on the compressive failure. Fi‐ nite element analysis showed that the local bending was developed due to the fiber waviness, which could be the trigger of fiber kinking.

Evaluation of Spatial Distribution of Second Phase in Particle Dispersed Composites With Machine Learning Technique Technical Publication. ICMP2017‐4349 Kenjiro Sugio, Yosuke Ohtani, Yongbum Choi, Gen Sasaki, Hiroshima University, Higashi‐Hiroshima, Hiroshima, Japan In order to evaluate spatial distribution of second phase in composites, gravity centers (GCs) of second phase particles have to be extracted from OM and SEM images accurately and automatically. At the present state, image processing techniques such as smoothing, threshold‐ ing, morphology transformation and contours extraction were combined to extract the GCs. However, the manual modification is necessary to extract the GCs accurately. In this study, machine learning technique was applied to recognize the GCs of second phase in composites. Cascade classifier and support vector machine (SVM) implemented in OpenCV was used for the particle detection. Haar and Histogram of Oriented Gradients (HOG) were utilized to train the cascade classifier and the SVM. When the cascade classifier with the Haar feature was utilized for particle detection, the maximum detection rate was 55%. When the cascade classifier with the HOG feature was utilized, the maximum detection rate was 48%. Although the detection rate of the Harr feature is larger than that of the HOG feature, the false detec‐ tion rate of the HOG feature is smaller than that of the Harr feature. When the SVM with HOG feature was utilized, the maximum detection rate was 78%.

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Development of CNF/Frame‐Resistant Magnesium Alloy Composites Technical Publication. ICMP2017‐4351 Gen Sasaki, Youqiang Yao, Kenjiro Sugio, Hiroshima University, Higashi‐Hiroshima, Hiroshima, Japan Recently, flame resistant magnesium alloys are grate watched because of not only frame proof but also good mechanical properties at room and high temperature for transportation instrument field. In order to improve the mechanical properties of this alloy, it seems that the addition of the dispersant such as carbon materials is one of suitable solution because of no reaction between carbon and magnesium. But as the wettability between magnesium alloy and carbon are usually low, it is very difficult to prepare the composites by casting process. In this study, in order to prepare the composites, the improvement of the wettability is the important problem. In this study, vapor grown carbon fibers (VGCFs) was used as the dispersant, which is one of carbon nano‐fiber (CNF), because of excellent properties, small size and high cost performance. On the other hand, matrix used is Mg‐5mass%Al‐3mass%Ca (AX53). At first, the wettability between the alloy and the carbon sheet which is highly orientated by (001) plane in graphite sheets. Because the surface of VGCF is covered by (001) plane completely. The wettability at 573 K in vacuum is about 120o, which is low wettability. In order to improve the wettability, nickel film was coated on graphite sheet by vapor deposition method. By using nickel coating with 3.7 ?m in thick‐ ness, the wettability was improved to 90o. Then, thin Ni film was coated on VGCF by electro‐less plating method. And, nickel coated vapor grown carbon fibers (VGCFs) reinforced magnesium‐calcium alloy composites are fabricated by compo‐casting process. Microstructures and mechanical properties of the composites are investigated. For the 0.5mass % Ni‐coated VGCFs reinforced AX53 alloy composite, VGCFs were well dispersed in the matrix. The tensile strength, yield strength and elongation were improved, as compared with AX53 matrix alloy. The tensile fracture analysis shows that the damage mechanism of composites is still brittle fracture. Moreover, a relatively larger amount of 1.0 % VGCFs results in formation of VGCF clusters in the Mg matrix, which lead to failure of the material with lower strength.

Combined Effects of Nano‐sized Silicon Carbide and Molybdenum Disulfide Dispersed in Polymer Overlay on Friction Prop‐ erties of Journal Bearing Oral Presentation. ICMP2017‐4352 Kazuki ENOMOTO, Takayuki DOI, Takuma NAKAOKI, Hatsuhiko USAMI, Meijo University, Nagoya, Aichi, Japan Owing to degradation of environmental loading, increase of fuel efficiency for internal combustion engines are strongly demanded. It is well recognized that the decrease and stabilize of the friction resistance is an important factor to improve the fuel efficiency. To satisfy the demands of the friction characteristics, various surface modification including coatings are applied to the interface, such as piston skirt and journal bearing surfaces, where the friction loss was larger. However, the sliding condition including is not uniform in an internal combus‐ tion engine, the surface modification method depended on the sliding condition is anticipated. The present study describes mechanical and tribological properties of polymer overlay containing aligned solid lubricant. Polyamide imide and molybdenum disulfide less than 5mm in size are mixed with a twin‐screw kneader then are used as coating materials. Nano‐sized silicon carbide particle was occasionally added to the overlay material. The overlay was fabricated on the micro size textured aluminum alloy surface with a developed high speed spin coating process. The resulted overlay surface contained parallel aligned MoS2, confirmed with x‐ray diffraction and affected subsurface texture. It was found that addition of the SiC resulted in the increase of the hardness. The tribological properties were evaluated with a 3 ball on disc type testing apparatus in lubricated condition. Results showed that the wear loss of the overlay decreased by the addition of the SiC. Furthermore, the wear loss of the mated SUJ2 surface was considerably smaller and the surface was modified with the formation of solid lubricant film from the additives of the oil. Optimum contents of the SiC and MoS2 into the PAI was evaluated.

Molecular Orientation Simulation in Extrusion Drawing of PLA Billets With the Finite Element Method Technical Publication. ICMP2017‐4353 Masato SAKAGUCHI, Tokyo University of Science, Chiba, Japan, Satoshi Kobayashi, Tokyo Metropolitan University, Hachioji, Tokyo, Japan, Shinji Ogihara, Tokyo University of Science, Noda, Chiba, Japan Poly(lactic acid) (PLA) attracts much attention as a material of bone fixation device which is used for fracture treatment, because it de‐ grades to nontoxic lactic acid through non‐enzymatic hydrolytic degradation. Applications of PLA bone fixation device are limited to low loaded region, because of their lower mechanical characteristics. The self‐reinforcing by drawing can increase mechanical properties of PLA without reinforcement and the piezoelectricity which is obtained by drawing improves treatment rate of bone fracture. Therefore, the drawing attracts much attention as a method which increases mechanical properties of PLA bone fixation device. Mechanical properties

107 and molecular orientation of drawn PLA fiber and film have been investigated. And, mechanical properties of drawn bulk PLA which is ap‐ plied bone fixation device has also been investigated. However, investigation of orientation behavior in bulk PLA is difficult because com‐ plicated deformation behavior during drawing. The purpose of this study is to investigate about molecular orientation obtained by drawing in bulk PLA. The molecular orientation obtained by drawing in bulk PLA was investigated by combination of the finite element method and the chain network model. The strains generated in drawn PLA billet was calculated with the finite element method and the molecular ori‐ entation of this billet was determined with the chain network model which is used in analysis of drawn polymer fiber and/or film in past studies. Then, the molecular orientation and the orientation distribution generated in PLA billet which drawn with differential mold shapes and extrusion ratios were calculated and compared to experimental value.

Dry Laser Peening on Metal Thin Film Using Transparent Solid Medium Technical Publication. ICMP2017‐4354 Yuko Aono, Atsushi Hirata, Hitoshi Tokura, Tokyo Institute of Technology, Tokyo, Tokyo, Japan Thin film materials have a crucial role in micromachine systems; however, treatments to control the properties are limited. Laser peening is a surface treatment method that improves the mechanical properties of a metal and is conventionally applied to bulk materials. This paper introduces a novel treatment method of metal thin films that uses laser peening. Conventional laser peening is conducted underwater to prevent the expansion of plasma generated by laser abrasion, but the wet condition treatment is not compatible with micromachining processes. Therefore, the proposed method uses dry laser peening instead. The proposed method uses a transparent solid material instead of water as the medium for laser peening. Using a glass medium produced a greater improvement in hardness than conventional wet laser peening. The improvement took place at a lower laser power, but the glass cracked at higher laser power and the cracks prevents the laser beam from penetrating through the glass. An air gap between the specimen and solid medium was also considered. In the results, the peening effect was confirmed for a gap thickness of less than 100 µm, and the effect was stronger than that of wet laser peening when the gap was less than 20 µm. Finally, the proposed method was applied to a thin copper film. The hardness of the copper film was measured with a nano‐indenter before and after peening. The results showed that the peening improved the hardness of the thin film.

Thermal Treatment and Microstructure Observation for Japanese Sewing Scissors Made by the ““So‐Hizukuri”” Forging Process Technical Publication. ICMP2017‐4357 Hayato NAKATANI, Osaka City University, Osaka, Osaka, Japan, Yasuko KITAJIMA, Tokyo Ariake University of Medical and Health Sciences, Tokyo, Japan, Takuya SUGIMOTO, KOYO Netsuren Corporation, Kyoto, Japan, Akihiko GOTO, Osaka Sangyo University, Osaka, Japan, Hiroyuki HAMADA, Kyoto Institute of Technology, Kyoto, Japan Authors have been conducting evaluations by various engineering approaches for Japanese sewing scissors made by the forging process called “So‐hizukuri” which is uniquely developed in Japan to find out the secrets behind the their sharpness. Our past work has shown that two blades of the scissors were designed to contact each other only at the cutting point where the blades intersects to concentrate the stress during the opening‐closing stroke due to the slight concave curvature of the blade inner surface. Motion analysis during cutting with the “So‐hizukuri” scissors or a cheap 100‐yen (1‐dollar) ‐shop scissors for an expert tailor who uses scissors in his profession has also demonstrated that there are sharp contrasts in accelerations of the blades and number of cutting strokes between the two scissors. The sharpness of the blades has been also explained by the microscopic observation for the cross‐section of fabrics after cutting where the fibers remained their shape rather than collapsed by using the “so‐hizukuri” scissors. Further evaluations are carried out here by metallic structure observations and hardness measurements. It is found that the blades of the “So‐hizukuri” scissors are composed of two layers of soft iron and steel, and the steel layer shows fine and uniformly sized martensite structure with partially distributed spheroidal cementite after quenching. In addition it is also indicated that hardness of the steel layer is much higher than that of standard quenched steel. The craftsman achieves uniform cooling in the blades of distributed thickness by coating them with a kind of clay (“arakida‐tsuchi” in Japanese) to obtain the uniformly sized martensite structure. Shaking the heated blades in the water also enable them to be cooled uniformly with higher cooling speed. The craftsman’s actions of pressing the blades against the inner wall of the water vessel during the cooling and an‐ nealing by utilizing remaining heat are considered to be correspond to die quench or press quench and marquench, respectively. Although the craftsman does not care about these engineering bases behind his actions, he learns from both his trainings and experiences and sen‐ suously carries out them.

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Investigation for Tacit Knowledge on the Bending Technique of Floral Materials in Ikebana Oral Presentation. ICMP2017‐4358 Akihiko GOTO, Osaka Sangyo University, Osaka, Japan, Yuki IKENOBO, Norihito YAMAGUCHI, Ikenobo Society of Floral Art, Kyoto, Kyoto, Japan, Hiroyuki Hamada, Kyoto Institute of Technology Kyoto Institute of Technology, Kyoto, Kyoto, Japan, Norimichi Nanami, Nihon University, Chiyoda, Tokyo, Japan, Hayato NAKATANI, Osaka City University, Osaka, Osaka, Japan Ikebana, which is referred to as Kado in Japanese, is the Japanese floral arrangement art and has been preferred over centuries. Ikenobo is one of the most famous Ikebana?s schools in Japan, and the theories of flower arrangement unique to each school. Ikenobo?s Ikebana expresses the natural beauty of floral materials such as branches and plants without any tools including wires and tapes. It is required to formalize floral materials in the idealized 3D style with only the hands of humans taking into account the natural characteristics of floral materials. The bending technique of floral materials described as bending and shaping branches and plants is significantly important to approach the idealized style of Ikebana. Bending technique which is technically called as Tame in Ikebana varies with the kinds of floral materials depending on their natural characteristics. It is extremely difficult to understand and teach proper bending technique for floral materials. The idealized style of floral art is not able to be held when flower materials are not bending properly, causing the damaged and broken flower materials. Additionally, the teaching guidance on the bending technique corresponding to each flower material is obtained based on the rule of thumb. Herein, we examine the mechanical characteristics of flower materials by conducting bending experiments with flexible and rigid floral materials. In parallel, we perform questionnaires about the flexibility of floral materials from experts and inves‐ tigate the correlation between the subjective evaluation and the mechanical characteristics of flower materials.

Fabrication of Functionally Graded Aluminum Foam and its Compressive Properties Technical Publication. ICMP2017‐4359 Yoshihiko Hangai, Gunma University, Kiryu, Japan, Takao Utsunomiya, Shibaura Institute of Technology, Tokyo, Japan, Tomoaki Morita, Gunma University, Kiryu, Gunma, Japan, Osamu Kuwazuru, University of Fukui, Fukui, Japan Functionally graded (FG) metallic foams, in which the properties vary with the position, are expected to improve the performance of metal‐ lic foams. It is expected that FG metallic foams have controlled compression deformation behavior with the desired plateau stresses corre‐ sponding to the compression properties of metallic foams by controlling the pore structures or type of aluminum alloy at each position. In this study, FG porous aluminum consisting of two layers with low strength commercially purity aluminum and high strength aluminum alloy was fabricated. The pore structures of the fabricated porous aluminum were observed non‐destructively by X‐ray computed tomography (X‐ray CT) to confirm that the pore shape was similar to that of the NaCl particles. In addition, compression tests were conducted to reveal the compression behavior of the fabricated FG porous aluminum by comparing it with those of uniform porous aluminum with commer‐ cially purity aluminum and high strength aluminum alloy.

Wall Thickness Control of Magnesium Alloy Tubes by Semi‐dieless Drawing Process Oral Presentation. ICMP2017‐4360 Tsuyoshi Furushima, The University of Tokyo, Tokyo, Japan, Yutaro Hirose, Tokyo Metropolitan University, Hachioji, Japan, Ken‐Ichi Manabe, Tokyo Metropolitan University, Mechanical Engineer, Tokyo, Japan The semi‐dieless drawing process with using mandrel is proposed to control the ratio of thickness to outer diameter of magnesium alloy tubes. AZ31 magnesium alloy tubes with outer diameter of 5mm and thickness of 1.5mm and piano wires with diameter of 2mm are used in the experiments. The semi‐dieless drawing apparatus with high induction heating device is used. The theoretical formula for prediction of the thickness after semi‐dieless drawing is also suggested based on volume constancy law. As a result, the ratio of thickness and outer diameter can be controlled by changing tensile and feeding speeds in the semi‐dieless drawing. The proposed formula can predict the outer diameter and thickness of drawn tubes. The heating temperature does not affect controllability of thickness, but the drawing limit enhanc‐ es with increasing heating temperature and maximum reduction in area of 44.6% can be obtained in a single pass drawing. In addition, the magnesium alloy tubes with outer diameter of 3.35mm and thickness of 0.69mm by multi‐pass semi‐dieless drawing can be fabricated. Furthermore, it is found that the inner surface roughness of drawn tube becomes smooth due to sliding between inner side of tube and mandrel. From these results, the effectiveness of semi‐dieless drawing process for control of thickness can be demonstrated.

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The Selection Method for Excellent Kyoto Bows Based on the Bow Force Draw Curve Technical Publication. ICMP2017‐4361 Norimichi Nanami, Nihon University, Chiyoda, Tokyo, Japan, Kanjuro SHIBATA, Kanjuro Shibata Bow Studio, Kyoto, Japan, Syuhei YASUDA, Kazuaki Yamashiro, Shinji NOJIMA, Ken IMANISHI, Shinya MORI, Kyoto Institute of Technology, Kyoto, Ja‐ pan, Hiroyuki Hamada, Kyoto Institute of Technology Kyoto Institute of Technology, Kyoto, Kyoto, Japan, Akihiko GOTO, Osaka Sangyo University, Osaka, Japan, Hayato NAKATANI, Osaka City University, Osaka, Osaka, Japan Kyoto bows are the Japanese version of an archery bow and are favorably adopted by bow enthusiasts. The Kyoto bow is not designed based on the design drawing, and a bow maker with high skills makes it by hand from many years? experience. The bow consists of a bow‐ string and sandwich construction including bamboo faces and a wood core. The wood core is technically called Nakauchi, and it consists of three kinds of hard and repulsive woods; haze, higo, and maple. Since the outer and inner bamboos are bonded to Nakauchi with natural or synthetic adhesive, the bow is recognized as the adhesive structure of natural materials. The high bow force and repulsive force against the weight of the bow is the feature of excellent Kyoto bows. The past study was related to physics of archery bows and lacks the generaliza‐ tion of bow quality being attributed to the skills of bow makers. Herein, we investigate the mechanical characteristics of the bows for find‐ ing the approach to assess their product quality. Mechanical testing, eye tracking, and oral DENTO MIRAI technique are employed to un‐ derstand the craftspersonship. The bow selection based on the mechanical tests of the bow agrees well with the selection of the craftsper‐ son. The essence in the observation of the craftsperson is presented to select the excellent bow.

Examination of Optomization of Molding Condition on Hyblid Molding Oral Presentation. ICMP2017‐4363 Maskai Ohishi, Advanced Fibro‐Science Kyoto Institute of Technology, Kyoto, Kyoto, Japan, Akio Ohtani, Kyoto Institute of Technology, kyoto, Japan, Asami Nakai, Gifu University, Gifu, Gifu, Japan Hybrid molding is a molding method that combines stamping molding and injection molding methods using continuous fiber‐reinforced thermoplastic resin. It draws attention with its capability to carry out the high cycle molding in the same level as injection molding, while enabling the simultaneous molding of complex forms such as rib or attachment part. Hybrid molded product is composed of continuous fiber‐reinforced thermoplastic resin composite sheet that is considered as most representative of prepreg, and the resin containing short fiber provided by injection machine. The interfacial properties are assumed to be influenced by various molding conditions. Therefore in this study, molding product with rib structure was molded by using hybrid molding on a pre‐heated woven fabric reinforced thermo‐plastic composite prepreg. During molding, injection molding condition for injection molding mode, and press molding condition for injection compression mode, were changed respectively. Interfacial properties between prepreg and injected parts were examined by tensile test. As a result, clarifying that interfacial properties between prepreg and injected parts differed depending on the molding condition, and the optimal molding condition was obtained. In addition to that, comparing injection mode and injection compression mode, it verified that the interfacial strength of molded product produced by injection compression mode was higher than that of the item produced by injection mode. Furthermore, bending test and impact test of the molded items were conducted in order to compare the mechanical property be‐ tween a common molded product and the hybrid molded product. This comparison verified that the mechanical property of the hybrid molded product showed improvement comparing to the common molded product.

Skill Analysis of an Expert in Kioke Production Oral Presentation. ICMP2017‐4364 Asami Nakai, Gifu University, Gifu, Gifu, Japan, Mayuko TOYOOKA, Takeshi UESHIBA, Fujiseiokesyo, Osaka, Japan, Shinya MORI, Ken IMANISHI, Syuhei YASUDA, Kyoto Institute of Technology, Kyoto, Japan, Hayato NAKATANI, Osaka City University, Osaka, Osaka, Japan, Norimichi Nanami, Nihon University, Chiyoda, Tokyo, Japan, Hiroyuki Hamada, Kyoto Institute of Tech‐ nology Kyoto Institute of Technology, Kyoto, Kyoto, Japan, Akihiko GOTO, Osaka Sangyo University, Osaka, Japan Kioke is the Japanese traditional wooden barrel used for natural brewing such as Japanese sake and soybean paste. Since Kioke has a lot of fibril holes on the surface of the wood, it easily provides life environment to microorganisms necessary for brewing. Therefore, Kioke is suitable to make the deep taste of natural brewing product. On the other hand, Kioke is composed of three parts; side plates, a bottom plates, and bamboo strips. The high quality techniques are required to make each parts of Kioke. The cutting process of the round bamboo is the significantly important process to prepare for the bamboo strips, and it is necessary to break bamboo longitudinally through Medake located on bamboo joints with rotating bamboo. Due to the complexity, and difficulty in cutting, it takes a lot of time to master the tech‐ 110 nique. Additionally, the number of Kioke?s experts is currently small, and there exist a few manufacturing companies for Kioke in Japan. In this paper, we measure the deformation of bamboo through the large division process of bamboo and analyze the skill of the expert in order to preserve and succeed to the traditional techniques to make Kioke.

The Development in the Making Process of Silk‐Screen Printed Japanese Tiles Technical Publication. ICMP2017‐4365 Hayato NAKATANI, Osaka City University, Osaka, Osaka, Japan, Masaki SAKATA, ASADA Kawara Factory, Kyoto, Japan, Yo‐ shito NAKANO, Tomoko OTA, Kyoto Institute of Technology, Kyoto, Kyoto, Japan, Masahisa ASADA, ASADA Kawara Factory, Kyoto, Japan, Hiroyuki Hamada, Kyoto Institute of Technology Kyoto Institute of Technology, Kyoto, Kyoto, Japan, Norimichi Nanami, Nihon University, Chiyoda, Tokyo, Japan, Akihiko GOTO, Osaka Sangyo University, Osaka, Japan “Kyo‐gawara” is one of the traditional crafts in Kyoto. Silk‐screen printing technique has been applied to develop new Kyo‐gawara prod‐ ucts. Silk‐screen printing technique is one of the stencil printing techniques. A mesh fabric made of holes and film is used in this technique. Some patterns and artworks are printed because an ink passes through the hole, and it does not pass through the film. Silk‐screen printing technique has not been used in the Kyo‐gawara making process. The silk‐screen painting was performed on the surface of Kyo‐gawara and an effect of ink concentration on silk‐screen printed stripes was evaluated.

High Throughput Characterization Method for Glass Transition of Ti‐Ni‐Zr High Formable Shape Memory Alloys by Meas‐ uring Electrical Resistivity Technical Publication. ICMP2017‐4366 Junpei Sakurai, Motoki Murakami, Mizue Mizoshiri, Seiichi Hata, Nagoya university, Nagoya, Aichi, Japan Ti‐Ni‐based thin film high formable shape memory alloys (HF‐SMAs) are noble functional materials showing unique properties. These alloys are expected to be suitable materials for three dimensional (3D) microelectromechnical systems (MEMS) and microdevices. These alloys fabricated by a sputtering and melt spun are metallic (MGs) and show glass transition and then exhibit viscous flow in a supercooled liquid region (SCLR). In the SCLR, they are deformed to three‐dimensional structure easily like a glass work. Moreover, crystallized these alloys show martensitic transformation, and they are SMAs. Thus, SMAs MEMS and microdevices with 3D structure are obtained. The properties of amorphous Ti‐Ni‐based HF‐SMAs depend on alloy compositions strongly. In the case of Ti‐Ni‐Zr alloy systems, when Ni‐content is more than 50at%, these alloys show glass transition and crystallized alloys are HF‐SMAs. On the other hand, when Ni‐content is less than 50at%, these alloys don?t show glass transition and crystallized alloys are only SMAs. Therefore, we have to clarify the alloy composition of HF‐SMAs showing glass transition. In this paper, we proposed characterization method of glass transition temperature Tg by in‐situ measuring electric resistance during heating for combinatorial high throughput evaluation, instead of conventional sequential dif‐ ferential scanning calorimetery (DSC). The change of electric resistivity during heating until crystallization were measured by the two terminal method for detecting the Tg. Evaluated sample was prepared by r.f. sputtering system. Sample is winding shape to increase re‐ sistance and integrate many samples. Sample area was 2.2mm x 5.4mm x 0.5micrometer and electric resistance was approximately 2000ohm. Sample composition was Ti38Ni50Zr12. Thermal properties of this sample were measured by DSC and, Tg and crystallization temperature Tx were 682K and 760K, respectively. The electric resistivity of this sample increased slightly with increasing temperature. The electric resistance decreased slightly at 674K, and proposed method could detect Tg. Further increasing temperature, electric re‐ sistance decreased drastically at 752K of Tx. Difference results between the proposed method and DSC was caused by measurement of sample temperature. Temperature of DSC sample was measured directly by thermocouple. On the other hand, in the case of proposed method, since the sample temperature cannot be measured directly with thermocouple, temperature of its neighborhood aluminum sub‐ strate was measured as sample temperature. In the future, integrated samples are measured by the two‐terminal method and sample temperature is measured by thermography. Finally, the alloy composition of Ti‐Ni‐based HF‐SMAs are clarified.

Semi‐Viscoelastic FE Analysis of Process‐Induced Deformation in Composite Laminates Technical Publication. ICMP2017‐4368 Keiji Ogi, Ehime University, Matsuyama, Ehime, Japan, Hiroaki Matsutani, Narumichi Sato, Toray Industries, Masaki‐cho, Ehime, Japan Carbon fiber reinforced thermosetting resin composite laminates have already been applied to primary structure of civil aircraft. Since such 111 structures are basically fabricated using an autoclave, it requires much cost and processing time. Recently, in order to decrease the pro‐ cessing cost and time, so called out‐of‐autoclave (OoA) fabrication methods have been investigated. Both in the autoclave and OoA fabrica‐ tions, unexpected deformation such as spring‐in must be minimized to assure the dimensional accuracy and structural integrity. A lot of factors must be taken into account for predicting the residual stress during a cure process; eg. viscoelastic properties, cure shrinkage and coefficients of thermal expansion (CTE). In addition to the above factors, anisotropic material properties of composite laminates usually depend on not only temperature but also degree of cure (DOC). As a result, high numerical cost is generally required for simulating defor‐ mation during a cure process even though the simulation is performed with the aid of commercial finite element analysis software. In the present study, we propose a semi‐viscoelastic model for calculating deformation of a carbon/epoxy composite laminate during a whole cure process. For the purpose of reduction of analysis cost, the macroscopic engineering elastic constants of the composite prepreg were approximated by bilinear functions of the Young?s modulus of thermosetting resin on the basis of the self‐consistent micromechani‐ cal model. The relaxation Young?s modulus of the resin was expressed as an explicit function of reduced time, DOC and temperature in a form of a Prony series using the instantaneous and equilibrium Young?s moduli of the resin. In addition, a shift factor in a form of a linear function of temperature and DOC was proposed as a time‐temperature‐DOC superposition principle. In terms of CTE of the composite, the micromechanical model was employed. On the other hand, the incremental linear elastic (ILE) constitutive relation was employed in the calculation of stress instead of a linear viscoelasticity constitutive equation. In this sense, the present model can be called a ?semi‐viscoelastic? model. The numerical predictions using commercial FE software were compared with experimental results for several asymmetric laminates in which curvature was generated.

FEM Simulation and Experimental Evaluations Using an FBG Sensor of Process‐Induced Strain of Reinforcements of FRP Technical Publication. ICMP2017‐4369 Heiya Yamasaki, Tatsuro Kosaka, Kazuhiro Kusukawa, Kochi University of Technology, Kami, Kochi, Japan Residual stress occurred during molding process of FRP influences damage behaviors. However, it is difficult to measure process‐induced strain of reinforcement fibers or matrix during molding. In the present paper, we proposed a FEM simulation method using viscoelastic resin and an experimental method using Fiber Bragg Grating sensors for evaluation of process‐induced strain. We prepared optical‐fiber reinforced plastics as GFRP and measure the strain of reinforcement fibers using an embedded FBG sensor. The analytical results were compared to measured results by the FBG in order to confirm accuracy of the model. In the present paper, it was supposed that resin was a viscoelastic material as a function of degree of cure. Viscoelastic properties of resin were experimentally obtained. The temperature influence on the viscoelastic property was expressed by Arrhenius equation. Constitutive equation of resin was programmed by FORTRAN and assembled into a user subroutine of ABAQUS. The calculation model used in the anal‐ ysis was a 1/8 model of specimen. In the present paper, effect of molding temperature condition on residual strain of the reinforcements was paid attention. Two types of temperature patterns were used. In the analysis of single step, the specimen was heated from 25°C to 100°C. Three heating rate, where heating time was 40 minutes, 100 minutes and 200 minutes, were employed. For all conditions, temper‐ ature was kept for 3 hours at 100°C and the specimen was cooled to 25°C for 45 minutes. It appeared that the process‐induced strain of the reinforcement fiber decreased when heating rate is smaller. This reason is that higher degree‐of‐cure at lower temperature increase ther‐ mal expansion during heating stage and decrease curing shrinkage during temperature‐holding stage. In the analysis of double step, the specimen was kept in heated from 25°C to 100°C. The three patterns where heating time was 60? and 1 hour, 60? and 2 hours and 80 ? and 1 hours were employed. For all conditions, temperature was kept for 3 hours at 100°C and the specimen was cooled to 25°C for 45 minutes. It appeared that the process‐induced strain of the reinforcement fiber decreased when first holding section is longer. Additionally, it was found that the process‐induced strain hardly affected by the first constant temperature because thermal strain was erased by curing shrinkage.

Process and Motion Analyses of the Tying up Method of ?Kyo‐Kanokoshibori? between the Expert and Non‐expert Oral Presentation. ICMP2017‐4370 Reiko Furoi, Tezukayama University, Nara, Japan, Shodai Kawakatsu, Kyoto Institute of Technology, Kyoto, Kyoto, Japan, Ki‐ yoko Kiso, kyotsukasa, Kameoka, Kyoto, Japan, Hiroyuki Hamada, Kyoto Institute of Technology Kyoto Institute of Technolo‐ gy, Kyoto, Kyoto, Japan, Hayato NAKATANI, Osaka City University, Osaka, Osaka, Japan, Norimichi Nanami, Nihon University, Chiyoda, Tokyo, Japan, Akihiko GOTO, Osaka Sangyo University, Osaka, Japan “Kyo‐kanokoshibori” produced in Kyoto is the Japanese traditional dyeing technique to show the undyed part in three dimensions. Silk fab‐ ric tied tightly with silken threads is dyed. The reason for calling Kyo‐kanokoshibori is that the patterns of undyed granular shape on the 112 fabric are similar to the dappled skin of the Japanese deer. The technique of tying up is the most important factor to determine the quality of products in the whole processes. Fifty kinds of tying up methods in Kyo‐kanokoshibori are categorized into mechanical and hand working techniques. The mechanical technique uses a tying up stand with a short needle attached to a hook to bind each dot three or four times with a cotton thread. The procedures of the hand working technique are completed by hand, and they are further classified according to the number of times and presentations of winding the thread. The ultimate tying up method requires four winds, and normally the thread is wound 4 times and cinched twice. Thus, the threading to 1 knot of pattern spans more than six times, leading to an enormous amount of time of sumptuous procedures. Also, the inheritance of the technique is not simple and easy due to its detailed knowledge, and the lack of successors is a serious problem. In this paper, we perform process and motion analyses of the tying up method between the expert and non‐expert to preserve the traditional technique.

Shortening in Resin Impregnation Time of VaRTM Process and Interlaminar Toughening for GFRP by Inserting Polyamide Mesh Technical Publication. ICMP2017‐4371 Hayato NAKATANI, Yosuke HANDA, Katsuhiko OSAKA, Osaka City University, Osaka, Osaka, Japan During vacuum assisted resin transfer molding (VaRTM) process a distribution medium which is incorporated on fiber preform as a surface layer is used to shorten impregnation time of resin. The flow rate of resin is increased by out‐of‐plane flow where resin is infused into fibre preform in through‐thickness direction via the distribution medium. After the curing of the matrix resin it is removed with peel plies from the molded composites surface. This leads to higher production cost of the composites and also waste of materials. In this study the distri‐ bution medium is replaced by thermoplastic polyamide meshes and is inserted between fiber fabrics rather than placed on the surface. The mesh is expected to improve not only the resin flow but also interlaminar toughness in the composite laminate by remaining in it after the VaRTM process. Multipoint measurements for resin arrivals in GFRP (Glass fiber fabrics / epoxy composites) during VaRTM process are carried out by using embedded fiber optic sensors. It is confirmed that the polyamide mesh inserted in the fiber preform increased the flow rate during the impregnation of resin, and that thicker polyamide mesh resulted in higher flow rate. This fact is related to experimentally obtained permeability of the polyamide mesh with different thicknesses. Numerical simulation based on CV/FEM approach also represents both the flow front of resin where the resin preferentially proceeds in the polyamide mesh and flow rate at each measurement point. End notched flexure (ENF) tests using with specimens which have bonded doubler plates of CFRP to both top and bottom surfaces [CF/GF/GF/CF] and [CF/GF/PA/GF/CF] are carried out. Pre‐crack is introduced in the GF/GF interface or the one of the GF/PA interfaces. The crack length can be predicted by a simple beam theory for bonded doubler plates during the ENF testing. It is found that interlaminar frac‐ ture toughness G_IIC are improved by inserting the thinner and finer polyamide mesh due to the complexity of the crack path. From these results it is shown that improvements in both resin flow and interlaminar fracture toughness can be achieved by the single action of insert‐ ing the polyamide mesh.

Identification of Damage Types in Composites Based on Remote AE Measurement With a Fiber‐Optic Sensor Technical Publication. ICMP2017‐4372 Yoji Okabe, Fengming Yu, The University of Tokyo, Tokyo, Japan, Naoki Shigeta, IHI Corporation, Tokyo, Japan In recent years, the authors have developed a novel optical fiber sensor (OFS) system to detect acoustic emission (AE) signals in composite materials by using phase‐shifted fiber Bragg gratings (PSFBGs). Since this OFS system has advantages of the high sensitivity and the ul‐ tra‐broadband response for the axial strain in the optical fiber, this system can measure the AE waveforms precisely. Since optical fibers have high environment resistance, we attempted to apply this system to AE measurement for composites under ulti‐ mate environments. For this purpose, the PSFBG sensor should be arranged far from the ultimate environments. Hence a new adhesive method for remote measurement (ADRM) was proposed for remote sensing of AE signals that propagate through the lead optical fiber from the composites to the PSFBG. As a result, it was found that the AE signals can be detected by the OFS remotely keeping its waveform, because the AE Lamb waves are converted into a pure longitudinal mode in the optical fiber. This method enables us remote sensing of AE signals. Then, based on this AE measurement with the ADRM configuration, we proposed a novel method to identify damage types in carbon fiber‐reinforced plastic (CFRP) laminates. Because the PSFBG sensor measures pure dynamic strain, the detected AE signals has high physical reliability, which make elastic wave theory suitable for analysis of the signal. The analysis clarified the different characteristics of Lamb wave modes in three types of AEs caused by a transverse crack, delamination, and fiber breakage. Additionally, the ratios of the am‐ plitudes of the S0 mode to the A0 mode and the peak frequencies quantitatively evaluated the mode characteristics in the AE signals. Sim‐ ultaneously using the two physical parameters, we identified the three types of damage among the AE signals detected in a three‐point 113 bending test. Furthermore, the finite element method‐based AE wave propagation simulation agreed well with the identification results. Hence, the proposed identification method with the remote AE measurement method using PSFBG sensor has a possibility to clarify the damage progress in composite materials under ultimate environments.

Joining characteristics and residual stress characteristics of friction welding between dissimilar shapes and dissimilar materials Oral Presentation. ICMP2017‐4373 Tsuyoshi Takahashi, National Institute of Technology, Kushiro College, Kushiro city, Japan, Masaaki Kimura, University of Hyogo, Himeji, Hyogo, Japan Friction welding was applied to dissimilar shapes and dissimilar materials of aluminum alloy. Concretely, a combination of a solid bar of 6061 Al alloy and a pipe of Al‐Si12CuNi (AC8A) Al cast alloy was investigated. When the joint was made by a continuous drive friction weld‐ ing machine (conventional method), the AC8A portion of the joint showed heavy deformation and the AA6061 showed minimal defor‐ mation. The large deformation of AC8A side was caused by increasing friction torque during braking. To prevent braking deformation until rotation stops, a joint was made by a continuous drive friction welding machine that has an electromagnetic clutch. When the clutch was released, the relative speed between both specimens simultaneously decreased to zero. When the joint was made with a suitable joining condition, the joining could be successfully achieved and that had approximately over 50% efficiency. However, all joints showed the frac‐ ture between the traveled weld interface and the AC8A side, because the weld interface traveled in the longitudinal direction of AC8A side from the first contacted position of both weld faying surfaces. Hence, it was clarified that the friction welding between a solid bar of AA6061 and a cast pipe of AC8A was not desirable since the traveling phenomena of the weld interface were caused by the combination of the shapes of the friction welding specimens. On the other hand, the residual stress of a test piece has changed with differences in the joining condition mentioned above. Since residual stress was added to service stress, it can cause a durable fall. In order to clarify the char‐ acteristics of residual stress by the dissimilar friction welding operation, the residual stress measured by the detailed X‐ray diffraction was carried out. A material combinations were AA6061 vs AC8A and AA6061 vs SUS304. The residual stress distributions of the material specimen were measured three times. The first time was the Residual stress was measured 3 times. The first time was immediately after the friction welding. The second time was after processing the specimen shape. The third time was after the corrosion test. As a result, it turned out that the distribution of residual stress changes greatly with friction welding conditions.

Development of Chloride‐Free Oil for Cold Forming of Stainless Steel Technical Publication. ICMP2017‐4374 Tomohiro Takaki, Kazuhiko Kitamura, Makino Takehiko, Japan/Nagoya Institute of Technology, Nagoya, Aichi, Japan, Jun‐ichi Shibata, JX Nippon Oil & Energy Corporation, Yokohama, Japan Galling and wear has been a tribological problem in sheet metal forming of stainless steel. It is a reason why the stainless steel is covered with chemically‐inactive chromium oxide, which is difficult to form a chemical reaction film on the stainless steel for lubrication. Industrial‐ ly, lubrication oil with chloride additives has been used as a high performance lubricant for metal forming of stainless steel. Higher perfor‐ mance chloride‐free oil, however, is required after the chloride type oil was revealed as a cause of environmental pollution. In this paper, ball ironing test has been devised on the basis of the results of a practical operation including deep drawing and ironing. The results of this ironing test are equivalent to the practical test on the tribological performance and the chemical reactivity of oil with some extreme‐ ly‐pressure additives, EP‐additives. Some typical EP‐additives with sulfur are estimated by the ironing test. After the tests, an EP‐additive with sulfur is proposed. Additionally, by the test several sample oils are estimated, which contain mainly the additives with sulfur and addi‐ tionally other typical additives with calcium and phosphorus. The sample oil, as shown highest performance in ball ironing test, successively passed the 10 000‐shots practical process with severe ironing of stainless steel. After the 10 000‐shots, it was found that no galling are ob‐ served on the work are exhibited. This is an example of a chloride‐free oil to replace the conventional oil with chloride.

Effects of die shape and molding condition on composite pipes by pultrusion molding Oral Presentation. ICMP2017‐4376 Asami Nakai, Kyuso Morino, Tatsuya Banno, Masaoki Yagi, Gifu University, Gifu, Gifu, Japan, Akio Ohtani, Kyoto Institute of Technology, kyoto, Japan

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Recently, fiber reinforced thermoplastic is in the spotlight. What thermoplastic resin gives to molding is the secondary workability and the recyclability. Molding system without chemical reaction can shorten the cycle than the system with thermosetting resin. In one of the high cycle molding system for continuous fiber reinforced plastic with thermoplastic resin, there is pultrusion molding system. We have pro‐ posed one of the high‐cycle‐molding for FRTP with fibrous intermediate material and pultrusion systems by using braiding technology. Braided fabrics are pulled in the pultrusion molding die. Resin fiber in the braided fabric is solidified after heating and impregnated in the mold process, molding is continuously pulled at a drawing device. At this stage pultrusion molding system has issues that productivity is still lower for automotive application. Therefore, establishment of molding conditions which shortens molding time is demanded. In this re‐ search, effects of pultrusion speed and temperature condition on molding were investigated. Effects of the shape of molding die were also investigated. Temperature and pressure histories were measured during pultrusion moldings. Then, impregnation and mechanical prop‐ erties of molded composite pipes were measured.

Effect of Needle Punching Process on Fatigue and Residual Properties of Chopped Strand Mat Composites Technical Publication. ICMP2017‐4379 Daiki Ichikawa, Kyoto Institute of Technology, Kyoto, Kyoto, Japan, Ryo Marui, Marui Textile Machinery Co.,Ltd., Osaka, Ja‐ pan, Tohru Morii, Shonan Institute of Technology, Fujisawa, Japan, Akio Ohtani, Kyoto Institute of Technology, kyoto, Japan Fiber Reinforced Plastics (FRP) have been expected to be used for structural materials in various field because of its high specific stiffness and strength. In the case of using FRP for structural materials, joint structure must be needed. Most comfortable and reliable joint system is mechanical joint with bolt and nut or rivet. However, mechanical joint system for composite laminates have a problem; mechanical proper‐ ties decrease because of delamination around hole by stress concentration. Therefore, improvement of inter‐laminar strength is important. In this study, needle punch techniques were focused on to improve composite strength around open holes. This technique was usually used for fabricating non‐woven fabrics. Fiber webs were punched by a plate with lots of special needles with many barbs. A part of fibers in in‐plane direction was aligned in out‐of‐plane direction. In this study, needle punch process was applied on chopped strand mat. Tensile test, fatigue test of 10 cycles stop and end residual strength test were carried out. Tensile properties, fatigue properties, residual proper‐ ties and fracture mechanism of FRPs with needle punched chopped strand mat with or without hole were investigated.

Dynamics of Smart Inflatable Tsunami Airbags (TABs) for Tsunami Disaster Mitigation Technical Publication. ICMP2017‐4380 Mohsen Shahinpoor, University Of Maine, Orono, ME, United States, Hiroshi Asanuma, Chiba University, Chiba, Chiba, Japan For communities living and working near a large body of water around the world natural disasters such as earthquakes and tsunamis are the major threats. This is particularly true for the countries in the Asia‐Pacific region for which earthquakes and tsunamis are the major obstacles towards sustainable developments and survival. In this connection, Japan is expected to serve a leading role in the promotion of tsunami disaster mitigation because of its long history to cope with tsunami disasters. Some critical facts about tsunamis are that they are most always caused by earthquakes. These earthquakes might occur far away or near where people live. Further, some tsunamis can be as large over 120 feet in height and they can move inland several hundred feet and all low‐lying coastal areas can be struck by them at a very high speed of more than 120 km/hr. Presented is mathematical modeling of the inflation dynamics of deployable tsunami wave con‐ fronting walls, sometimes called tsunami air bags (TAB) that can be rather quickly set up and strongly anchored to the ocean floor to with‐ stand the impact of a tsunami wave and thus protect the buildings and structures on shore. These dedicated inflatable smart structures are designed such that, after inflation, upon tsunami impact they can perform two smart deployment tasks. The first one is for the structure to deploy in the form of a porous structure containing internal folds and pockets and reconfigure due to tsunami impact to perform energy absorption by forcing the tsunami water waves to pass through the porous inflatable structure forcing the tsunami waves to lose kinetic energy due to viscous drag and pressurizing the inflated walls. The second task is related to a special design of the inflatable structure that causes it to deploy to either further vertically rise or become a hollow inflatable dam upon the tsunami impact. Modes of failure of these inflatable walls against the tsunami impact are also discussed in this presentation

Real‐Time Monitoring of Biological Cells Traction and Migration Dynamics by Ionic Polymer Metal Composites (IPMCs) Mi‐ cropillars/Substrates Technical Publication. ICMP2017‐4381 Abouhamed Saberi, Sharon Ashworth, Mohsen Shahinpoor, University of Maine, Orono, ME, United States 115

In molecular cell biology many types of substrates are used to culture cells over them and in essence study cellular dynamics such as adhe‐ sion, traction and migration. In many cases these substrates are made of rigid materials like glass. To mimic the in vivo substrates which are wet and soft and tissue like, cells may be grown on compliant substrates made with smart multi‐functional electroactive materials such as ionic polymer metal composites (IPMCs). Many studies accentuate the importance of force and nanometer‐level movements in cell adhe‐ sion, cell growth, differentiation, cell shape and function through mechanical tension in the actin cytoskeleton. For instance the change in force applied by a cell to its extracellular matrix (ECM) play an important role in cell adhesion both in static and dynamic conditions (for instance the shear force caused by blood flow in vessels). Cell adhesion regulates the cell growth or cell differentiation mechanisms. Re‐ al‐time dynamic tracking and sensing of biological cells adhesion, traction forces and migration may be performed by employing smart sub‐ strates and micropillars made with electroactive polymeric materials such as ionic polymer metal composites or IPMCs. The big advantage with IPMC substrates and micropillars is that they act both as sensors, actuators and even energy harvesters in the presence of assemblies of cells. Traditional biological scientists utilize soft substrates made of gels to mimic the wet and soft tissues in biological systems and to study the migration of cells and related physical characteristics such as velocity, force, adhesion and traction and in general cell migration and me‐ tastasis. Study of each of these subjects and parameters require complicated procedures. For instance, time‐lapse microscopy techniques are commonly employed that require advanced image processing techniques to track cells. During this time span, cells should be kept in an incubator to imitate their actual environments. One of the challenging physical parameters is the measurement of the force applied by a cell on its substrate in real time. Ionic polymer metal composites (IPMCs) as smart multi‐functional materials with simultaneous sensing and actuation capabilities present a unique system to dynamically monitor cell growth, differentiation, migration, adhesion and traction. Cur‐ rently used micro pillars made with polyacrylamide or polyethylene glycol gels and more recently with Polydimethylsiloxane (PDMS) mi‐ croposts from microfabricated silicon masters only give information on cellular activities after the fact while IPMCs are capable of real time sensing of cell dynamics, adhesion and traction. This paper discusses some initial observations and the potential of such cell dynamics ob‐ servations and tracking.

Data Assimilation for Estimation of Composite Curing Process by Integrating Simulation and Measurements Technical Publication. ICMP2017‐4383 Junya Ishizuka, Ryosuke Matsuzaki, Takeshi Tachikawa, Tokyo University of Science, Noda, Chiba, Japan In the past, smart manufacturing techniques for carbon fiber‐reinforced plastic (CFRP) were studied to increase the efficiency of molding. The molding state was predicted using numerical simulations based on information obtained by monitoring the molding process. However, the sensors embedded in the interlaminar interface of the CFRP degraded the modeling quality. Therefore, another state estimation method that does not affect the internal performance of the composite structure is required. In this study, we constructed a high‐accuracy model state estimation technique for use during curing. The technique uses data assimilated by integrating a heat‐curing numerical simula‐ tion with the values observed in experimental measurements. In this technique, we estimate the internal temperature distribution and the coefficient of thermal conductivity of a composite structure from the observed temperature of the surface using an ensemble Kalman filter (EnKF), which is a sequential data assimilation technique. EnKF does not require the linearization of the model, so it is possible to adapt a nonlinear state, such as the thermal conduction phenomenon of CFRP. To validate the proposed method, we conducted numerical experi‐ ments for structures with non‐uniform coefficients of thermal conductivity by simulating the stacking of plates of silicone rubber. We heated the composite model uniformly from the lower side and measured the upper‐side temperature and the heating temperature as the observed values. The observed values used in this experiment were produced by numerical simulation and given measurement errors. The results confirmed that the proposed method could accurately estimate the internal temperature of composite structures using the surface temperature. In addition, the proposed method could capture trends of areas with high or low values of thermal conductivity, which were model parameters. Moreover, we tried to verify the proposed method using observed values acquired by an actual experiment. Using the proposed method with data from the actual experiment, in which temperature was measured by thermocouples, the internal temperature of CFRP laminates were estimated from the surface temperature.

Mechanical Properties of CFRTP Fabricated by FDM 3D Printer Technical Publication. ICMP2017‐4384 Taishi Nakamura, Tokyo university of science, Noda‐shi, Chiba‐ken, Japan, Ryosuke Matsuzaki, Tokyo University of Science, Noda, Chiba, Japan, Akira Todoroki, Tokyo Inst Of Tech, Tokyo, Japan, Masahito Ueda, Nihon University, Chiyoda, Tokyo, Ja‐ pan, Yoshiyasu Hirano, Japan Aerospace Exploration Agency, Mitaka, Tokyo, Japan 116

3D printing first appeared in the 1980s and has experienced significant development recently. As the cost of 3D printers using thermo‐ plastic filaments has decreased, their use has become widespread. However, the parts produced by fused deposition modeling (FDM) 3D printers are intended for use in trial products or models. These parts lack the strength required for structural components because they use resin matrices, meaning they cannot be used in structures requiring high strength. Meanwhile, carbon fiber‐reinforced plastic (CFRP) has drawn attention as a composite material with high strength and fracture toughness. However, establishing the facilities required to manu‐ facture CFRP involves significant economic expenditure. The purpose of this study was to manufacture a low‐cost high‐strength structure for use in aerospace and automotive structures. In order to accomplish this, we developed an FDM 3D printer and produced a resin fila‐ ment pre‐impregnated with carbon fiber for the printer. The printer used an incorporated cutting mechanism to cut the continuous carbon fiber. Three CFRTP and ABS specimens were manufactured using the FDM 3D printer. The specimens were then subjected to tensile testing at a rate of 1 mm/min to evaluate the mechanical properties of each specimen. The results showed the tensile strength of the CFRTP specimen to be 4 times higher than that of the ABS specimen. The elasticity modulus of the CFRTP specimen was 4.8 times higher than that of the ABS specimen. The bending strength of the CFRTP specimen was 2.9 times higher than that of the ABS specimen. The bending elastic modulus of the CFRTP specimen was 5.1 times higher than that of the ABS specimen. However, these values were lower than the theoreti‐ cal values calculated using the law of mixtures. We conducted a cross‐sectional observation of the CFRTP specimen, which showed res‐ in‐rich and non‐impregnated resin spheres. The data from these observations showed lower dynamic characteristics in the case of the res‐ in‐rich and non‐impregnated resin spheres.

Hot Forging Characteristics of High Aluminum Content TRC Materials Oral Presentation. ICMP2017‐4385 HISAKI WATARI, TOKYO DENKI UNIVERSITY, Sitama, Japan, Sueji Hirawatari, Gunma University, Ota, Japan, Tomohiro Kishi, TOKYO DENKI UNIVERSITY, Saitama, Japan, Shinichi Nishida, Gunma University, Ota, Select State/Province, Japan, Mayumi Suzuki, Toyama Prefectural University, Imizu‐city, Japan, Toshio Haga, Osaka Institute of Technology, Osaka, Japan In order to clarify the possibility of practical use of high tensile magnesium alloys manufactured by a rapid solidification process, hot forging behaviors of high aluminum contents magnesium alloy sheets that were fabricated by a horizontal twin roll casting process was investigat‐ ed. Although the range of aluminum contents of magnesium alloys which are commercially available is 3~9 %, high tensile strength magne‐ sium alloys containing 10 to 12% aluminum, such as AZ101, AZ111, and AZ121 have been manufactured for the hot forging test by the use of press machine with a novel servo die cushion system. Firstly, relationship between casting parameters and microstructure, mechanical properties of cast sheet in twin roll casting were investigated. Secondary, manufacturing parameters, such as types of lubricant, forging temperature and magnitudes of back pressure during hot forging were investigated. It has been found that twin roll casting of thick magne‐ sium alloy sheet was possible at roll speeds of 2.5~10 m/min. Obtained thickness of cast sheets were 5~10 miri meters. It has been clarified that the diameter of the microstructure of the high tensile strength magnesium alloy that contains relatively high aluminum content, was about 30 micro meters due to microscopic observation. Finally, it has also been confirmed that hot forging of high tensile magnesium alloys that contain relatively high aluminum content is possible without cracks at 300‐350 centigrade. By applying appropriate back pressure dur‐ ing hot forging was effective for successfully forging of cast magnesium alloys.

Cold Forming Characteristics of Wrought Magnesium Alloys Oral Presentation. ICMP2017‐4386 HISAKI WATARI, TOKYO DENKI UNIVERSITY, Sitama, Japan, Hayatto Aso, Kazuhito Tsuruoka, TOKYO DENKI UNIVERSITY, Saitama, Select State/Province, Japan The growing demand for light weight products for automotive industries has been increased due to global trend of environmental preser‐ vation. In recent several years, although production of magnesium has risen dramatically, production of magnesium alloy sheet remains still at a very low level in practical use. The aim of the study is to establish a guideline for roll design in the roll forming for wrought magnesium alloy sheet. A three dimensional elasto‐plastic analysis by finite element method has been conducted to examine differences of cross sec‐ tion shapes and bending strains of wrought magnesium alloy sheet and cold rolled steel sheet during cold roll forming. Exact angles in bent sections were measured in terms of roll pass schedules. Edge wave as well as bend in longitudinal direction of formed products also measured to examine effects of roll passes schedules on formed shape of V sections. A three dimensional finite element sim‐ ulation has also been performed to discuss exact cold roll forming phenomenon for wrought magnesium alloy sheets considering spring back. New guidelines of cold roll forming for magnesium alloy sheets have been proposed. It has been found that perdition of spring back could be possible if an appropriate finite element model is used. 117

Improvement of Forming Accuracy Using Pre‐Formed Shape by Friction Stir Incremental Forming Technical Publication. ICMP2017‐4388 Masaaki Otsu, Hiroshi Goto, Masato Okada, University of Fukui, Fukui, Fukui, Japan, Hidenori Yoshimura, Kagawa Universi‐ ty, Kagawa, Japan, Ryo Matsumoto, Osaka University, Osaka, Japan, Takayuki Muranaka, Fukui National College of Tech‐ nology, Fukui, Japan In friction stir incremental forming, formed shape becomes a little smaller than objective one due to springback. To improve forming accu‐ racy, tool path was modified by two step porcess. The first modification process was applying experimentally obtained calibration equation about flange drop with a parameter of a distance from a blank holder to the starting position of forming. The second modification process was forming along the path outer of the true shape. The distance between the formed shape with the first modification process and the ideal shape was measured. After that, the second modified path was located the distance outer from the true shape. A5052 aluminum alloy sheets was used for specimens. The size of the specimen sheets was 150 mm x 150 mm and the thickness was 0.5 mm. A hemispherical tool with a diameter of 6 mm was used for forming. The tool was rotated at 10000 rpm and moved at 3000 mm/min and sheets were formed into a frustum of conical shape which height of 20 mm and wall angle of 25 °. Distance from the edge of blank holder to start position of forming was changed and the degree of flange drop was measured. From the experimental results, modification equation for the initial indentation for the first tool path was created as a first step modification process. After forming with the first modification, errors of initial diameter of a frustum of cone, forming height and bottom diameter were measured. Errors of wall angle and overall shape were measured due to springback. The second step modification of tool path was carried out. After conducting the first and second modification, errors of initial diameter, forming height, bottom diameter and wall angle were improved from 7.62 mm to 0.23 mm, 4.76 mm to 0.16 mm, 2.27 mm to 0.27 mm and 1.09 ° to 0.12 °, respectively.

The Development of the Flap Gate Type Land Lock Technical Publication. ICMP2017‐4389 Kyoichi Nakayasu, Yuichiro Kimura, Toshiaki Morii, Yoshito Yamakawa, Hitachi Zosen Corporation, Osaka‐shi, Osaka, Japan Large scale flood disasters caused by tsunamis, storm surges, or heavy rains are frequently happening in the world in recent years. We de‐ veloped flap gate‐type rising seawall ?neoRiSe?. It rises up automatically due to buoyancy by inundation. It protects a target area against the inundation without power machineries and human operation, and it also means easy maintenance and low risk of product failure. We constructed 78 neoRiSe in Japan. And there are various types of neoRiSe as land lock type, wall‐attached type, duct‐attached type, and super long span type. These technologies will contribute to flood disaster prevention and mitigation.

Mechanical Properties Measurement of Micro Boron Carbide Samples Simulating the Fuel Debris Technical Publication. ICMP2017‐4390 Moriyasu Kanari, Naoki Iitsuka, Keita Tominaga, National Institute of Technology, Ibaraki College, Hitachinaka‐shi, Ibaraki‐ken, Ibaraki‐ken, Japan Although fuel debris containing hard boron carbide (B4C) control‐rods should be securely removed and kept away from three reactors at Fukushima Daiichi nuclear power station, owing to high‐dose radiation we have not yet approached these reactors and have no information of the debris? properties required to develop cutting tools. In the present study, we aim to establish a nanoindentation application meas‐ uring the mechanical properties of fuel debris by using simulating B4C particles which have sample size in a range of sub‐millimeters. We examined how surface polishing process and sample size affect on mechanical properties measurement of the B4C particles embedded in epoxy resin. While 1mm B4C particles polished with #240 abrasive paper had elastic modulus and hardness which are practically close to those from a literature at errors of 1.6% and 9.1%, those values of 100?m particles polished with #1500 paper were significantly lower even in the modulus at a factor of 46%. We conclude that the lowered mechanical properties in the 100?m particles were caused by the inclined sample surface made by the insufficient surface polishing process.

Analysis and Measurement of Dynamic Properties of an O‐Ring Supporting a High Speed Bearing Technical Publication. ICMP2017‐4391 Tadayoshi Shoyama, The University of Tokyo, Bunkyo, Tokyo, Japan, Koji Fujimoto,, The University of Tokyo, Bunkyo‐ku, Tokyo, Japan High speed turbo machineries experience severe vibrations such as resonance or self‐excited whirl of bearings. Utilizing O‐rings as support‐ 118 ers of bearing is promising way to suppress these oscillations. But the prediction of dynamic properties of the O‐rings is hard because of its non‐linearity. In this paper, we measured the shear viscoelasticity of O‐ring material for high frequency up to 1 kHz. The properties for each frequency were modeled and the FEM dynamic analysis was conducted. The calculated dynamic properties of O‐rings agreed with experi‐ mental results of an actual O‐ring.

Nondestructive Testing Method for Concrete Structures by Using Water Jet Technical Publication. ICMP2017‐4392 Kazuya Mori, Saeko Tokuomi, Kumamoto University, Kumamoto, Japan A new concrete‐structure testing method has been developed in which the traditional hammer has been replaced with a water jet. In this new method, objects are pounded by water droplets at regular intervals. Firstly, hidden voids in the concrete can be detected as they pro‐ duce a distinctive sound which is picked up by a superdirective gun microphone. Our results found that it is possible to detect voids of 200mm at a depth of 25mm in concrete. Secondly, defective surface tiles can be detected due to their distinctive sound. To test for defec‐ tive tiles, 600 mm by 900 mm tiles were used; one tile had a defect behind while several others firmly attached. Our results found that the defective tile was successfully detected when at a distance of four meters from the water gun.

Experimental Characterization of Thermal Shock Fracture in Ceramics Under Various Stress Conditions Technical Publication. ICMP2017‐4393 Shuichi WAKAYAMA, Daiki CHIBA, Fumito MATSUOKA, Tokyo Metropolitan University, Hachioji‐shi, Tokyo, Japan, Katsumi YOSHIDA, Tokyo Institute of Technology, Meguro‐ku, Tokyo, Japan, Takenobu SAKAI, Saitama University, Saitama‐shi, Saitama, Japan The thermal shock fracture behavior of alumina ceramics was characterized by Disc‐on‐Rod test, which was developed by the authors. Thin disc specimen was uniformly heated to high temperature and the center region of specimen was quenched by means of contacting with the cool metal rod. Then, the center of disc specimen was subjected to the biaxial tensile stress. The temperature distribution of specimen was measured by a high speed infrared camera and used for the determination of transient thermal stress field by the finite element analysis. Furthermore, microfracture process was characterized by AE measurement. In order to obtain various thermal stress ratio, elliptical speci‐ mens, as well as circular specimens, were prepared. Consequently, experimental technique for evaluating thermal shock behavior under various stress ratio has been developed.

Some Suggestions For Improvement Of The Topology Optimization For Additive Manufacturing of Fiber Reinforced Composites Oral Presentation. ICMP2017‐4394 Kohji Suzuki, Chiba Institute of Technology, Department of Mechanical Engineering, Chiba, Japan Recently, additive manufacturing, or 3D printing, of fiber reinforced composite materials has been attracting more and more attentions in various industrial fields such as aerospace, automotive, civil and so on. In addition, more and more people have been recognizing that the topology optimization design methodologies will be able to be used as powerful tools for finding more rational and cost‐ and weight‐saving structural components with additive manufacturing, such as fused deposition modeling (FDM) 3D printers. By the way, fiber reinforced composites such as carbon fiber reinforced plastics (CFRP) are inherently different from the conventional structural materials and pro‐ cessing like steel and aluminum alloy for turning and milling machinings (that is, conventional subtractive manufacturing) in that they have possibly orthotropic and gradient material properties when processed with additive manufacturing tools. Therefore, it will be quite benefi‐ cial that ones think of some improvement of the mathematical formulations and computational algorism for topology optimization in order to suit it to the case of additive manufacturing of fiber reinforced composites. In this paper, the author tried to suggest three ideas of his own for the above‐mentioned technical topic. The first one is about allowing intermediate density in the final optimization results since in additive manufacturing of fiber reinforced composites, crude density portions which are not crucial in terms of overall structural integrity may be realistic. The second one is about relaxation of design variable domain definition in order to enhance density in the portion where more reinforcement is necessary. The last one is about considering orthotropic materials properties since as already mentioned fiber rein‐ forced composites essentially have drastic difference of elastic and strength properties between the longitudinal (that is fiber reinforcing) and transverse directions. From a few numerical examples, the present suggestions of the author’s own will be shown to be quite rational and effective to find better topology optimized structural components molded with any additive manufacturing techniques.

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Study on Evaluation Method and Mechanism of Adhesion Behavior at Mechanically Joined Parts in Cast Aluminum Alloys Technical Publication. ICMP2017‐4396 Yukio Miyashita, Nagaoka University of Technology, Nagaoka, Japan, Ruben Septianus, Graduate school, Nagaoka University of Technology, Nagaoka, Japan, Yuichi Otsuka, Nagaoka University of technology, Nagaoka, Japan, Tetsuri Yamada, Kiyoshi Shirato, Isuzu Motors Ltd., Fujisawa, Japan Un‐aboidable and un‐preferable adhesion occurres at the mechanically joijned part in an automotive engine component produced by cast aluminum alloy. In the present study, evaluation method of the adhesive behavior was studied at first. Moreover, process and mechanism of adhesive bahavor was investigated with the method proposed. The adhesion has successfully occurred in cast aluminum alloys with the method proposed based on fretting fatigue testing method. Two adhesion behaviors occurred, the weak adhesion and the strong adhe‐ sion. The contact pressure and relative slip amplitude have a significant effect to the adhesion behavior. The initial contact pressure will break the oxide layer, lead metal to metal contact, and resulting the initial plastic deformation between two contact surfaces. The inter‐ locking phenomena between the asperities will be strongly related to this action. However, if the large relative slip amplitude occurred between two surfaces, the junction of the interlocked asperities will be broken and the adhesion will not occur. The effect of oxide layer could be neglected in the current adhesion tests. The different material combination have a different adhesion behavior and mechanism. In case of hard‐soft materials combination, the strong adhesion occurred in the early stages of process. When the contact pressure is ap‐ plied, the high asperities of the harder surface material indent the softer material surface, resulting plastic deformation in a local area. In this stage, the oxide layer already broken, leads metal to metal contact. By cyclic loading, the indentation of the harder material become intense with the friction, resulting a plastically deformed structure on the softer material surface. In this stage, the weak adhesion oc‐ curred. The relative slip amplitude between two contact surface decrease due to interlocking phenomena between the surface rough‐ ness. The friction become more intense and the solid state welding phenomena occurred in some local area. In case of soft‐soft materials contact, the strong adhesion in this case needed a longer time to occurs. When the contact pressure is applied, the asperities of both sur‐ face material will indent each others, resulting plastic deformation on the both surfaces. The friction become intense by applying cyclic loading, resulting a plastically deformed structure on the both material surface. The weak adhesion in this case will need a longer time to occur. The relative slip amplitude between two contact surfaces decrease due to interlocking phenomena between the surface roughness, then the solid state welding phenomena occurred.

Lap Joining of Dissimilar Grade Aluminum Alloys by Friction Stir Forming Process: A Study on the Effect of Tool Plunge Depth on Shear Strength of the Joints Technical Publication. ICMP2017‐4400 TINU P SAJU, Indian Institute of Technology, Guwahati, Assam, Kamrup, India, R. Ganesh Narayanan, Department of Me‐ chanical Engineering, Guwahati, Assam, India This paper presents a novel attempt to use latest Friction stir form technique for joining dissimilar grade aluminum alloys. The process has the advantage of obtaining best in class joint strength by simultaneous metallurgical bonding and mechanical interlocking. However, the details related to this process are very scarce in literature. The process is still utilized only for joining dissimilar automotive sheet metals like aluminum alloys to automotive steel. This paper extends the potential of the process for joining dissimilar grade aluminum alloy sheets namely AA 5052‐H32 to AA 6061‐T6. A comprehensive study on the effect of tool plunge depth on the joint formation is conducted with a goal towards attaining optimized shear strength. A lap shear strength up to 7 kN is reported at medium tool plunge depth. The evolution of the joint with detailed macrostructure analysis and failure mode analysis are also presented.

Support Structure Distribution and Deformation of Ni‐Base Alloy Fabricated by Selective Laser Melting Oral Presentation. ICMP2017‐4401 Toshi‐Taka Ikeshoji, Kindai University, Higashi‐Hiroshima, Hiroshima, Japan, Masahiro Araki, TRAFAM, Higashi‐Hiroshima, Hiroshima, Japan, Makiko Yonehara, Kindai University, K.U.RING, Higashi‐Hiroshima, Hiroshima, Japan, Kazuya Nakamura, TRAFAM, Higashi‐Hiroshima, Hiroshima, Japan, Ryo Akamatsu, Graduate School of Kindai University, Higashi‐Hiroshima, Hi‐ roshima, Japan, Hideki Kyogoku, Kindai Univ, Higashihiroshima 739 2116, Hiroshima, Japan When 3D‐model is built by the selective laser melting process, the support structure is necessary to insert under the model, which is ex‐ pected to restrict the thermal deformation during the building process. To investigate the sufficient density of support structure, it is sup‐ posed to build the cantilever of Inconel 718 Ni‐based alloy with the comb‐like support structure, and its thermal deformation after the 120 cooling down process and after the removing of support structure is estimated using the non‐linear finite element analysis. In despite of number of teeth of comb‐like support structure, the vertical and horizontal shrinkage did not reveal the significant difference. Therefore, the number of teeth could be determined by other factors, e.g. heat dissipation to control the microstructure, the widest separation capa‐ ble to form under skin, etc.

Loading History Dependence of MnS Grain Deformation in Free‐Cutting Steel SUM23 Oral Presentation. ICMP2017‐4404 Masaaki Itabashi, Tokyo University of Science, Suwa, Chino, Nagano, Japan Structural steel with adding elements S, P and Pb is called as free‐cutting steel. Cutting resistance is reduced and machinability is improved. In this study, deformation of MnS grains in such a steel, which is induced by a certain loading pattern, is focused. Another free‐cutting steel SUM24L has such a property so that MnS grain is penetrated by matrix steel after a certain loading. The previous study for SUM 24L steel pointed that the number of the penetrations may be used to distinguish the loading pattern. The same property is expected to MnS grains in SUM23 steel. Six loading patterns are adopted as experimental conditions as follows: as‐received (abbreviated as AR), pre‐fatigued of the maximum stress 100 MPa (PF), quasi‐static tension (S), dynamic tension (D), pre‐fatigue+quasi‐static tension (PF+S) and pre‐fatigue+dynamic (PF+D). The longitudinal section of each specimen is observed with an optical microscope. The penetrations of matrix to MnS grain are counted with information of major axis. There are two penetration types, that is, full and partial. Some grains have both types. First, total number of MnS grains with/without the penetrations. Secondly, grains of greater than mean major axis (24 micrometers) are picked up. Thirdly, the numbers of grains are normalized by the total number of grains in unit area. In the three steps, PF+S condition shows the highest frequency of characteristic deformation and PF does the lowest. Comparing with the observation for SUM24L steel, the loading history dependence of such penetrations is not the same. Especially, for PF+S loading pattern, the number of penetrated grains is the lowest in SUM24L, while the highest in SUM23. The cause of the discrepancy has not been clear yet. Anyway, the density of MnS grains in free‐cutting steel is not so uniform. The present authors expect that the increase of the observed area leads more accurate tendencies of this series of trial experiments.

Microcrack Observations of SiC Fiber/SiC Composite Under Tensile Loading Using Digital Image Correlation Technical Publication. ICMP2017‐4405 Masashi SATO, Tokyo University of Agriculture and Technology, Koganei‐shi, Tokyo, Japan, Tatsuya KIKUTA, Tokyo University of Science, Noda‐shi, Chiba, Japan, Takuya AOKI, Japan Aerospace Exploration Agency, Mitaka‐shi, Tokyo, Japan, Toshio OGASAWARA, Tokyo University of Agriculture and Technology, Koganei‐shi, Tokyo, Japan SiC fiber‐reinforced SiC matrix composites (SiC/SiC) are expected to be applied to the hot section of a next‐generation aircraft engine be‐ cause of lightweight and excellent heat‐resistance. SiC/SiC composites exhibit considerable non‐linear stress‐strain behavior, which is caused by the crack propagation of SiC matrix. Oxidation of interphase layer (C or BN) between fiber and matrix occurs at elevated temper‐ ature in air, resulting in strength degradation. Air ingress through the matrix cracks of SiC/SiC composites affects the oxdation of inter‐ phase, therefore it is important to understand the matrix crack propagation behavior. However, it is significantly difficult to observe the matrix crack propagation directly at elevated temperatures. The object of this study is to demonstrate the evaluation of microcrack pro‐ gression of an orthogonal 3‐D fabric SiC/SiC composite under tensile loading at elevated temperature by using digital image correlation (DIC). The SiC fiber used in this study is Tyranno‐ZMI provided from Ube Industries. SiC matrix was made using chemical vapor infiltration (CVI) and polymer impregnation and pyrolysis method. CVI‐C (200‐300 nm) was used for the interphase layer. SiC fiber was woven into an orthogonal 3D fabric. The thickness of each layer was approximately 0.2 mm. Speckle pattern is required for DIC method. The representa‐ tive size of each dot should be less than 0.02 mm to observe the microcracks in transverse layer. In this study, the microstructure of SiC/SiC composites was utilized as speckle pattern. The SiC/SiC composite includes micro‐voids, fibers, and interphase, therefore the speckle pat‐ tern can be easily obtained as a scattering intensity distribution. The pattern was used for DIC method. Tensile tests were carried out on a screw‐driven mechanical test rig (Instron 8862, UK) at room temperature in air, and at 1200 °C in vacuum. The images of the specimen surface under tensile loading were taken using a CMOS image sensor camera (WRAYMER WRAYCAM‐NT1000, Japan) with a prime lens (Nikon AI AF Micro‐Nikkor 200mm f/4D IF‐ED, Japan) and a bellows (Nikon PB‐6, Japan) through a small window of the vacuum chamber. The image size was about 1.9 mm x 2.5 mm. As a result, the matrix cracks in transverse layers were observed as higher strain regime as compared with the average strain. The matrix crack propagation behaviors estimated by DIC showed a good agreement with those ob‐ tained by a conventional replica film method. It has been demonstrated that DIC method is useful to evaluate the microcrack propagation behavior of SiC/SiC composites. 121

Output Voltage Characteristic in Large Strain of Metal Matrix Piezoelectric Composite Technical Publication. ICMP2017‐4406 Tetsuro Yanaseko, Kogakuin University, Hachioji, Tokyo, Tokyo, Japan, Yuki Hirayama, Chiba University, Chiba‐shi, Chiba, Japan, Hiroshi Sato, National Institute of Advanced Industrial Science and Technology, Tsukuba, ibaraki, Japan, Hiroshi Asanuma, Chiba University, Chiba, Chiba, Japan Large deformation in structures occurs by disasters such as earthquakes, the lifetime of the structures is degraded by the deformation. Structural Health Monitoring (SHM) technique, structural soundness monitoring by measuring the deformation using sensors attached to the structures, has attracted attention in recent years. In SHM technique, output behavior at large deformation region and robustness of the sensor are very important. In this research, output voltage characteristic in large strain region of metal‐core piezoelectric fi‐ ber/aluminum composite was investigated by tensile vibration test. As a result, output voltage generated from the composite was de‐ creased with increasing applied strain. The output voltage decreasing was occurred by reduction of stress transfer between matrix and piezoelectric layer of the fiber because of the fracture of the piezoelectric layer by applying large strain. However, the output voltage was verified at about 20% strain, the composite demonstrated very high robustness compared to conventional piezoelectric ceramics, and it shows that the composite was expected to apply to the SHM technique

Fabrication of Irradiated Grid Onto the Photochromic Paint for Deformation Measurement Technical Publication. ICMP2017‐4409 Satoshi Kishimoto, National Institute for Materials Science, Tsukuba, Ibaraki, Japan It is very important to measure the deformation of the structural parts of the large constructions for the health monitoring or damage evaluation. There are a lot of methods to measure the deformation of the structural materials such as Moiré method, digital correlation method and grid method, and etc... However, in these methods, a grid or random patter pattern must be fabricated on the specimen’s surface before testing. So, it is very difficult to apply these methods to the structural parts. In this study, a fabrication method of the grid pattern on the structural parts was developed. The metal or polymer specimen was covered by the photochromic paint. And the laser beam was exposed on to the photochromic. The grid was placed onto the photochromic paint on the specimen’s surface and the ultra‐violet light was exposed to the grid. A grid was fabricated by the changing the color.

Fractgraphic Analysis on Competition between Crack Propagation and Self‐Healing in Self‐Healing Ceramics at High Temperature Oral Presentation. ICMP2017‐4411 Wataro Nakao, Lee Jang‐Won, Yokohama National University, Yokohama, Kanagawa, Japan Most attractive feature of fiber‐reinforced self‐healing ceramics is to in‐situ arrest crack propagation by self‐healing in service. If the com‐ petition behavior can be evaluated detailly, applications and usefulness of self‐healing ceramics might be expanded. At the first step to establish the new fracture criteria including self‐healing ability, the present study aims to investigate the fractographic analysis on the competition between crack propagation and self‐healing. For the purpose, a typical fiber‐reinforced self‐healing ceramics was loaded by constant tensile stress at high temperature in air. The deformation and fracture behavior in this situation were observed by optical micro‐ scope. Furthermore, the crack propagation pass in the specimen suffered by the stress for appropriate times was systematically analyzed by slicing the specimen. From the obtained results, the effect of self‐healing on crack propagation under constant stress was discussed.

Effects of Adhesives on Evaluation Method of Interfacial Strength of Plasma‐Sprayed HAp Coating Oral Presentation. ICMP2017‐4413 Yuichi Otsuka, Yoshihisa Hiraku, Yuki Hakozaki, Yukio Miyashita, Yoshiharu Mutoh, Nagaoka University of technology, Na‐ gaoka, Japan The purpose of this study is to evaluate interfacial strength of plasma‐sprayed HAp coating by using more general adhesives. Plas‐ ma‐sprayed HAp coating has been applied to bond bone with the surfaces of artificial hip joint. However, HAp coating is subjected to crack or delamination by mechanical load. It is therefore important to evaluate interfacial strength of bonding HAp with implants. Conventional standard codes for measurement of interfacial strength of calcium phosphate coating determine the use of a specific adhesive without 122 rational reason. Our group previously proposed pre‐immersion treatment process in preparation of interfacial testing specimens in order to obtain valid value of interfacial strength, The adhesive used in the test is for medical purpose and not general one. In order to widen ap‐ plicability of proposed method, a selection policy of adhesive is indispensable. Metal Lock Y610 (ML adhesive) was selected as one of general adhesives. Interfacial strength tests by using ML adhesive were conducted. The results of interfacial strength test was compatible with the one reported by previous study, which suggest that the selection of general type of adhesive was successful. analyses were also conducted to confirm a suppressed infiltration of ML adhesives.

Investigation of Self‐healing Ability of Al4SiC4 as Healing Agent Oral Presentation. ICMP2017‐4414 Natsuko Kimura, Wataru Nakao, Yokohama National University, Yokohama Kanagawa, Japan Al4SiC4 was found to be a useful self‐healing agent to be available at lower temperatures than SiC. Self‐healing ceramics are expected as a next‐generation structural material because self‐healing ceramics can overcome excessive brittleness there by having higher mechanical reliability than ordinary ceramics. Most useful self‐healing ceramics has excellent self‐healing ability induced by high temperature oxidation of self‐healing agent. In order to design self‐healing ceramics that can be applied to a extensive using environments and applications, it is important to have more self‐healing agents. In this study, the required properties of Al4SiC4 for self‐healing agent were investigated by means of analysis of the elementary processes of high‐temperature oxidation and assessment of the oxidation rate under constant heating. The usefulness of Al4SiC4 for self‐healing agent was estimated by comparing the obtained results with the references of SiC. As a result, Al4SiC4 exhibited enough high oxidation rate to occur self‐healing at 300 oC lower than that of SiC.

Constitutive Relation of Adhesive Layer Under Combined Loading Conditions Technical Publication. ICMP2017‐4418 Norihide Abe, Yuki Yamagata, Yu Sekiguchi, Chiaki Sato, Tokyo Institute of Technology, Yokohama, Japan Adhesive bonding can be applied to the joint for various types of materials. Additionally, absorbing vibration, preventing electrolytic corro‐ sion and sealing gaps are expected by using the adhesive bonding. Therefore, it can be one of the leading joining methods for the structural parts of vehicles. Adhesive properties at high loading rates have been widely studied using various methods because it is important for the safety of vehicles. Under actual use conditions of automobiles, however, not only the loading rates but also the loading types, i.e., tensile and/or shear, become important to evaluate the joint strength. In this research, strength of adhesively bonded cylindrical butt joint speci‐ mens were experimentally and numerically evaluated under high‐rate combined loading conditions. In the experiment, the stress and strain in the adhesive layer were measured using a servo‐controlled hydraulic testing machine. In the analysis, Drucker‐Prager Model was utilized as a yield function of the material and the deformation was calculated by an elasto‐plastic constitutive relation defined with the yield func‐ tion and a damage parameter. Analytical results showed good agreement with experimental results.

Development of Cu/Untwisted CNT Composite With High Ampacity and Conductivity Technical Publication. ICMP2017‐4419 Hiroyuki Kawada, Waseda University, Tokyo, Japan, Takahiro sakai, Department of Applied Mechanics Graduate School of Waseda Univeristy, Shinjuku, Tokyo, Japan, Taesung Kim, Waseda University, Shinjyuku‐Ku, OO, Japan, Hidefumi Nikawa, Honda R&D Co., Ltd., Saitama, Wako, Japan, Atsushi Hosoi, Waseda University, Tokyo, Japan It is well‐known that the electrical circuit metal wire have reached to their upper limit of the current capacities (ampacities) in the conduc‐ tors. Because of the decreased lifetime and performance, developments of new conductors with higher ampacities are of great concern. However, the high ampacity and the high conductivity are mutually exclusive properties, so the material development with both of high ampacity and high conductivity is almost impossible using a single current electrical material. Carbon nanotubes (CNTs) have been consid‐ ered a nanomaterial with high electrical conductivity and thermal, low bulk density, which are estimated to be 1000 times higher current capacity than Cu, and are expected as next generation for conductor and wiring material. The CNT spun yarn (a continuous form of CNT assembly) by drawing and twisting from highly aligned CNT arrays. The CNTs in these yarns are held together by strong van der Waals forc‐ es. However, the macroscopic CNT structure has low conductivity. Therefore, in order to overcome this problem, new conductor with high current capacity and high conductivity can be fabricated by employing CNT/metal composite. In this study, untwisted CNT yarns were fabricated by drawing process of CNTs through a die. Untwisted CNT yarn has better electric characteristics than existing twisted CNT yarn. Cu‐CNT yarn was prepared by method with aqueous copper sulfate bath. Cu‐CNT composite yarn produced by electrodeposi‐ 123 tion have been processed in a number of ways. The ability to successfully embed CNTs in a metal matrix has been previously shown to be a prerequisite for enhanced properties, such as ampacity. As the results, it was confirmed that despite the hydrophobic nature of CNT mate‐ rial, aqueous copper sulfate could wet the fiber core enabling deposition in the fiber interior, by sufficiently immersing in a solution before depositing the copper. Conductivity and current capacity of the sample were measured to investigate the deposition patterns of copper in the gap between the CNTs. The Cu‐CNT composite fiber in which copper was deposited only the surface of CNT yarn (Cu‐CNT surface composite yarn) were fabricated for comparison. As the results, Cu‐CNT uniform composite yarn (copper was deposited inside the gaps between CNTs) exhibited higher ampacity than Cu‐CNT surface composite yarn. This can be attributed to CNTs covering the surface of Cu suppressed thermal vibration due to electro migration.

Fabrication of the Long Length and Small Diameter Hole Array by a 3D Printer Technical Publication. ICMP2017‐4421 Satoshi Kishimoto, National Institute for Materials Science, Tsukuba, Ibaraki, Japan A long length and small diameter hole array was fabricated by Additive Manufacturing using 3D Laser Metal Printer.

Mechanical Properties and Oxidation Resistance of Si‐Alloy Melt‐Infiltrated Tyranno ZMI Fiber Composites Oral Presentation. ICMP2017‐4423 Takuya AOKI, Japan Aerospace Exploration Agency, Mitaka‐shi, Tokyo, Japan, Toru Tsunoura, Tokyo Institute of Technology, Tokyo, Tokyo, Japan, Katsumi YOSHIDA, Toyohiko Yano, Tokyo Institute of Technology, Meguro‐ku, Tokyo, Japan, Toshio OGASAWARA, Tokyo University of Agriculture and Technology, Koganei‐shi, Tokyo, Japan Tyranno ZMI fiber/silicide‐silicon matrix composites were fabricated via melt infiltration (MI) of binary silicon alloys. Binary silicon alloys were used as an infiltrant to conduct MI processing below 1400°C and inhibit the strength degradation of the amorphous SiC fibers. The alloy matrices formed were dense and comprised primarily of silicide‐silicon eutectic structures. For example, in the case of Si‐16at%Ti alloy MI, the matrix of the composite comprised TiSi2 and Si. The TiSi2‐Si matrix composite melt‐infiltrated at 1375°C showed a pseudo‐plastic tensile stress‐strain behavior followed by final fracture at ~290 MPa and ~0.9% strain. However, when the MI temperature of the Si‐Ti alloy was increased to 1450°C, substantial reduction in the stiffness and ultimate strength of the composite occurred under tensile loading. Mi‐ crostructural observations revealed that these degradations were attributed to the damages that occurred on the reinforcing fibers and pyrolytic carbon interfaces during the Si‐16at%Ti alloy MI process. The present experimental results clearly demonstrated the effective‐ ness of the low‐temperature MI process using binary silicon alloys in strengthening Tyranno ZMI fiber composites and reducing the pro‐ cessing cost. Oxidation behavior of Tyranno ZMI fiber/silicide‐silicon matrix composites was evaluated in a wet air environment at tem‐ peratures between 800°C and 1200°C for 100 hours. The TiSi2‐Si matrix composite showed excellent oxidation resistance similar to the pure Si matrix. However, the HfSi2‐Si matrix formed by Si‐8.5at%Hf alloy MI showed thick oxidation layer, indicating poor oxidation re‐ sistance. In this study, in order to understand the oxidation mechanisms of the silicide‐silicon matrices, the oxidation test results were dis‐ cussed on the basis of the thermodynamic considerations.

Effect of Strain Rate Dependence of Cell Wall Material on Dynamic Compressive Behavior of Aluminum Foams Technical Publication. ICMP2017‐4424 Ken‐ichi Tanigaki, Keitaro Horikawa, Hidetoshi Kobayashi, Osaka University, Toyonaka, Osaka, Japan, Kinya Ogawa, Insti‐ tute of Space Dynamics, Kyoto, Kyoto, Japan The cell wall material of aluminum closed‐cell foams is often regarded as pure aluminum, however, it contains calcium impurities. Cylindri‐ cal shaped specimens made of the cell wall material were prepared by casting and machining process. The strain rate dependence of the stress‐strain relationship of the cell wall material was obtained by the split Hopkinson pressure bar (SHPB) method and quasi‐static tests. The cell‐wall material showed higher yield stress and strain rate sensitivity than pure aluminum due to calcium impurities. From the experimental results, Johnson‐Cook and Cooper‐Symonds parameters of strain rate sensitivity were determined. Then a three‐dimensional finite element model of closed‐cell foams was made using random sequential addition and Voronoi tessellation method. It had cubic external dimensions of 10x10x10 mm and consisted of about 200 cells. The thicknesses of cell walls were adjusted to achieve the relative density of 10%. They were constructed using 2nd order shell and solid elements and placed between two rigid plates. The LS‐DYNA code was used for numerical calculations. First, we conducted finite element analysis (FEA) of quasi‐static compressive defor‐

124 mation. As a result, it was found that the solid element model shows compressive mechanical behavior corresponding with the previous quasi‐static experimental results. Then, FEA of faster deformation up to a strain rate of 103 using the solid element model were conducted. The strain‐rate dependence of the yield stress of the model was determined by the resultant forces acting on rigid walls. It was in good agreement with the previous experimental SHPB studies.

Propagation Behavior of Stress Waves in Two Connected Elastic Bodies With Mechanical Impedance Matching Technical Publication. ICMP2017‐4425 Yuya Seo, Osaka University, Toyonaka, Osaka, Japan, Kinya Ogawa, Institute of Space Dynamics, Kyoto, Kyoto, Japan, Hide‐ toshi Kobayashi, Keitaro Horikawa, Ken‐ichi Tanigaki, Osaka University, Toyonaka, Osaka, Japan When impulsive forces are applied to structures, stress waves usually propagate in the structure and the reflected and transmitted waves are often generated at joints. Since some stress waves are superimposed each other, stress concentration may occur at unexpected places. These stress concentration causes the damage and/or destruction of structure, thus reflected stress waves should be absorbed into an adequate dumping medium in some instances. When we consider a simple problem that stress wave propagates two connected cylindri‐ cal elastic bodies, according to one‐dimensional theory of elastic stress wave propagation, it is well known that the reflected wave doesn’t occur if the mechanical impedances of two elastic bodies is identical. Because dumping materials mostly have low density and low me‐ chanical properties, the relatively large difference in their cross sections is requested to match their mechanical impedances. This large difference in cross sections may induce three‐dimensional effect on the propagation manner of stress waves, so that one‐dimensional the‐ ory becomes insufficient to explain stress wave propagation. Therefore, it is very important to investigate the three‐dimensional effect induced by relatively larger geometrical difference in elastic bodies connected on the propagation behavior of stress waves. In this study, the behavior of elastic stress wave propagating two connected cylindrical elastic bodies with different cross‐sectional area, different Young’s modulus and identical mechanical impedances, was examined using dynamic finite element method (FEM). In particular, various type of connecting parts were adopted between two cylinders and it was focused on how these connecting parts have effects on the re‐ flected wave. It was found that the incident wave accompanied by a couple of pulses which has the same amplitude and opposite sign was observed and it was the reflected wave from connecting part involving dis continuity caused by the appearance and disappearance of the three‐dimensional stress distribution around there. It was also found that a connection manner to insert the smaller diameter cylinder into the other cylinder with a certain length is quite effective for the reduction of the reflected wave, because of the superposition of waves from two edges and control of local deformation. Furthermore, the most effective insert lengths in the connection were obtained using different bars with various diameter.

Arbitrary Order Simulation With a Simplified Multi‐Physical Model of IPMC Sensor Technical Publication. ICMP2017‐4426 Jun Takeda, Kentaro Takagi, Nagoya University, Nagoya, Aichi, Japan, Zicai Zhu, Xi’an Jiaotong University, Xian, Shaanxi, Ja‐ pan, Kinji Asaka, AIST, Ikeda, Osaka, Japan Ionic polymer‐metal composites (IPMCs) generate electrical potential under deformation. As sensor material, IPMCs are expected to be applied in a wide range of fields because of its attractive characteristics such as flexibility, lightweight and easiness to process. There have been several researches on modeling of IPMC sensors. Recently, Zhu et al. have proposed a IPMC sensor model which describes redistribution of water molecules, cations and distribution of electrical potential under deformation well. The model is characterized by focusing on the significance of water transport; however, the model is represented by a set of nonlinear partial differential equations (PDEs). In a previous paper, we proposed a method of simplification of the complicated model to a set of low order linear ordinary dif‐ ferential equations (ODEs). We linearized the PDE model and solved the approximated linear PDEs with the method of separation of varia‐ bles. We carried out simulations with both the PDE model and the obtained ODE model, and compared the results for validating the ob‐ tained ODE model. In simulation, we used the ODE model with minimal order approximate solution. Regarding the redistribution of water molecules and the generated voltage, the results of the ODE model showed good agreements with the results of the PDE model. In con‐ trast, we confirmed that the minimal order ODE model cannot simulate the redistribution of cations due to insufficiency of the order of the approximated solution. In this paper, we carry out simulations of several ODE models with higher order to validate the obtained ODE model of IPMC sensors. As we did in the previous paper, we use finite element analysis software, COMSOL Multiphysics, to simulate the original PDE model. To simulate the higher order ODE models, we use MATLAB. Regarding the redistribution of cations, the higher order model we use, the better agreement with the result of the PDE model we can show. In addition, we also confirm that the simulated sensor voltage of the higher order models shows better agreement with that of the PDE model. 125

Magnetic and Magnetostrictive Properties in Heat‐Treated Co‐Fe Wire for Design of Smart Material/Device Technical Publication. ICMP2017‐4427 Takahiro Yamazaki, Yokohama National University, Yokohama, Japan, Takahisa Yamamoto, Hirosaki University, Hirosaki, Japan, Yasubumi Furuya, Yokohama National University, Yokohama, Japan, Wataru Nakao, Yokohama National University, Yokohama Kanagawa, Japan A new Co rich Co‐Fe magnetostrictive alloy excellent in workability is superior in mechanical strength and magnetic sensitivity as compared with the conventional Fe‐based magnetostrictive materials such as Terfenol‐D and Galfenol. Inexpensive and high sensibility of magneto‐ strictive materials, which exhibit reversible strains with applied magnetic fields, are demanded for the applications of sensors and actua‐ tors. In this study, for several heat‐treated samples at morphotropic phase boundary (MPB), structure identification by XRD, evaluation of magnetic and magnetization characteristics by VSM measurement, and evaluation of output voltage characteristics by drop collision test were investigated. The magnetostriction of as‐drawn Co‐71at% Fe sample increased up to 130 ppm with the increases of crystallographic bcc (110) orientation strength by wire‐drawing. Also, the magnetostrictive susceptibility extremely was improved by 820 oC of heat‐treatment. The output properties from vibration power generation test reached up to 6V and 13mW with the impact loading onto the test specimen from the height of 30 cm. These results indicated that magnetic domain wall behavior during magnetization by fine grains as well as internal residual micro‐stress in the grains. The developed magnetostrictive Co rich CoFe type alloys showed good material worka‐ bility to make the thin plate and wire as well as very good energy‐harvesting effect under mechanical vibration, therefore, this new mag‐ netostrictive alloy will become applicable for energy harvesting devices and wireless sensing devices in structural health monitoring etc.

Recent Advances in Disaster Mitigation and Sustainable Engineering Oral Presentation. ICMP2017‐4430 Hiroshi Asanuma, Chiba University, Chiba, Chiba, Japan The author has been proposing to use novel technologies, materials and structures such as smart structures/materials and related tech‐ nologies for revolutionary prevention/mitigation of disasters. A typical example is the deployable breakwater which can be used for energy harvesting daily in the ocean in a compact size as well as a smart breakwater autonomously deployable by the force/energy and material of tsunami or high wave. The author et al. discussed new reliable approaches to cope with disasters, which intend to enable sustainability as well as disaster mitigation, and they named it as ?Disaster Mitigation and Sustainable Engineering.? The author is starting a research com‐ mittee on the novel engineering as a part of The Japan Society of Mechanical Engineers (JSME) Materials and Processing (M&P) division. Since the earthquake and tsunami disasters on March 11, 2011, the author has been having no chances to promote the new engineering concept because there has been no room for thinking of futuristic project due to suffering from enormous damages to be recovered as soon as possible. Even in highly advanced country like Japan, many people have been dead or injured by variety of natural disasters. In or‐ der to cope with this situation, new ideas and developments have to be proposed and done by not only professionals but also general citi‐ zens. Engineering Liberal Arts lead by Tsuge (former president of The Japan Federation of Engineering Societies) is the key to realize sophis‐ ticated disaster prevention/mitigation toward future. Disaster Mitigation and Sustainable Engineering needs Engineering Liberal Arts to be successful, and it will be a good example for it. In this paper, disaster mitigation especially based on smart structures/materials are de‐ scribed. To explain the proposed concept more comprehensively, two examples, that is, artificial forest and novel deployable structure based on honeycomb to be used against flooding etc. are proposed and demonstrated. The other challenges and products are also intro‐ duced. The researches listed below are mainly undergoing by the author and/or his collaborators. 1) Applications of Piezoelectric Polymers in Electrical Power Generation Using Ocean Waves (Su). 2) Dynamic Deployment of Smart Inflatable Tsunami Airbags (TABs) for Tsunami Disaster Mitigation (Shahinpoor). 3) A Novel Underwater Inflatable Structures for Smart Costal Disaster Mitigation (Adachi). 4) Disaster Deployable Devices (Nejhad et al.). 5) Structural Health Monitoring of Pipelines for Environment Pollution Mitigation (Felli et al.). 6) The Contribution of LARES to Global Climate Change Studies with Geodetic Satellites (Sindoni et al.). 7) Smart Disaster Mitigation in Italy (Felli et al). 8) Smart Disaster Mitigation in Thailand (Aimmanee et al.). The following are also undergoing. Asanuma, Kubo, Maruyama and Tanaka started to develop a multi‐layered flexible and deployable structural material system to diminish the force of tsunami and dissipate its en‐ ergy by separating water flow and letting them conflict with each other. Various outstanding challenges have been also done in industries and some are already commercialized. The following products are attractive, that is, neo RiSe land‐mounted movable flap‐gate type seawall (Hitachi Zosen), Project MOSES, Aqua Dam, and so on. In addition, Takenaka Corporation proposed innovative ?Breakwater and breakwater group.? Disaster Mitigation and Sustainable Engineering has to be brushed up to become a basis for the above introduced emerging field with more variety of disasters to be smartly overcome or rather utilized.

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Numerical Study Of Plasma State While Internal Deposition Of DLC Films Onto Metal Tube Oral Presentation. ICMP2017‐4431 Ryota Takamura, Hiroki Akasaka, Tokyo Institute of Technology, Tokyo, Japan, Naoto Ohtake, Tokyo Institute of Technology, Maguro‐ku, Tokyo, Japan Diamond‐like carbon (DLC) films are amorphous film that consists of sp3 and sp2 bonded carbon and hydrogen. DLC films possesses high hardness(~10 GPa) and low friction coefficients(~0.1), and has been applied as wear protecting film to various mechanical products such as cutting tools. DLC films has been widely applied to external surfaces, but application to internal surfaces are still few. This is due to the dif‐ ficulty of depositing DLC films uniformly onto internal surface, such as inner wall of tubes. Conventional low gas pressure chemical vapor deposition (CVD) processes, which utilizes plasma with low plasma density (ni < 10^10 cm^3) cannot be applied to inner wall of narrow tube such as diameter of 20 mm or less. This is due to the thickness of the ion sheath formed along inner wall of the tube wall exceeds the inner radius of the tube, causing steady sustainment of plasma within tube impossible. We have developed nano‐pulse plasma CVD pro‐ cess with high gas pressure of over 500 Pa for internal deposition of DLC films onto metal tubes. Using CH4 for source gas, successfully de‐ posited DLC films onto internal surface of metal tube with high aspect ratio, 4 mm in diameter and 300 mm in length. From observation, we could see that plasma was generated and sustained inside the tubes, but could not analyze the plasma state. To understand the state of plasma and utilize for optimizing experimental parameter, we have conducted numerical simulation of initial plasma generated inside the tube using simulation software COMSOL. Axial symmetric, one dimensional model was used for this simulation model to replicate the ex‐ perimental set up. Gas phase reactions considered were, electron collision reactions such as excitation, ionization, and recombination, of CH4 family and gas phase chemical reactions of hydrocarbons were considered. From the numerical simulation, nano second order tem‐ poral change of plasma state, such as sheath formation, electron avalanche and afterglow was observed. It was shown that the nano‐pulse plasma resembled glow discharge in electron/ion density distribution when pulse voltage was applied. Also, highest electron temperature was observed when applied pulse voltage became highest, and highest electron/ion density was observed shortly after, indicating after‐ glow.

Effects of Boundary Condition and Cell Structure on Dynamic Axial Crushing Honeycomb Technical Publication. ICMP2017‐4433 Tsutomu Umeda, Koji Mimura, Osaka Prefecture University, Sakai, Osaka, Japan The dynamic axially crushing behavior of metal honeycombs was studied with laying emphasis on the effects of boundary condition and cell structure on its characteristics as an energy absorber. Numerical honeycomb models of some metal foil materials were made by taking the plastic deformation of adhesive layer, the failure of adhesively‐bonded joint and the initial imperfection into consideration. The parameters of cell geometry were varied to examine the effects on the crushing behavior and the energy absorption capacity. Then, to investigate the effects of boundary condition on the crushing mode and the energy absorption capacity, some boundary conditions such as the fixed end condition, the contact condition at the upper and lower ends and the periodic boundary condition at the side surfaces were applied to the honeycomb model. Typical calculated results under different strain rates and geometric conditions were compared with the corresponding experimental results, and the effects of material properties on the mean buckling stress were also discussed. Particularly, the effects of the branch angle and the boundary condition on the crushing mode and the energy absorption capacity were discussed. The effects of the oblique loading were also examined to consider the actual crushing condition.

Fundamental Studies on Smart Wave/Flood Mitigation Structures Oral Presentation. ICMP2017‐4435 Hiroshi Asanuma, Chiba University, Chiba, Chiba, Japan This paper describes fundamental studies aiming at developments of smart disaster prevention/mitigation materials and structural systems based on Disaster Mitigation and Sustainable Engineering. In this study, the concept is introduced comprehensively and a couple of exam‐ ples are shown. As the first example, a novel deployable structure based on honeycomb to be used against flooding etc. is proposed and demonstrated to be autonomously deployable due to increase of water level. This autonomously height‐controlled river or anti‐flooding bank system can be regarded as a smart structure. Energy harvesting materials and systems are under consideration and development to make the two introduced systems smarter and fully realize the concept. As the second example, artificial forests are examined to have better capability of high wave or tsunami mitigation by changing various parameters such as configuration, density and material. Multifunc‐ tional design is also mentioned. In this study, the effect of type of material and its combination were mainly investigated as a function of number of rows. As for the general basic problems such as selection of materials, bonding of materials, long term durability, mainte‐ 127 nance, repeatability, the authors have been trying in various ways. For example, in order to realize the deployable structures, lightweight materials such as aluminum alloys and carbon fiber reinforced plastics are better to be used instead of steels. To do this, relatively thick aluminum oxide layer was found to increase bonding strength and fracture toughness as well as to enhance corrosion resistance and pre‐ vent galvanic corrosion.

Recent Developments in Smart Composites and Laminates Oral Presentation. ICMP2017‐4436 Hiroshi Asanuma, Chiba University, Chiba, Chiba, Japan Recent developments in smart composites and laminates originally proposed and fostered by the author are introduced in this paper. Two types of developments are main contents, which are (1) Type I that uses highly functional ceramics in a metallic matrix as protective envi‐ ronment, and (2) Type II that uses a couple of competitive structural materials without using those sophisticated functional materials to generate functions. The Type I could be realized by embedding fragile functional fibers such as optical fiber, FBG (Fiber Bragg Grating) sen‐ sor and metal‐core piezoelectric ceramic fiber in aluminum matrices by the Interphase Forming/Bonding Method. The Type II can be ex‐ plained that composite of competitive structural materials may have not only high mechanical properties, but also functional properties generated by their inconsistent secondary properties. As examples of this type, CFRP/Al active laminates, active FRMs and Ti fiber/Al mul‐ tifunctional composites were successfully developed. The active laminates have been especially modified to acquire higher performances and/or new functions, such as higher actuation capabilities, healing function, internal thermal management function using IPMCs, and so on.

Development of Thermoelectric Device Utilizing Selective Direct Bonding Technology Utilizing Anodic Oxide Film on Aluminum Surface Oral Presentation. ICMP2017‐4437 Hiroshi Sato, National Institute of Advanced Industrial Science and Technology, Tsukuba, ibaraki, Japan, Tetsuro Yanaseko, Kogakuin University, Hachioji, Tokyo, Tokyo, Japan, Hiroshi Asanuma, Chiba University, Chiba, Chiba, Japan, Hatune Ka‐ wanishi, Chiba Univ., Chiba, Chiba, Japan In this study, we propose a new accordion type thermoelectric power generation device using a metal direct bonding technology. It was found that when an anodic oxide film was formed on the aluminum surface and directly bonded to the nickel material, portions protected by the anodic oxide film were not bonded. By using this selective direct bonding technique, it is possible to easily produce a large number of accordion type ?‐structured thermoelec‐ tric devices at a time while suppressing an increase in internal resistance. Moreover, the accordion type has high heat dissipation efficiency and can flexibly deform into the shape of various heat sources.

Damage Detection Method for the Structural Parts of the Large Constructions by Moiré Method Technical Publication. ICMP2017‐4439 Satoshi Kishimoto, National Institute for Materials Science, Tsukuba, Ibaraki, Japan It is very important to measure the deformation of the structural parts in the large constructions for the health monitoring or damage de‐ tection or damage evaluation. There are a lot of methods to measure the deformation of the structural materials such as Moiré method, digital correlation method and grid method, and etc... In this study, a crack detection and deformation measurement method for the structural parts of the large constructions by Moiré method was developed.

Design of Dielectric Elastomer Based Actuators and Sensors Oral Presentation. ICMP2017‐4440 Kevin Kadooka, University of Washington, Seattle, WA, United States, Hiroya Imamura, Nabtesco, Tokyo, Japan, Sara Nei‐ denberg, Minoru Taya, University of Washington, Seattle, WA, United States Dielectric elastomers are a type of soft transducer material attractive for their use in actuator and sensor systems thanks to their light weight, flexibility, high energy density, and silent operation. This work discusses two applications of dielectric elastomer actuators and 128 sensors fabricated using additive fabrication by a robotic dispenser system. The two applications are (1) a variable stiffness dielectric elas‐ tomer actuator (VSDEA) designed to exhibit large deformation and high holding force, and (2) a high‐resolution dielectric elastomer sensor (DES) for detecting tactile forces. Despite the ability for conventional dielectric elastomer actuators (DEA) to exhibit large strains, they are generally unable to produce large stresses, due to the compliance of the material. This is a significant limitation for soft robotic systems based on DEA, since interacting with the environment often requires both large stress and strain of an end‐effector. To this end, bestowing DEA with a variable stiffness property allows the actuator to achieve large deformations and large holding forces when necessary. This work describes a VSDEA consisting of a multitude of unimorph DEA stacked together, where the adhesion between each DEA unit is medi‐ ated by electrostatic chucking force. Under normal conditions, the DEA units freely slide against one another, and low stiffness and large deformations are possible. When high stiffness is desired, chucking voltage is applied to the VSDEA, and opposite charges form on the in‐ terfaces of the DEA units, resulting in tight bonding and overall stiffening of the actuator. An actuator based on this principle is demon‐ strated supporting seventeen times its own weight. In addition to high performance actuators, soft robotic end effectors may require re‐ al‐time high‐resolution tactile data to interface with their environment. This work demonstrates a capacitive dielectric elastomer sensor with 1 mm resolution and 16 x 16 mm coverage. By incorporating dome features on the surface of the sensor, it is possible to distinguish the three‐dimensional components of the tactile force acting on the sensor. Besides robotic applications, the sensor is also demonstrated detecting the location and path of the radial artery for IV insertion in medical applications.

Mechanical Properties of Si‐Based Bond Coat Materials in Environmental Barrier Coating System: Effect of Heat Treatment Technical Publication. ICMP2017‐4441 Ryo Inoue, Yuki Fujii, Syou Usami, Kazuma Chikamoto, Tokyo University of Science, Tokyo, Japan, Yasuo KOGO, Tokyo Uni‐ versity of Science, Katsushika‐ku, Tokyo, Japan Bond coat (BC) layer in environmental barrier coating (EBC) system plays an important role to protect SiC fiber‐reinforced SiC matrix (SiC/SiC) composite from oxidation at high temperature and to improve adhesion between substrate and EBC layer. In the present study, Mullite/Si/SiC model was fabricated by air plasma spray (APS) process. Heat exposure test was carried out at 1300? for 100 hours. Micro‐ structural changes were examined using scanning electron microscope (SEM), energy dispersive X‐ray spectroscopy (EDS) and electron back scatter diffraction (EBSD) analysis, Measurement of fracture toughness by indentation fracture (IF) technique before and after heat expo‐ sure was also done. As‐deposited Si BC layer contains large amounts of pore between each of splats. EBSD analysis also identifies that amorphous region is formed at the boundary between splats. After heat exposure, amorphous Si is fully crystalized. As increasing heat ex‐ posure time, porosity in Si‐BC layer decreases and reaction‐formed product nucleates at inter‐splats boundaries. EDS analysis also identifies reaction formed product is composed of Si and O element. Anisotropic crack growth from Vickers impression is observed in both as‐deposited and heat exposed Si‐BC layer. The length of radial cracks perpendicular to through‐the‐thick direction are longer than that of parallel to through‐the‐thick direction. This is attributed to residual compressive stress induced by thermal expansion mismatch during cooling. Crack length deceases with increasing heat exposure time. Resulting fracture toughness of Si BC layer increases with increasing heat exposure time. In the present study, the origin of change in fracture toughness is discussed based on microstructural observation. In addition, improvement of fracture toughness of bond coat material will be also discussed.

Optimization of FBG Sensor Sensitivity for Disaster Prevention in Pipelines Technical Publication. ICMP2017‐4445 Antonio Paolozzi, Scuola Di Ingegneria Aerospaziale ‐ Sapienza University of Rome and Centro Fermi, Roma, OO, Italy, Ferdi‐ nando Felli, Sapienza University of Rome, Rome, Italy, Cristian Vendittozzi,, Universidade de Brasilia, Brasília, Distrito Federal, Brazil, Claudio Paris, Museo Storico della Fisica e Centro Studi e Ricerche Enrico Fermi, Roma, Italy, Italy, Hiroshi Asanuma, Chiba University, Chiba, Chiba, Japan Pipelines are widely used worldwide and may represent an environmental issue because of leakage induced by either natural events such as earthquakes and landslides or thief fraudulent activity. In particular the last instance involve use of a drill on the pipeline which could be detected by a vibration sensor. In the paper it will be shown that vibration sensors based on FBG is a more convenient solution with respect to conventional sensors particularly when the pipes are buried or exposed to harsh environment. In fact FBGs are basically made of glass and can therefore easily withstand chemical attack from many substances. In Refs. [1,2] the idea of using an FBG sensor for monitoring the drill operation on a pipe has been developed and tested both in the lab and on field on a longer pipeline. It was experimentally found that the excitation frequency was 150 Hz. Furthermore it was shown that in spite of the very small amplification factor the sensor had good performances. That has been explained because the measurement was performed on the strain induced by the vibration and not on the 129 displacement. In this paper we will show how to improve the sensitivity of the sensor by increasing the amplification factor. First it is im‐ portant to analyze the excitation frequency because the optimization of the sensor proposed here aim at designing a sensor tuned ap‐ proximately at that frequency. Second an analysis of the several parameters affecting the response of the sensor are analyzed such as its length and mass. The theoretical results show a large improvement in sensitivity by adding a small mass to the system and/or by increasing the cantilever beam length.

Structural Analysis of Automobile Gas Filling Pump Nozzle Casted Aluminum Functional Material Oral Presentation. ICMP2017‐4447 Ozdogan KARAÇALI, ISTANBUL UNIVERSITY, ISTANBUL, AVCILAR ISTANBUL, Turkey Automobile gas filling pump is a device that allows the gas thank to be filled. Nozzles are attached to the gas pump via flexible hoses, al‐ lowing them to be placed into the vehicle’s filling inlet. The hoses are robust to survive heavy wear and tear, including exposure to weather and being driven over, and are often attached using heavy spring or coil arrangements to provide additional strength. One of the most im‐ portant functions for the pump is to accurately measure the amount of fuel pumped. A 3D finite element model of the filler neck and re‐ spective gas pump was investigated. In this research, finite element analysis method was used to model and foresee the strength of the continuously flow of the fuel causing the stress on the surface of the gas pump holder material. Computational study was conducted to measure the mass flow effect on the surface and pressure distributions near the nozzle’s throat under various outlet pressures. Geometry and material of gas pump was investigated to measure the mass flow effect on the surface and pressure distributions near the nozzle’s throat under various outlet pressures. Numerical simulations were employed to clarify internal flow of gas and characteristics of the gas pump and nozzle material. The numerical calculation is for steady‐state conditions through a finite element volume simulation of 3D. The main advantages and novel features of the gas pump nozzle described in the paper are smooth flow of gas through vented unit to the valve unit and the possibility of using cfd simulation, which enables mass production and thus low‐cost micropumps. A liquid pump rate of 1500l min 1 and a gas pump rate of 690l min 1 were achieved. Structural finite element analysis was employed to analyze stress and strain of the gas pump. The results of the fully coupled model validated the gas transfer function to the gas pump approach.

Research on Variation Characteristics of the Temperature Field of Galvanized Steel Sheet in the Laser Brazing Combined with Simulation and Experiment Oral Presentation. ICMP2017‐4448 H.J. Liu, X.D. Zhang, Tongji University, Shanghai, Shanghai, China Based on the analysis of the laser brazing heat transfer behavior, a laser brazing simulation model was established using the finite element software ABAQUS, which chose galvanized steel welded specimens as base metal, CuSi3 as filler wire. In the process of numerical simula‐ tion, the general characteristics of temperature field and the single‐factor effect of the main welding parameters (laser power, welding speed and spot diameter) on the temperature field of galvanized steel sheet in the laser brazing were analyzed and attained. The results show that the laser brazing has large heat input, and its temperature change violently, and can effectively protect the galvanized layer, etc. The increase of laser power in a certain range (2500~3100W) results in the rise of highest brazing temperature, but the heat affected zone is scarcely affected. Welding speed (40mm/s~60mm/s) and spot diameter (4.0mm~5.5mm) also has an apparent effect on the heat affect‐ ed zone respectively within an interval. The higher the welding speed, the smaller the spot diameter, the smaller the heat affected zone. Finally, after the laser brazing experiments of galvanized steel sheet and comparison of the simulation data with the experimental data taking welding width as measurement standard, the numerical simulation model is testified to be reliable and has a certain guiding signifi‐ cance.

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NAMRC2017‐3 132 NAMRC2017‐54 142 NAMRC2017‐101 153 NAMRC2017‐151 163 NAMRC2017‐4 132 NAMRC2017‐56 142 NAMRC2017‐102 153 NAMRC2017‐152 163 NAMRC2017‐6 132 NAMRC2017‐57 142 NAMRC2017‐103 153 NAMRC2017‐153 164 NAMRC2017‐8 132 NAMRC2017‐58 143 NAMRC2017‐106 153 NAMRC2017‐154 164 NAMRC2017‐9 133 NAMRC2017‐60 143 NAMRC2017‐107 154 NAMRC2017‐156 164 NAMRC2017‐10 133 NAMRC2017‐61 143 NAMRC2017‐108 154 NAMRC2017‐157 165 NAMRC2017‐12 133 NAMRC2017‐62 144 NAMRC2017‐109 154 NAMRC2017‐158 165 NAMRC2017‐13 133 NAMRC2017‐63 144 NAMRC2017‐110 154 NAMRC2017‐160 165 NAMRC2017‐15 134 NAMRC2017‐64 144 NAMRC2017‐112 155 NAMRC2017‐161 165 NAMRC2017‐16 134 NAMRC2017‐65 144 NAMRC2017‐114 155 NAMRC2017‐162 166 NAMRC2017‐19 134 NAMRC2017‐66 145 NAMRC2017‐115 155 NAMRC2017‐163 166 NAMRC2017‐20 134 NAMRC2017‐67 145 NAMRC2017‐117 155 NAMRC2017‐165 166 NAMRC2017‐21 135 NAMRC2017‐68 145 NAMRC2017‐118 156 NAMRC2017‐166 166 NAMRC2017‐22 135 NAMRC2017‐69 145 NAMRC2017‐119 156 NAMRC2017‐171 167 NAMRC2017‐23 135 NAMRC2017‐70 146 NAMRC2017‐120 156 NAMRC2017‐172 167 NAMRC2017‐24 136 NAMRC2017‐71 146 NAMRC2017‐121 156 NAMRC2017‐173 167 NAMRC2017‐26 136 NAMRC2017‐72 146 NAMRC2017‐122 157 NAMRC2017‐174 167 NAMRC2017‐27 136 NAMRC2017‐73 146 NAMRC2017‐124 157 NAMRC2017‐176 168 NAMRC2017‐28 136 NAMRC2017‐74 146 NAMRC2017‐125 157 NAMRC2017‐178 168 NAMRC2017‐29 137 NAMRC2017‐76 147 NAMRC2017‐126 157 NAMRC2017‐179 168 NAMRC2017‐30 137 NAMRC2017‐77 147 NAMRC2017‐127 158 NAMRC2017‐180 168 NAMRC2017‐31 137 NAMRC2017‐78 147 NAMRC2017‐128 158 NAMRC2017‐181 169 NAMRC2017‐32 137 NAMRC2017‐82 148 NAMRC2017‐129 158 NAMRC2017‐182 169 NAMRC2017‐33 138 NAMRC2017‐83 148 NAMRC2017‐130 158 NAMRC2017‐ORAL1 169 NAMRC2017‐34 138 NAMRC2017‐84 148 NAMRC2017‐131 159 NAMRC2017‐ORAL2 169 NAMRC2017‐35 138 NAMRC2017‐85 148 NAMRC2017‐132 159 NAMRC2017‐36 138 NAMRC2017‐86 149 NAMRC2017‐134 159 NAMRC2017‐37 139 NAMRC2017‐87 149 NAMRC2017‐135 159 NAMRC2017‐39 139 NAMRC2017‐88 149 NAMRC2017‐136 160 NAMRC2017‐40 139 NAMRC2017‐89 150 NAMRC2017‐137 160 NAMRC2017‐41 140 NAMRC2017‐91 150 NAMRC2017‐138 161 NAMRC2017‐42 140 NAMRC2017‐92 152 NAMRC2017‐140 161 NAMRC2017‐43 140 NAMRC2017‐93 150 NAMRC2017‐142 161 NAMRC2017‐44 140 NAMRC2017‐94 151 NAMRC2017‐144 161 NAMRC2017‐45 141 NAMRC2017‐95 151 NAMRC2017‐145 162 NAMRC2017‐46 141 NAMRC2017‐96 151 NAMRC2017‐146 162 NAMRC2017‐47 141 NAMRC2017‐97 152 NAMRC2017‐147 162 NAMRC2017‐48 141 NAMRC2017‐98 152 NAMRC2017‐148 162 NAMRC2017‐52 142 NAMRC2017‐99 152 NAMRC2017‐149 163 NAMRC2017‐53 142 NAMRC2017‐100 152 NAMRC2017‐150 163

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Effect of Lattice Design and Process Parameters on Dimensional and Mechanical Properties of Binder Jet Additively Manu‐ factured Stainless Steel 316 for Bone Scaffolds Technical Publication. NAMRC2017‐3 Sairam Vangapally, Minnesota State University, Mankato, Kuldeep Agarwal, Minnesota State University, Mankato, Alex Sheldon , Minnesota State University, Mankato, and Shaobiao Cai, Minnesota State University, Mankato In view of the fact that various resources are shared as services globally today in the manufacturing industry, the assessment and optimiza‐ tion for manufacturing capability of human‐robot collaborative disassembly is the premise to realize the aggregation and optimization of the disassembly services, and provides the best basis for the optimal scheduling in the workshop. While human are the most basic manu‐ facturing resource and industrial robots (IRs) are the most advanced, we establish a set of complete manufacturing capability assessment system and assessment model for human‐robot collaborative disassembly in this paper. For the reason that most of the capability assess‐ ment method before ignored the data source selection of the assessment object, only used real‐time data or historical data, this paper fuses the historical data and real‐time data through manifold algorithm to get more accurate results. On this basis, we assess the manufac‐ turing capability of human, robots, human‐robot collaboration using the improved method combining PCA and Grey correlation degree method and AHP in disassembly process. Finally a case study is implemented to demonstrate the feasibility and effectiveness of the pro‐ posed method.

An Improved Heuristic for No‐wait Flow Shop to Minimize Makespan Technical Publication. NAMRC2017‐4 Honghan Ye, University of Kentucky, Wei Li, University of Kentucky, and Amin Abedini, University of Kentucky No‐wait flow shop production has been widely applied in manufacturing, where no waiting time is allowed between intermediate opera‐ tions. However, minimization of makespan for no‐wait flow shop production is NP‐hard. In this paper, we propose an average idle time (AIT) heuristic to minimize makespan in no‐wait flow shop production. Compared with three existing best‐known heuristics, our AIT heuris‐ tic can achieve the smallest deviations from optimum, based on Taillard’s benchmarks and 600 randomly generated instances, in the same computational complexity.

IoT‐enabled Smart Factory Visibility and Traceability using Laser‐scanners Technical Publication. NAMRC2017‐6 Ray Y. Zhong, Department of Mechanical Engineering, University of Auckland, NZ, Xun Xu, Department of Mechanical Engi‐ neering, University of Auckland, NZ and Lihui Wang, Department of Mechanical Engineering, University of Auckland, NZ Smart Factory is one of the critical components in Industry 4.0 which is our next industrial generation. This paper introduces an Internet of Things (IoT) ‐enabled Smart Factory Visibility and Traceability Platform (iVTP for short) to ultimately achieve real‐time production visualiza‐ tion within a smart factory. iVTP uses IoT technology to identify various manufacturing objects. Specifically, radio frequency identification (RFID) devices are used for converting various resources into smart manufacturing objects (SMOs) and their interactions thus are able to real‐time reflect the production operations and behaviors. By innovatively using a laser‐scanner in the shopfloor, iVTP is able to real‐time display the movements of various SMOs and twin the real‐time RFID data to show their states. A Cloud‐based system architecture which enables all the services packaged and deployed in a Cloud allows typical end‐users to easily define their production logics, download useful services, and develop their customized services. Several demonstrative scenarios are presented to show how iVTP can facilitate the typical decision‐making, production and logistics operations in a smart factory.

Analysis of Surface Finish Improvement during Ultrasonic Assisted Magnetic Abrasive Finishing on chemically treated Tungsten substrate Technical Publication. NAMRC2017‐8 Nitesh Sihag, Birla Institute of Technology and Science, Pilani, Prateek Kala, Birla Institute of Technology and Science, Pilani Pulak Mohan Pandey, Indian Institute of Technology Delhi In the era of globalization, the demand of new products with advanced material and process technologies is increasing. Conventional man‐ ufacturing techniques are not capable to process the advanced engineering materials with stringent properties. This paper presents a novel approach to finish some advanced engineering materials with stringent properties, which is a challenge for existing conventional machining processes. In this study the positive outcomes of Chemical‐Mechanical Polishing (CMP), Magnetic Abrasive Finishing (MAF), and ultrasonic vibrations have been integrated and a new process Chemo Ultrasonic Assisted Magnetic Abrasive Finishing (CUMAF) is developed. The machining performance has been enhanced with the process resulting in better surface finish and reduced finishing time. In order to estab‐ lish the process, an experimental study was done to analyze the effect of five different process variables on the surface roughness of sam‐ ple. The response surface methodology and analysis of variance was used to design the experiments and analyze the results respectively. A regression model was also developed and validated, to foresee the process response. Optimization of the model was carried out at the end to obtain the best performance. 132

Investigation into the use of Adhesive Fillers and Soft Start Curing to Reduce the Distortion of a Work‐piece Supported by PAAW Joints Technical Publication. NAMRC2017‐9 Kristopher Doll, The Pennsylvania State University, Haochen Xie, The Pennsylvania State University, and Edward De Meter, The Pennsylvania State University Fractional thickness reduction is a critical measure of localized distortion for a part held within a PAAW fixture. The maximum fractional thickness that may result is the fractional volumetric shrinkage of the adhesive. However this will only occur under the special conditions that the work‐piece interface stiffness is very small and the joint aspect ratio is large. This research has shown that for conditions that vary from this, adhesives with comparable values of fractional volumetric shrinkage can lead to significantly different fractional thickness reduction. This is due to variations in the ability of these adhesive to form a neck and to elastically stretch after polymerization. Neck formation is a critical factor for all joint conditions. Elastic stretching is only relevant for cases in which the workpiece interface is very stiff. This research has also shown that soft start curing is an effective means of reducing fractional thickness reduction. It works by facilitating neck formation. As joint conditions become more favorable for neck formation, the effectiveness of soft start curing increases. Alterna‐ tively for conditions in which the work‐piece interface stiffness is very low and the joint diameter‐to‐thickness ratio is very large, soft start curing provides no advantage over conventional curing.

Machine learning‐based CPS for clustering high throughput machining cycle conditions Technical Publication. NAMRC2017‐10 Javier Díaz, Plethora IIoT, Concha Bielza, Department of Artificial Intelligence, School of Computer Science, Technical Univer‐ sity of Madrid, and Pedro Larrañaga, Department of Artificial Intelligence, School of Computer Science, Technical University of Madrid Cyber‐physical systems (CPS) have opened up a wide range of opportunities in terms of performance analysis that can be applied directly to the machine tool industry and are useful for maintenance systems and machine designers. High‐speed communication capabilities enable the data to be gathered, pre‐processed and processed for the purpose of machine diagnosis. This paper describes a complete real‐world CPS implementation cycle, ranging from machine data acquisition to processing and interpretation. In fact, the aim of this paper is to pro‐ pose a CPS for machine component knowledge discovery based on clustering algorithms using real data from a machining process. There‐ fore, it compares three clustering algorithms —k‐means, hierarchical agglomerative and Gaussian mixture models— in terms of their con‐ tribution to spindle performance knowledge during high throughput machining operation.

A Fundamental Investigation of Modulated Tool Path Turning Mechanics Technical Publication. NAMRC2017‐12 Ryan Copenhaver, University of North Carolina at Charlotte, Mark Rubeo, University of North Carolina at Charlotte Steven Guzorek, University of North Carolina at Charlotte, Saurabh Landge, University of North Carolina at Charlotte, K. Scott Smith, University of North Carolina at Charlotte, John Ziegert, University of North Carolina at Charlotte, and Tony Schmitz, University of North Carolina at Charlotte This paper describes an experimental machining platform that provides metrology during tube turning (orthogonal cutting) for force, global temperature, feed motion, tool wear, and chip formation during continuous feed and modulated tool path, or MTP, turning. MTP is a tech‐ nique which produces discontinuous chips by superimposing tool oscillations in the tool feed direction on the nominal feed rate to repeat‐ edly interrupt the cutting process. AISI 1026 cold‐drawn steel machining experiments are performed and data is presented for: 1) feed mo‐ tion and modeling; 2) force measurement and modeling; 3) temperature measurement; and 4) chip formation for constant and MTP tool paths. Shear‐localized chip formation that begins and ends during a single MTP chip is demonstrated.

Incorporating a Social Implementation Program into a Manufacturing Education Program in Japan: Case Study in Collabo‐ ration with a Medical Facility Technical Publication. NAMRC2017‐13 Hukuzo Yagishita, National Institute of Technology, Numazu College and Mikio Fujio, National Institute of Technology, Numazu College The College of Technology (called Kosen) is an educational program established in 1962 in Japan to train practical engineers for five years after high school [1]. The curricula of Kosen are characterized by that engineering practice and experiment programs are set from 1st grade and gradually increase as proceed of grade. After that, advanced course for two years was established. In December 2012 the academic policy was changed to bring up the practical and creative engineers who can be active in the various fields. To attain the academic policy Engineering Design Program was attempted. Recently Social Implementation Program was newly proposed instead of Engineering Design 133

Program. In Numazu National College of Technology (NNCT), considerations of the needs of Shizuoka prefecture’s research culture pro‐ ject and the success of both Brush up Project of Manufacturing Engineers and Fuji Medical Engineer Training (F‐met) Project led the Col‐ lege’s staffs to make new curricula based on Social Implementation Program through seven years from teenager. The new curricula were applied from 2013. Several case studies for Social Implementation Program are executed based on the new curricula of NNCT. A case study in collaboration with a medical facility is described as an example of Social Implementation Program and the effect on a manufactur‐ ing education is discussed.

Augmented Reality‐assisted Intelligent Window for Cyber‐Physical Machine Tools Technical Publication. NAMRC2017‐15 Chao Liu, University of Auckland, Sheng Cao, University of Auckland, Wayne Tse, University of Auckland, and Xun Xu, Univer‐ sity of Auckland Aiming at advancing current machine tools into a higher level of intelligence and autonomy, this paper presents a new generation of ma‐ chine tools, i.e. Cyber‐Physical Machine Tool (CPMT), inspired by the recent advances in Cyber‐Physical Systems (CPS). CPMT refers to a CPS‐enabled machine tool that integrates physical machine tool and machining processes with computation and networking capabilities. Augmented Reality (AR) is used to enable intuitive and efficient human‐machine interactions between humans and CPMT. This paper pro‐ poses an AR‐enabled Intelligent Window for CPMT. The Intelligent Window is essentially an advanced Human‐Machine Interface (HMI) which provides users with intuitive interactions with CPMT. The proposed Intelligent Window consists of four main functional modules, i.e. Real‐time Control, AR‐enabled Process Monitoring, AR‐enabled Machining Simulation, and Process Optimization. An AR‐enabled intelligent window for an EMCO Concept 105 milling machine is developed making use of a touch‐screen computer. The advantages and potentials of CPS and AR in manufacturing are discussed based on the experience gained from the experiments.

Study on the Innovation Incubation Ability Evaluation of High Technology Industry in China from the Perspective of Value‐Chain ‐ Technical Publication. NAMRC2017‐16 Jianlin Zhou, Dalian University of Technology, Guohong Wang, Dalian University of Technology, Shulin Lan, Dalian University of Technology, and Chen Yang, Dalian University of Technology This paper establishes the innovation incubation ability evaluation model by using optimal combination weight and analyzes the innovation incubation ability of high technology industry based on data from 31 provinces during the period of 2008‐2012. The results show that from general prospective, the innovation incubation ability of high technology industry enters into the slow development phase in accord with “W” shape in China; From the regional prospective, Guangdong, Jiangsu and Beijing are in the lead; Tibet, Ningxia lag behind other regions; The rank of some regions is changeful; From sub‐ability prospective, while resource investment ability and research and development abil‐ ity overall show a downward trend, economic transformation ability shows a upward trend; Besides, research and development ability makes more important contribution to the innovation incubation ability of high technology industry.

Dynamic Modeling of Manufacturing Capability for Robotic Disassembly in Remanufacturing Technical Publication. NAMRC2017‐19 Zongqing Zheng, Wuhan University of Technology, Wenjun Xu, Wuhan University of Technology, Zude Zhou, Wuhan Univer‐ sity of Technology, Duc Truong Pham, University of Birmingham, Yongzhi Qu, Wuhan University Technology, and Jian Zhou, Wuhan University Technology Product disassembly plays an important role in the sustainable manufacturing, and it is usually the first step in remanufacturing process, which determines the efficiency and capability of remanufacturing. Industrial robot (IR) as an intelligent manufacturing equipment to in‐ crease the productivity and reduce energy consumption (EC), has been applied to semi‐automated product disassembly, and the thing that matters is studying and modeling of manufacturing capability for robotic disassembly in remanufacturing. In this paper, the IR disassembly capability is modeled dynamically using OWL, based on the mapping relation which associating the disassembly capability attributes and the real‐time data. Furthermore, a method of association rules mining (ARM) based on bees algorithm (BA) is proposed to mine the associ‐ ation relationships from the data of disassembly processes. The effectiveness of the proposed modeling method is validated by a case study, and the results show that the dynamic modeling method could efficiently reflect the current state and dynamic capability of IRs dur‐ ing product disassembly process in remanufacturing.

Manufacturing Capability Assessment for Human‐Robot Collaborative Disassembly based on Multi‐Source Data Fusion Technical Publication. NAMRC2017‐20 Huiping Cheng, Wuhan University of Technology, Wenjun Xu, Wuhan University of Technology, Qingsong Ai, Wuhan Uni‐ versity of Technology, Quan Liu, Wuhan University of Technology, Zude Zhou, Wuhan University of Technology, and 134

Duc Truong Pham, University of Birmingham In view of the fact that various resources are shared as services globally today in the manufacturing industry, the assessment and optimiza‐ tion for manufacturing capability of human‐robot collaborative disassembly is the premise to realize the aggregation and optimization of the disassembly services, and provides the best basis for the optimal scheduling in the workshop. While human are the most basic manu‐ facturing resource and industrial robots (IRs) are the most advanced, we establish a set of complete manufacturing capability assessment system and assessment model for human‐robot collaborative disassembly in this paper. For the reason that most of the capability assess‐ ment method before ignored the data source selection of the assessment object, only used real‐time data or historical data, this paper fuses the historical data and real‐time data through manifold algorithm to get more accurate results. On this basis, we assess the manufac‐ turing capability of human, robots, human‐robot collaboration using the improved method combining PCA and Grey correlation degree method and AHP in disassembly process. Finally a case study is implemented to demonstrate the feasibility and effectiveness of the pro‐ posed method.

Effect of Lubrication on Machining Response and Dynamic Instability in High‐Speed Micromilling of Ti‐6Al‐4V Technical Publication. NAMRC2017‐21 Rinku Mittal, Indian Institute of Technology, Bombay, Salil S. Kulkarni, Indian Institute of Technology, Bombay, and Ramesh Singh, Indian Institute of Technology, Bombay The micromilling process is increasingly being used in biomedical, defence, electronics and aerospace industries for fabrication of miniatur‐ ized products of complex shapes. For difficult‐to‐cut materials like Ti alloys, limited stiffness of the micro‐tool is a major impediment. This limitation can be overcome by using high rotational speeds which leads to reduction in chip load and, therefore, the cutting forces. Howev‐ er, high spindle speeds and low tool stiffness can render the process unstable due to dynamic variation in cutting forces. High speed mi‐ cromilling of Ti6Al4V generates high temperature in cutting zone due to low thermal conductivity of Ti alloys which can also lead to a varia‐ tion in cutting force and, hence, dynamic instability. Cutting fluid can play an important role because of its capacity to reduce friction and its ability to dissipate the heat generated between the micro tools and the workpiece. This study is focused on studying the effect of lubri‐ cation on the cutting forces and dynamic instability called chatter in high speed micromilling of Ti6Al4V. Experiments were carried out at different spindle speeds and feeds in both dry and lubricated condition. A significant reduction up to 38% in the cutting forces has been found in lubricated machining as compared with the dry machining. Two distinct regimes, lubrication sensitive (at rotational speeds > 47,000 rpm) and lubrication insensitive (at rotational speeds < 47,000 rpm) have been observed in this study. A critical spindle speed of 47,000 rpm has been identified which corresponds to the onset of lubrication dominant regime. To capture the effect of process mechan‐ ics, mechanistic force model using velocity‐chip load dependent coefficients has been used to predict the forces and stability boundary. The predicted stability boundary limits have been compared with the experimental onset of chatter at four different spindle speeds. FFT spec‐ trum analysis of acceleration of workpiece has been done to detect the process instability.

Effect of Vibration Assistance on Surface Residual Stress in Grinding of Ti6Al4V Alloy Technical Publication. NAMRC2017‐22 Naresh Kumar Maroju, Oklahoma State University and Xiaoliang Jin, Oklahoma State University Titanium alloy Ti6Al4V is widely used in aerospace, biomedicine, and marine industries due to its high strength‐density ratio and corrosion resistance property. Grinding is used to achieve final surface quality of the component, in which the surface residual stress plays an im‐ portant role in the fatigue life of the component. This study presents the investigation of surface residual stress in vibration assisted grind‐ ing of Ti6Al4V. A finite element model is developed to predict the surface residual stress in both Conventional Grinding (CG) and Vibration Assisted Grinding (VAG). The effect of progressive strain hardening of the workpiece material due to multiple grit passes is considered to analyze the surface residual stress. The model is validated through 1‐D and 2‐D vibration assisted grinding experiments. The surface residu‐ al stress is measured through 2‐D X‐ray diffraction technique. It is observed that implementing vibration assistance results in increased compressive residual stress due to the indentation effect, which enhances the fatigue life of the component.

A Study of Milling Surface Quality during Period‐2 Bifurcations Technical Publication. NAMRC2017‐23 Andrew Honeycutt, University of North Carolina at Charlotte and Tony Schmitz, University of North Carolina at Charlotte This paper provides time domain simulation and experimental results for surface location error and surface roughness when machining under both stable (forced vibration) and unstable (period‐2 bifurcation) conditions. It is shown that the surface location error follows simi‐ lar trends observed for forced vibration, so zero or low error conditions may be selected even for period‐2 bifurcation behavior. The surface roughness for the period‐2 instability, on the other hand, is always larger than for stable conditions because the surface is defined by every other tooth passage and the apparent feed per tooth is subsequently increased. Good agreement is observed between simulation and ex‐ periment for stability, surface location error, and surface roughness results.

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Integrated Design, Manufacturing and Analysis of Airfoil and Nozzle Shapes in an Undergraduate Course Technical Publication. NAMRC2017‐24 Barbara Linke, UC Davis, Ian Garretson, UC Davis, Fahad Jan, UC Davis and Mohamed Hafez, UC Davis To increase student interest in engineering and utilize the known benefits of active, project‐based learning, a new undergraduate course on airfoil and nozzle design and manufacturing is under development at the University of California Davis. The course will demonstrate the air flow around airfoils at high speeds by using a water table experiment. The water table utilizes the hydraulic analogy and is a much simpler and cheaper setup than a wind tunnel. The students will learn about computational design of airfoils and nozzles, sustainable manufactur‐ ing, and experimental testing with self‐made models. These models highlight capabilities of different manufacturing processes (in particular turning, milling, water jet cutting, and wire extrusion as additive manufacturing process) to produce specific shapes, dimensions and sur‐ face qualities. Special regard is given to process planning, costing, energy, post‐processing and waste. The dimensional accuracy will impact the results in the water table experiments. From this, the students can understand that both approaches, analytical modeling and experi‐ mentation are needed for engineering problems.

An Experimental Method to Determine the Minimum Uncut Chip Thickness (hmin) in Orthogonal Cutting Technical Publication. NAMRC2017‐26 Reginaldo Coelho, The University of Sao Paulo, Anselmo Diniz, University of Campinas, and Tatiany Silva, University of Cam‐ pinas Chip formation has been studied for more than a century, using initially process description followed by experimental procedures and mathematical models. Initially cutting edges were modeled as perfectly sharp, but real cutting tools contain small radius. Some of them are as low as few micrometres. Micro‐machining operations often need uncut chip thickness (h) lower than the edge radius leading to its min‐ imum value (hmin), under which material may not be removed. There is an extensive range of values for hmin in literature, as a percentage of the edge radius re. The criterion for establishing hmin varies extensively as the cutting conditions used. The present work proposes an innovative method to study hmin with realistic values of cutting and feed speed (vc and vf) in orthogonal cutting. Using the proposed method two edges, one sharp (re = 6 mm) and one blunt (re = 120 mm), were tested in 3 different conditions. After these 3 tests, hmin was detected for each of the cutting conditions. Values were found to depend on the cutting conditions, mainly on the maximum h possible to be achieved and on the way it grows during the interaction between edge radius and workpiece material. It was also suspected that BUE can be formed in front of the tool, depending on the way the uncut chip thickness increases along the interaction. The method also proved to be capable of detecting hmin and several other relations with the main parameters affecting it.

Surface Finish of a Hardened Stainless Steel Using a New Burnishing Tool Technical Publication. NAMRC2017‐27 Fang‐Jung Shiou, National Taiwan University of Science and Technology, Shih‐Ju Huang, National Taiwan University of Sci‐ ence and Technology, Albert Shih, University of Michigan, Jiang Zhu, Tokyo Institute of Technology, and Masahiko Yoshino, Tokyo Institute of Technology The objective of this research is to develop a new ball‐burnishing tool embedded with a load cell integrated with a CNC lathe, to improve the surface roughness and hardness of the SUS420J2 mould steel. The optimal ball burnish process parameters of the cylindrical part have been determined by conducting the Taguchi’s L18 matrix experiments, the ANOVA analysis, and the verification tests. Based on the exper‐ imental results, the optimal combination of the process parameters is as follows: the ball material of WC, the burnishing force of 650 N, the feed rate of 0.05 mm/rev, the velocity of 25 m/min, the lubricant of the cutting fluid (oil/water concentration of 1/20) and the number of pass of 3. The surface roughness of the test specimen could be improved from Ra 1.1 μm to Ra 0.025 μm (Rmax0.202 μm) and the surface hardness could be increased from HRc 51 to HRc 52.5 on average using the optimal process parameters. Applying the optimal process pa‐ rameters to a workpiece with different tapers, then the surface roughness could be improved from Ra 1.0 μm to Ra 0.04‐0.06 μm on aver‐ age.

Enhancement of Mechanical Properties of FSWed AA7075 Lap Joints through in‐Situ Fabrication of MMC Technical Publication. NAMRC2017‐28 Gianluca Buffa, University of Palermo, Davide Campanella, University of Palermo, and Livan Fratini, University of Palermo Friction Stir Processing (FSP) has been demonstrated feasible to create local Metal Matrix Composites (MMCs) in light alloys matrix. In this research, local MMCs were produced contextually to the weld using Friction Stir Welding (FSW). SiC particles were added to AA7075 lap joints by creating a proper groove on the top surface of the bottom sheet. Different welds were produced with increasing number of tool passes. The effect of the multiple passes was investigated through shear tests, macro and micro observations, average grain size and mi‐ crohardness measurements. The welded joints were compared to a reference weld produced with no reinforcements. It was found that poor mixing between matrix and reinforcement phase is obtained with one tool pass. On the contrary, proper mixing is obtained with three tool passes, resulting in an increase in the maximum load in shear tests of 50% with respect to the reference conditions.

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The Effect of Horn Knurl Geometry on Battery Tab Ultrasonic Welding Quality: 2D Finite Element Simulations Technical Publication. NAMRC2017‐29 Wayne Cai, GM Ultrasonic welding has been widely used in semiconductor industry for several decades. Recently, it has become a major joining technique in automotive industry as demand for the electric vehicle increases. Even though there have been several numerical analyses, simulations of ultrasonic welding for multiple sheets and dissimilar metals with the actual tool geometry (such as the knurl pattern of the horn, or sonotrode) have not been reported. In this study, finite element procedures for the ultrasonic welding process are developed using 2D plain‐strain elements. The procedure focuses on simulating localized mechanical behavior of battery tab welding for different knurl geome‐ tries with very affordable computations. The procedure has been validated, and the results provide guidelines for designing the horn knurl geometry to improve the weld quality. The research provides scientific understanding and guidelines for improving ultrasonic weld quali‐ ty of battery packs.

Experimental Determination of the Effective Viscosity of Plasticized Aluminum Alloy 6061‐T6 during Friction Stir Forming Technical Publication. NAMRC2017‐30 Daniel Franke, University of Wisconsin‐Madison, Justin Morrow, University of Wisconsin‐Madison, Michael Zinn, University of Wisconsin‐Madison, Neil Duffie, University of Wisconsin‐Madison, and Frank Pfefferkorn, University of Wisconsin‐Madison Friction stir forming (FSF) refers the process variant of friction stir welding (FSW) where a joint is realized through the creation of mechani‐ cal interlocking between two constituents by forcing one material to flow into the other. In order to increase the understanding of material flow in this process, a method of quantifying the plasticity flowing material during the FSF process is needed. A method is proposed in which a capillary hole is drilled into a backing plate used for FSF, and material is extruded through the capillary during processing. The flow of material is characterized and related back to an effective viscosity using the models that form the basis of a capillary rheometer. Initial testing shows promising agreements with CFD simulations of the FSW process. Furthermore, promising initial agreement is shown when using effective viscosity values determined for the capillary method in a previously derived model that describes the infiltration for carbon fiber with plasticized aluminum produced by the FSW/FSF process.

A Comparative Study on Micro‐Electro‐Discharge‐Machined Surface Characteristics of Ni‐Ti and Ti‐6Al‐4V with Respect to Biocompatibility Technical Publication. NAMRC2017‐31 Muhammad Jahan, Miami University, Pegah Kakavand, Western Kentucky University, and Farshid Alavi, Western Kentucky University Ti‐6Al‐4V (grade 5 titanium alloy) and NiTi (shape memory alloy) are two commonly used materials for biomedical orthopedic and ortho‐ dontic applications. The surface characteristics of the biomedical implants play a significant role on the biocompatibility and mechanical strength of the implants. The objective of this study is to investigate and compare the surface characteristics of NiTi shape memory alloy (SMA) and Ti‐6Al‐4V alloy after machined using micro‐electro‐discharge machining (micro‐EDM). The machined surfaces were analyzed for topography, composition, migration of materials and microhardness. The results showed that NiTi SMA produced comparatively smoother surface finish. The analysis of elemental composition indicated migration of materials to the workpiece from the dielectric and the tool electrode. There is formation of TiO2 and NiTiO3 layers on the machined surfaces of Ti‐6Al‐4V and NiTi respectively. The surface micro‐ hardness increased in both NiTi and Ti‐6Al‐4V workpieces after micro‐EDM due to the formation of the oxide layers. The formation of oxide layers can be beneficial for both materials when used as biomedical implants, as commercial implants contain protective oxide coatings to minimize the corrosion inside human body.

Simulation of Elastic Properties of Solid‐Lattice Hybrid Structures Fabricated by Additive Manufacturing Technical Publication. NAMRC2017‐32 Guoying Dong, McGill University, Yunlong Tang, McGill University and Yaoyao Fiona Zhao, McGill University The lattice structure is promising in a variety of engineering applications because of its unique mechanical properties. To satisfy certain functional requirements, lattice structures combined with the skin and solid are preferred in many cases. Additive Manufacturing (AM) has reduced the difficulty in fabricating Solid‐Lattice hybrid structures, which brings more potential for applications. However, analyzing such a complex structure is challenging for traditional methods. In this paper, a new simulation model is proposed to reduce the computational cost and avoid poor mesh quality in simulating elastic properties of Solid‐Lattice hybrid structure by Finite Element Analysis. The connecting area of the lattice strut and the solid is investigated to determine the best parameter for the new simulation model. A structure is designed and the experiment is conducted to validate the proposed method. A comparison between the new simulation model and the traditional one shows that the computational cost is dramatically decreased and the mesh quality is improved by the proposed method. And both of the simulation results are close to the experimental result which can be used to predict the mechanical performance of Solid‐Lattice hybrid structures. 137

Ultrasonic Vibration‐Assisted Laser Engineered Net Shaping of Inconel 718 Parts: A Feasibility Study Technical Publication. NAMRC2017‐33 Fuda Ning, Texas Tech University, Yingbin Hu, Texas Tech University, Zhichao Liu, Texas Tech University, Weilong Cong, Texas Tech University, Yuzhou Li, Texas Tech University, and Xinlin Wang, Texas Tech University Laser engineered net shaping (LENS) has been applied as a key technology in direct manufacturing or repairing of high added‐value metal parts. Recently, many investigations on LENS manufacturing of Inconel 718 parts have been conducted for potential applications of the aircraft turbine component manufacturing or repairing. However, fabrication defects such as pores, cavities, and heterogeneous micro‐ structures always exist in the parts, affecting part qualities and mechanical properties. Therefore, it is crucial to LENS‐manufacture Inconel 718 parts in a high‐quality and high‐efficiency way. Ultrasonic vibration has been introduced into various melting metal solidification pro‐ cesses for process improvements. However, there are no reported investigations on ultrasonic vibration‐assisted (UV‐A) LENS of Inconel 718 parts. In this paper, for the first time, UV‐A LENS is proposed to reduce the fabrication defects of Inconel 718 parts. The experimental investigation is conducted to study the effects of ultrasonic vibration on microstructures and microhardness of the parts fabricated by UV‐A LENS and LENS without ultrasonic vibration. The results showed that ultrasonic vibration could reduce the porosity, refine the microstruc‐ ture with a smaller average grain size, and fragment the detrimental phase with a uniform distribution, thus enhancing the microhardness of the fabricated parts.

The Effect of Hydraulic Bulge Process on the Surface Topography of Annealed AISI 304 Stainless Steel Technical Publication. NAMRC2017‐34 Ayotunde Olayinka, Mechanical Engineering Dept., University of Louisiana at Lafayette, William Emblom, Mechanical Engi‐ neering Dept., University of Louisiana at Lafayette, Thomas Pasacreta, Microscopy Centre, University of Louisiana at Lafa‐ yette, and Scott Wagner, School of Technology, Michigan Technological University In this study, the relationship between surface topography and strain was established for annealed 0.2 mm thick AISI 304 stainless steel thin sheet that had been hydroformed. The effect of the die diameter on the surface topography was also examined. Sheets were bulged using stepwise application of hydraulic pressure; forcing the sheet metal through 5‐mm and 11‐mm diameter open dies. The strains at the pole of the bulge of the work pieces were determined analytically using the Jovane analytical method, this was achieved by measuring the height of the pole of the bulge for every applied hydraulic pressure for a particular die. The surface topography at the micro level was found by scanning the bulge of the sample using an atomic force microscope over an area of 60μm by 60μm. The results of this study indi‐ cates that the bearing ratio was unaffected by the change in strain for both the 5‐mm die and the 11‐mm diameter dies. The average roughness and root mean square roughness show a linear relationship with the strain. Furthermore, the peak‐to‐peak roughness and the maximum depth of the surface profile show a linear relationship with the strain.

Investigation of Sintering Shrinkage in Binder Jetting Additive Manufacturing Process Technical Publication. NAMRC2017‐35 Yujia Wang, McGill University and Yaoyao Fiona Zhao, McGill University Binder jetting process is an additive manufacturing technology that produces objects layer by layer from 3D digital data. After printing pro‐ cess, the secondary post‐processing operations, including curing and sintering, are used to solidify the object. The linear dimensional accu‐ racy is one of the most important end‐product qualities in manufacturing process. However, it is not easy to control it since the whole pro‐ cess combines several steps and covers different disciplines. Sintering process can affect the shrinkage rate significantly through using dif‐ ferent sintering profiles. This project focuses on investigating the effect of sintering parameters on linear dimensional accuracy. The Taguchi method is used to design 9 groups of orthogonal experiments. After that, the results are converted to signal‐to‐noise (S/N) ratio and using analysis of variance (ANOVA) to analyze. There are 3 sets of recommended sintering parameters to achieve the best dimensional accuracy for each axis and there is also 1 set of recommended sintering parameters which considers dimensional accuracies of all 3 axes. Comparing with the shrinkage rates measured using default sintering profile, the dimensional accuracies are improved.

Experimental Optimization of Fused Deposition Modelling Processing Parameters: a Design‐for‐Manufacturing Approach Technical Publication. NAMRC2017‐36 Ala’aldin Alafaghani, University of California, Merced, Ala Qattawi, University of California, Merced, Buraaq Alrawi, Univer‐ sity of California, Merced and Arturo Guzman, University of California, Merced The Additive Manufacturing (AM) technology initially was developed as a rapid prototyping tool for visualization and validation of designs. The recent development of AM technologies, such as Fused Deposition Modelling (FDM), is driving it from rapid prototyping to rapid man‐ ufacturing. However, building end‐user functional parts using FDM proved to be a challenging task. The difficulty rises from the large num‐ ber of processing parameters that effect the final part design such as: building direction, extrusion temperature, layer height, infill pattern and more. The processing parameters of FDM influence the quality of the parts and their functionality. In addition, a more systemic under‐ standing is required to elaborate on the impact of the FDM processing parameters on the final part’s mechanical properties, dimensional

138 accuracy and building time. The presented manuscript provides an experimental study to investigate the independent effect of each pro‐ cessing parameter on the mechanical properties and dimensional accuracy repeatability of FDM parts. A total of 18 test specimen samples were printed using varying processing parameters. In order to investigate the repeatability and resulted tolerances, the dimensions of these specimen were measured and compared with a 3D CAD model. The presented work then utilizes a tensile test according to ASTM D638 to obtain the mechanical properties of each fabricated sample. In addition, the work provides a Finite Element Analysis (FEA) model for AM parts. The work suggested to simulate their behavior under mechanical loads for future investigation on the coupled effects of pro‐ cessing parameters.

A Fundamental Study of Nano Electrodeposition Using a Combined Molecular Dynamics and Quantum Mechanical Electron Force Field Approach Technical Publication. NAMRC2017‐37 Anne Brant, University of Cincinnati and Murali Sundaram, University of Cincinnati Nano electrochemical additive manufacturing (Nano ECAM) is an emerging technology that combines the trends of miniaturization and additive manufacturing to fabricate complex 3D parts at the nano scale. A combined molecular dynamics and quantum mechanical electron force field approach is used in this work to study the electrochemical and physical input parameter effects on output deposition behavior to obtain fundamental understanding of Nano ECAM process. It was found that electron tunneling behavior occurs below a threshold inte‐ relectrode gap (IEG), which is not solvable by reducing the current. This tunneling would mean the electrons were not available to cause the electrolyte ions to deposit onto the substrate. Additionally, if the IEG was too high and the current was too low, the input electrons and cations from the electrolyte would combine and remain in a constant position near but not adsorbed to the surface. Furthermore, the ef‐ fects of varying Watt’s bath concentration were studied. It was found that there was an ideal concentration to perform Nano ECAM at, with values above and below causing deposition to occur less quickly and less efficiently. Finally, the work reported in this paper provides a very valuable computational framework for predicting the ECAM process results for subsequent experimental verification.

Three Dimensional Finite Element Simulation of Cutting Forces and Cutting Temperature in Hard Milling of AISI H13 Steel Technical Publication. NAMRC2017‐39 Qing Zhang, School of Mechanical Enginnering, Shandong University, Song Zhang, School of Mechanical Enginnering, Shan‐ dong University and Jianfeng Li, Shandong University Hard milling of hot work tool steel (AISI H13) is a novel machining process which could significantly improve the physical/mechanical per‐ formances of machined components. A three dimensional (3D) finite element (FE) analysis was developed in this research to investigate the complex nonlinear process. First, the geometric model of workpiece was established considering the previous machined surface profile in actual milling process. Secondly, the prediction ability of the model for simulating hard milling process was validated by comparing the simulated cutting forces with the experiment results. Finally, the effect of cutting speed and feed rate on cutting forces and cutting tem‐ perature were researched using the FE analysis. The results indicate that cutting forces increase with the increase of feed rate, while cut‐ ting temperature increases with the increase of cutting speed. The effects of cutting speed on cutting forces and feed rate on cutting tem‐ perature are not significant. The simulated temperature is much lower than austenitizing temperature of AISI H13 steel which means white layer is unlikely to be formed under cutting conditions used in this study. The research is benefit to fundamental understanding of mecha‐ nism and optimization of cutting parameters in hard milling.

Electrohydrodynamic Printing Multi‐scale Multi‐pattern Scaffold for 3D Cell Culture Technical Publication. NAMRC2017‐40 Jie Sun, NUSRI To understand the behavior of cells in 3D environment and their interactions with neighboring cells and matrix requires 3D culture systems. Scaffolds required in such systems should provide a biomimetic environment for routine 3D cell growth in vitro. In this study, we present a novel electrohydrodynamic printing (EHDP) technology to fabricate multi‐scale multi‐pattern scaffold using a biocompatible polymer mate‐ rial, polycarprolactone (PCL). With a self‐developed setup, we have explored the influence of process parameters (such as stage speed, solution concertation, feed rate and temperature) on fiber diameter and pattern. Furthermore, scaffolds with diverse patterns and fiber orientation have been fabricated including wall structure, gradient structure and coiled structure. The first two types of structures have been used for preliminary cell cul‐ ture study by growing cos7 cells. The image is used to assess cell viability and proliferation. The experimental results show that the gradient structure can effectively improve cell attachment, compared with the wall structure. As a new type of cell carrier, the EHDP printed multi‐scale multi‐pattern PCL scaffolds are promising for in vitro 3D cell culture and tissue engineering‐related applica‐ tions.

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Experimental Characterization of Clad Microstructure and its Correlation with Residual Stresses Technical Publication. NAMRC2017‐41 Santanu Paul, Indian Institute of Technology, Bombay, Khushahal Thool, Indian Institute of Technology, Bombay,Ramesh Singh, Indian Institute of Technology, Bombay,Indradev Samajdar, Indian Institute of Technology, Bombay, and Wenyi Yan, Monash University The repair of dies and molds used in the automobile industry by laser cladding (LC) is an important and emerging trend in additive manu‐ facturing (AM) today. LC provides an alternative to the traditional deposition techniques which are ad‐hoc and imprecise for powder met‐ allurgical steels used in the repair of these components. The current study focuses on understanding the correlation between microstruc‐ ture and the residual stress developed due to the deposition process. The microstructure was characterized using Electron Backscatter Diffraction (EBSD) analysis and the residual stress was measured using micro focus X‐ray diffraction technique. The EBSD study revealed that the relative difference in martensite phase fraction resulted in local grain misorientations. A thermomechanical finite element (FE) model was also developed to predict the magnitude and nature of residual stresses in the component. The FE model calculated the stress field by considering only the thermal strain developed between the clad and substrate layers. The FE model was able to capture the nature of residual stresses in the clad and substrate where the thermomechanical effects dominate. The study revealed the importance of incor‐ porating the effect of metallurgical transformation in FE model to accurately predict the residual stress variation in the substrate region.

Understanding Flexible Abrasive Brush Behaviour for Double Disk Magnetic Abrasive Finishing Based on Force Signature Technical Publication. NAMRC2017‐42 Prateek Kala, BITS Pilani, Varun Sharma, IIT Delhi, Girish Verma and Pulak Pandey, IIT Delhi, The Double disk magnetic abrasive finishing process poses better finishing characteristics while finishing paramagnetic thin work piece, when compared to plain magnetic abrasive finishing. This is due to the significant change in the behavior of the flexible magnetic abrasive brush (FMAB) formed for two cases under similar conditions. Observing and comparing the behavior of FMAB in action visually is a difficult task. However, FMAB average behaviour can be understood by observing the force signature. Thus present work aims at developing a setup that can be used to capture force signature for the two cases and then understand the FMAB behavior. The present work present the FMAB force signature obtained on varying working gap and rotational speed for the two types of process. The force signature and the basic mag‐ netic principle have been used to understand the FMAB behavior and thus understand implications on the finishing process.

Analysis of Different Surface Structures of Hard Metal Guiding Stones in the Honing Process Technical Publication. NAMRC2017‐43 Sven Klein, Institute of Manufacturing Technology ‐ Saarland University, Shiqi Fang, Institute of Manufacturing Technology ‐ Saarland University, and Dirk Bähre, Institute of Manufacturing Technology ‐ Saarland University Honing is a precise machining process with high standards for the resulting form, dimension and surface quality. Additionally, tolerances can even be further reduced by honing processes. Essential for the adherence of high quality is the interaction of the honing tool and the work piece. The following paper describes the static and dynamic correlation of the process forces of a single stone honing tool equipped with one honing stone and two guiding stones for bores with small diameters (under 20 mm). When working with bores of such small di‐ ameters, a direct measurement of the process forces with a tool‐integrated sensor is usually difficult to realize. Therefore, a theoretical model is being presented in this paper in order to illustrate a possibility of calculating the process forces within the honing tool. Missing coefficients of friction or tangential force coefficients (TFC) within the present system can be determined by an external test bench. Addi‐ tionally, guiding stones of hard metal with two different types of surfaces are being investigated and being compared with conventional guiding stones. The following measurement results are based on MATLAB® simulation which calculates the forces of the honing and guiding stones in consideration.

Data‐driven Weld Nugget Width Prediction with Decision Tree Algorithm Technical Publication. NAMRC2017‐44 Fahim Ahmed, Wayne State University, and Kyoung‐Yun Kim, Wayne State University This paper presents the capability of a decision tree algorithm to realize a data‐driven resistance spot welding (RSW) weldability prediction. Although RSW provides commendable advantages, such as low cost and high speed/high volume operations, the RSW processes are often inconsistent and these significant inconsistencies are a well‐known reliability issue. RSW process and data challenges including inconsisten‐ cy often hinder the utilization of the data‐driven weldability prediction. In this paper, we apply a decision tree algorithm on the RSW da‐ taset collected from an automotive OEM to plot regression trees and to extract decision rules for the weld nugget width prediction. With three RSW test datasets, we conclude that the decision trees help in predicting the nugget width and in determining the impact of design and process parameters to the nugget width response variable.

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Reduction of Tool Wear by Systematic Design of the Tool Clamping Situation Technical Publication. NAMRC2017‐45 Dominik Kraus, Institute for Production Engineering and Forming Machines, Technische Universität Darmstadt, Marc Lieber‐ enz, Institute for Production Engineering and Forming Machines, Technische Universität Darmstadt, and Peter Groche, Insti‐ tute for Production Engineering and Forming Machines, Technische Universität Darmstadt, As a result of the cutting impact, shear cutting processes initiate intensive vibrations in cutting presses and tools. With the aim to improve the press accuracy and tool lifetime, damping systems for reducing the press vibration are state of the art. However, only small attention is given to the tool vibration. Due to its mounting condition in a high‐speed press, the lower tool can vibrate like a bending plate. The ampli‐ tude of the tool displacement depends on the clamping situation of the plate edges. Moreover, the displacement amplitude correlates with the tool wear. Against this background, it is possible to reduce the wear of a shear cutting tool by systematic design of its clamping situa‐ tion. In this paper, a methodology for modelling the dynamic behavior of the tool is given. This approach allows a systematic design of the tool clamping situation with the objective to minimize the vibration and thereby the tool wear. Furthermore, the effect of the clamping situation on different process and tool parameters is given by experimental investigations.

Development of a Smart Plastic Injection Mold with Conformal Cooling Channels Technical Publication. NAMRC2017‐46 Hong‐Seok Park, University of Ulsan and Xuan‐Phuong Dang, Nha Trang University Injection molding is a popular method that is used to make plastic product due to high productivity, efficiency and manufacturability. This paper presents the development of a smart plastic injection mold with conformal cooling channels for making a complex automotive part with variable thickness at some positions. To cool the positions with thicker walls, we proposed local conformal cooling channels in which the cooling lines are in the spiral form. The mold was designed with special inserts. Selective laser melting (SLM) 3D printing has been used to make the inserts with conformal cooling channels inside. In the first phase of the development process, the research results show that conformal cooling channels reduce the cycle time approximately 30% compared to conventional cooling channels. To make the mold to be smart, the temperature of the mold will be monitored by sensor system. In addition, a quality control system is applied on this smart mold in order to ensure the quality of molded part.

Controlling Product Stiffness by an Incremental Sheet Metal Forming Process Technical Publication. NAMRC2017‐47 Daniel Hesse, Institute for Production Engineering and Forming Machines, TU Darmstadt, Florian Hoppe, Institute for Produc‐ tion Engineering and Forming Machines, TU Darmstadt, and Peter Groche, Institute for Production Engineering and Forming Machines, TU Darmstadt Each process and each machine is subject to fluctuations, which lead to deviations in the quality of the components to be manufactured. In order to counter these uncertainties, a flexible incremental sheet forming (ISF) process for the production of truncated cones components is presented. These flexible methods are in contradiction with conventional forming processes, which are mostly designed for steady pro‐ cesses with high production batch. However, with the multi‐technology machine 3D Servo Press, such a highly flexible process can be im‐ plemented on a forming machine for the first time. Through a determination of influence parameters and derivation of a model by means of simulative and experimental investigations, a closed‐loop control for axial stiffness of the part can be realized. The control of the stiff‐ ness is not trivial in that, it depends on the geometric quantities as well as on the material properties, i.e., Young’s modulus. The fluctua‐ tions are inherently present and can be adjusted by a stiffness correction model as shown in the presented work.

Optimization of Process Parameters for Minimization of Specific Power Consumption at Targeted Surface Roughness Technical Publication. NAMRC2017‐48 Nitesh Sihag, Birla Institute of Technology and Science Pilani, Pilani and Kuldip Singh Sangwan, Birla Institute of Technology and Science Pilani, Pilani The global competition and raising concerns over the environmental issues have forced the manufacturing industry to balance the energy consumption, rate of production and quality of the product. This requires the power consumption to be reduced and production rate to be maximized in accordance with the required quality of the product. The required quality, dictated by the surface finish, will be based on the customer preferences, the functional requirement of the product and the product itself. In context to machining, these quantities mainly depend upon the choice of process parameters. This study is an attempt to determine the suitable combination of the cutting parameters to optimize the power and the material removal rate (MRR) for the different targeted values of surface roughness using the predictive models developed by using response surface methodology (RSM). Analysis of variance (ANOVA) test has been used to test the fitness of the model.

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Designing, Manufacturing and Processing of Tailored Blanks in a Sheet‐Bulk Metal Forming Process Technical Publication. NAMRC2017‐52 Robert Schulte, Institute of Manufacturing Technology, Philipp Hildenbrand, Institute of Manufacturing Technology, Michael Lechner and Marion Merklein, Institute of Manufacturing Technology Sheet‐bulk metal forming is an innovative method for the manufacturing of functional components by applying bulk metal forming pro‐ cesses or combined sheet and bulk metal forming processes to sheet metal. The investigated process combines deep drawing and upset‐ ting. Occurring 2D and 3D stress and strain states lead to challenges regarding the material flow control during the forming process to en‐ sure a high die filling and accurate part geometry. Regarding these challenges, the application of conventional semi‐finished products is not expedient wherefore Tailored Blanks with a process adapted sheet thickness distribution are applied to the forming process. The Tailored Blank geometry is designed by a numerical analysis and manufactured by an orbital forming process considering the resulting geometric part properties during deep drawing and upsetting. Therefore, the whole process chain from the conventional circular blank to the finished functional component is linked and modelled. This enables a realistic description of the part properties as the effective plastic strain caused in the manufacturing of semi‐finished products is taken into account in the processing of the material. Subsequently the results are verified by experimental tests.

An Analytical Chip Thickness Model for Performance Assessment in Silicon Carbide Grinding Technical Publication. NAMRC2017‐53 Sanjay Agarwal, B.I.E.T., Jhansi, India, Sanchit Kr. Khare, I.T. M., Gorakhpur, India, Ved Prakash Pandey, I.T. M., Gorakhpur, India, and Manoj Patel, F.I.E.T., Bareilly, India The chip‐thickness models, used to assess the performance of grinding processes, play important role in predicting the surface quality. In the present paper, an attempt has been made to develop a new chip‐thickness model for the performance assessment of Silicon Carbide grinding by incorporating the real contact length in the existing basic chip‐thickness model. The new model has been validated by conduct‐ ing experiments, taking the surface roughness as a parameter of evaluation.

Support Structure Development and Initial Results for Metal Powder Bed Fusion Additive Manufacturing Technical Publication. NAMRC2017‐54 Dakota Morgan, Iowa State University, Emmanuel Agba, Iowa State University, and Chris Hill, Iowa State University The process of metal additive manufacturing is a relatively new method of fabricating complex parts in industry. Due to the infancy of the technology, limited documentation is available on how to rapidly and efficiently design and fabricate a given part. This paper covers one of the main practical issues of this technology, support generation and design when working with powder bed fusion metal additive manu‐ facturing. This process requires support structures to hold and secure a part being built onto a base plate. The following paper will provide an introduction to the main options of support structure, grid and full support, as well as cover key understanding and developments with support structures for metal additive manufacturing. These support options and their variability will be discussed along with a methodology of rapidly obtaining baseline parameters for their use in fabrication.

Multi‐Objective Optimization in Microturning of Titanium Alloy using Particle Swarm Technique Technical Publication. NAMRC2017‐56 Gopikrishnan A, Saranathan College of Engineering, Trichy and Kanthababu Mani, Anna University, Chennai In this work, multi‐objective optimization is carried out for tool based microturning process parameters for titanium alloy using particle swarm optimization (PSO). The experiments are carried out by response surface methodology (RSM) using central composite design (CCD). The input process parameters such as speed, feed and depth of cut are varied at three levels (low, medium and high). The output parame‐ ters considered are higher material removal rate (MRR), low surface roughness (Ra) and low tool wear (TW). From the PSO analysis, it is observed that the combination of microturning parameters such as speed (47 m/min), feed (20 μm/rev) and depth of cut (50 μm) results in high MRR, low Ra and low tool wear simultaneously. The results obtained from this study will be useful to manufacturing engineers for selecting the appropriate input microturning process parameters for manufacturing micro components using titanium alloy, which has wide applications in aerospace, marine, etc.

A Generic Sustainability Assessment Model towards Consolidated Parts Fabricated by Additive Manufacturing Process Technical Publication. NAMRC2017‐57 Sheng Yang, McGill University, Tanushree Talekar, McGill University, Mohamed Aslam Sulthan, McGill University, and Yaoyao Fiona Zhao, McGill University, Part consolidation (PC) is one of the effective ways to simplify product structure. Through part consolidation, it is expected to reduce weight and size, minimize assembly operation, improve performance, and prolong service life. As additive manufacturing (AM) evolves into 142 an end‐of‐use product manufacturing process, the possibility of part consolidation has further increased. However, the life‐cycle sustaina‐ bility aspect related to PC with AM is rarely known. To support design for environment, this paper proposes a framework to systematically investigate the environmental impact of PC on production, service, and end‐of‐life (EoL) activities. In this framework, generic quantitative models for PC‐related sustainability assessment of these life‐cycle stages are presented from an incremental perspective. In each model, change in sustainability indices are calculated with respect to the change propagated from the design change (PC) when PC is achieved. From the model, consolidated design shows definite promise at assembly and service stage; howevers, there is still uncertainty in deciding the sustainability benefit at manufacturing and EoL stage. In this paper, a case study with a redesigned floor attachment in a train is exem‐ plified and binder jetting (BJ) AM process is chosen as the default manufacturing process. Due to the lack of data of EoL and minor effect on maintenance as well as fuel economy, only the environmental impact on production is analyzed. The result reveals two important implica‐ tions: 1) consolidated design shows significant promise in reducing energy consumption and environmental impact (average 20%), but it results in an increase of health toxicity level; 2) reduction of environmental impact (up limit 13.2%) at assembly stage is not obvious. In the end, important conclusions and future research are outlined.

Variability of the Machinability Along the Cross Section of Ductile Iron Produced by Continuous Casting Technical Publication. NAMRC2017‐58 Aécio De Sousa, Federal Technological University of Parana, Álisson Machado, Federal University of Uberlandia and Pontifícia Universidade Católica do Paraná, Rosemar Da Silva, Federal University of Uberlandia, and Wilson Gursser, Tupy S.A. and UDESC In industry, the increase in the search for new materials is related to the cost and to the strength to weight ratio. In an effort to achieve these requirements new materials with low density and similar strength are employed or the resistance of traditional materials are in‐ creased by the addition of alloying elements or heat treatments. The choice usually depends on the mechanical and thermal properties and other aspects, such as manufacturing costs, recyclability, customer acceptance and machinability. Cast usually offer good machinabil‐ ity and low production cost, but long bars produced by continuous casting may present variability in their properties, including machinabil‐ ity along their cross sections. This is particularly true in bars with large cross sections. This work evaluates the behavior of the machining torque and surface roughness along the cross section of rectangular bars of nodular cast iron produced by continuous casting in slot‐milling operation. It was found that the pearlite microstructure of the matrix and the mechanical strength contributed to the highest machining torque presented by the intermediate and core regions, but they did not affect the surface roughness significantly.

Incorporation of Physics‐Based Machining Models in Real‐Time Decision Making via Metamodels Technical Publication. NAMRC2017‐60 Bhisham Sharma, Purdue University, Rishab Harikrishnan, Purdue University, Stuart McCrorie, Purdue University, Marc Con‐ ner, Purdue Universit, Meisam Salahshoor, GE Global Research Center, Abhijit Deshmukh, Purdue University and Michael Sangid, Purdue University Physics‐based machining models typically require significant computational resources and time which makes them impractical for quick process optimization calculations in an industrial shop‐floor setting. In this paper, we demonstrate the use of metamodeling to help over‐ come the inefficiency of traditional engineering modeling tools. Metamodels are surrogate models of an existing model that provide an approximate relationship between a set of input process variables and output response variables. Using 2D orthogonal machining as a case study, we utilize the Response Surface Methodology to develop surrogate models which provide approximate relationships between ma‐ chining variables such as cutting tool speed, depth of cut, rake angle, and tool and workpiece materials, and response variables such as maximum residual stress, residual stress transition depth, surface hardness, tool wear, and wear depth. The Kriging interpolation method is used to generate response surface maps. Finally, we develop the idea of a mobile application which can be easily deployed in an industrial setting to efficiently use such metamodels for physics‐based decision making during the initial manufacturing process development phase.

Human Motion Prediction for Human‐Robot Collaboration Technical Publication. NAMRC2017‐61 Hongyi Liu, KTH Royal Institute of Technology and Lihui Wang, KTH Royal Institute of Technology In human‐robot collaborative manufacturing, industrial robots would work alongside human workers who jointly perform the assigned tasks seamlessly. A human‐robot collaborative manufacturing system is more customised and flexible than conventional manufacturing systems. In the area of assembly, a practical human‐robot collaborative assembly system should be able to predict a human worker’s inten‐ tion and assist human during assembly operations. In response to the requirement, this research proposes a new human‐robot collabora‐ tive system design. The primary focus of the paper is to model product assembly tasks as a sequence of human motions. Existing human motion recognition techniques are applied to recognise the human motions. Hidden Markov model is used in the motion sequence to gen‐ erate a motion transition probability matrix. Based on the motion transition probability matrix, human motion prediction becomes possi‐ ble. The predicted human motions are evaluated and applied in task‐level human‐robot collaborative assembly.

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An Optimization Model for Operating Room Scheduling to Reduce Blocking Across the Perioperative Process Technical Publication. NAMRC2017‐62 Amin Abedini, University of Kentucky, Wei Li, University of Kentucky, and Honghan Ye, University of Kentucky Operation room (OR) scheduling is important. Because of increasing demand for surgical services, hospitals must provide high quality care more efficiently with limited resources. When constructing the OR schedule, it is necessary to consider the availability of downstream re‐ sources, such as intensive care unit (ICU) and post anesthesia care unit (PACU). The unavailability of downstream resources causes block‐ ings between every two consecutive stages. In this paper we address the master surgical schedule (MSS) problem in order to minimize blockings between two consecutive stages. First, we present a blocking minimization (BM) model for the MSS by using integer program‐ ming, based on deterministic data. Second, we test the effectiveness of our model under variations in case times and patient arrivals, by using simulation. The simulation results show that our BM model can significantly reduce the number of blockings by 94% improvement over the base model

Flexible Fixturing Configuration Design of Thin‐Walled Part Based on Magnetorheological Effect Technical Publication. NAMRC2017‐63 Yongqing Wang, Dalian University of Technology, Qi Luo, Dalian University of Technology, Haibo Liu, Dalian University of Technology, Xianjun Sheng, Dalian University of Technology, and Jun Zhang, Dalian University of Technology, In this article, a novel flexible fixturing configuration based on magnetorheological (MR) effect for thin‐walled part was designed. In this configuration, two crucial issues need to be concerned. One was the force needed to support the thin‐wall part efficiently when the mag‐ netorheological fluid (MRF) solidified in certain magnetic field, the other was the layout method of magnet array to arrange the magnetic field reasonably. Firstly, the relationship of MRF elastic modulus and the magnetic induction intensity was obtained experimentally. And then, the distribution of exciting magnetic field was analyzed numerically, which was aimed to optimize the NdFeB electric permanent magnet (EPM) array layout. From the analysis result, a reliable fixturing status was designed for thin‐walled part to resist machining force and reduce machining deformation by the proposed method.

Dynamic Detection of Instability Defects in Tube Rotary Draw Bending Technical Publication. NAMRC2017‐64 Enrico Simonetto, University of Padua – DII, Andrea Ghiotti, University of Padua – DII, Stefania Bruschi, University of Padua – DII and Roberto Gemignani, BLM group Tube rotary draw bending is commonly used to manufacture complex shaped elements in a wide range of geometries and applications. When thin‐walled tubes are formed with small bending radii, the components may suffer of wrinkling at the intrados due to the critical process parameters. Off‐line optimization approaches are used to predict the correct process parameters and tool geometries, but they require accurate material characterization or numerical simulation analyses, and strongly depend on the scattering of the geometry and properties of the rough material. Therefore, the availability of on‐line approaches to provide an adaptive response of the machine, i.e. in terms of dies velocity or applied pressure, is crucial for the efficiency of highly automated production lines. The paper presents the investigations carried out to assess the capability of dynamic analysis techniques to detect the instability defects that may affect the tubes in critical operating conditions. A new experimental approach, based on the analysis of dynamic data from the machine, is presented, as well as the evaluation of its performances when applied to the industrial process. The proposed approach ap‐ pears promising for the detection of wrinkling, once they appear on the tube, and capable to give accurate feedback for the fast adjust‐ ment of the process parameters.

A Framework for Evaluating Additive Manufacturing Feasibility: SAM‐CT Technical Publication. NAMRC2017‐65 Susan Smyth, General Motors Corporation, and Michael Grieves, Florida Institute of Technology Additive manufacturing (AM) is a rapidly evolving technology with significant promise to revolutionize the manufacturing industry as a dis‐ ruptive technology. AM as a technology is rapidly advancing on a number of dimensions, speed, size, quality, and material types to name a few. As these advances occur, AM is expected to develop over time from a prototyping to full scale factory floor automotive production technology. New manufacturing technologies always need to be assessed by asking two critical questions: 1) Can an item be manufac‐ tured with this technology? and 2) Should it be manufactured with this technology? As AM evolves, these questions will need to be contin‐ ually revisited. This paper will propose a framework, SAM‐CT for answering these questions. SAM‐CT stands for Size, Accuracy, and Material – Cost and Throughput. The use of SAM is to answer “Can it be AM manufactured?”, while CT is used to evaluate “Should it be AM manu‐ factured?”. The paper will describe each of SAM‐CT areas and the data elements, including CAD, needed for evaluation in order to facilitate an automated approach to SAM‐CT.

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Optimum Process Parameters for Springback Reduction of Single Point Incrementally Formed Polycarbonate Technical Publication. NAMRC2017‐66 William Edwards, Penn State University, Tyler Grimm, Penn State University, Ihab Ragai, Penn State University and John Roth, Penn State University Many industries and researchers are attempting to minimize manufacturing costs of forming low volume components. Single point incre‐ mental forming (SPIF) is used to form a single piece of material using a CNC mill, in which a tool path for the desired geometry is created to guide the tool in incremented steps to deform a thin sheet of material. Throughout this process, residual stresses accumulate, causing springback to occur after the fixture is no longer constraining the material. This research experiments with the effect of SPIF forming pa‐ rameters on the springback of polycarbonate sheets. Springback reduction was also obtained by applying heat to the formed sheet. The parameters studied included rotational spindle speed, feed rate, step size, and heat. The spindle rotational speed and feed rate experi‐ ments show a decrease in springback; however, applying heat proved to be most effective when reducing springback.

Hybrid CO2 Laser Waterjet Heat (LWH) Treatment of Bindered Boron Nitride Composites with Hardness Improvement Technical Publication. NAMRC2017‐67 Jingnan Zhao, Tianjin University of Science and Technology, Pranav Shrotriya, Iowa State University, and Kwang Shiong Wong, Boron nitride (BN) material is chemically and thermally stable which makes it desirable for high speed machining in demanding chemical and thermal environments. Although the hardness of BN material is well below that of single polycrystalline diamond (PCD), a laser water‐ jet heat (LWH) treatment process provides a new approach to achieve hardness values that are comparable to diamond hardness. This study investigates the hardness change of LWH‐treated bindered cBN/TiN and cBN/AlN composites. Results indicate that measured hard‐ ness increase is dependent on the laser beam pass and the distance from the beam center.

Big Data Analytics Based Fault Prediction for Shop Floor Scheduling Technical Publication. NAMRC2017‐68 Wei Ji, KTH Royal Institute of Technology, and Lihui Wang, KTH Royal Institute of Technology The current task scheduling mainly concerns the availability of machining resources, rather than the potential errors after scheduling. To minimise such errors in advance, this paper presents a big data analytics based fault prediction approach for shop floor scheduling. Within the context, machining tasks, machining resources, and machining processes are represented by data attributes. Based on the available data on the shop floor, the potential fault/error patterns, referring to machining errors, machine faults and maintenance states, are mined for unsuitable scheduling arrangements before machining as well as upcoming errors during machining. Comparing the data‐represented tasks with the mined error patterns, their similarities or differences are calculated. Based on the calculated similarities, the fault probabili‐ ties of the scheduled tasks or the current machining tasks can be obtained, and they provide a reference of decision making for scheduling and rescheduling the tasks. By rescheduling high‐risk tasks carefully, the potential errors can be avoided. In this paper, the architecture of the approach consisting of three steps in three levels is proposed. Furthermore, big data are considered in three levels, i.e. local data, local network data and cloud data. In order to implement this idea, several key techniques are illustrated in detail, e.g. data attribute, data cleansing, data integration of databases in different levels, and big data analytic algorithms. Finally, a simplified case study is described to show the prediction process of the proposed method.

Compliance Analysis of a Novel Tool Head with Parallel Kinematics Considering Joint Clearance Technical Publication. NAMRC2017‐69 Guang Yu, Tsinghua University, Jun Wu, Tsinghua University, Liping Wang, Tsinghua University, Zhufeng Shao, Tsinghua University, and Ying Gao. With the proposed novel 3 degrees of freedom (DoFs) tool head of 3‐PRRU parallel kinematics, this paper investigates the compliance of the 3DoFs tool head by taking the joint clearance into account. Since the moving platform needs to bear the external wrench, the internal force of passive joints is deduced with the kinetostatic analysis. Then the compliance model is established considering the joint clearance. Based on this model, the mapping relationship between the clearance and position error of the joint is analyzed. The error transformation matrix is derived by the differentiation of kinematic equations, and translational and rotational errors of the moving platform caused by the joint clearance are determined. Furthermore, the stiffness matrix of the 3DoFs tool head is derived by using the matrix structural analysis. The total deflection of the moving platform is obtained by considering both the joint clearance and the elastic deflection deduced from the stiffness matrix. Simulation results indicate that the deflection caused by joint clearance has a significant impact on the accuracy of the moving platform, and should be considered in the accuracy analysis.

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Particle Learning in Online Tool Wear Diagnosis and Prognosis Technical Publication. NAMRC2017‐70 Jianlei Zhang, North Carolina State University, Binil Starly, North Carolina State University, Yi Cai, North Carolina State Uni‐ versity, Yuan‐Shin Lee, North Carolina State University, and Paul Cohen, North Carolina State University Automated tool condition monitoring is critical in intelligent manufacturing to improve both productivity and sustainability of manufactur‐ ing operations. Estimation of tool wear in real‐time for critical machining operations can improve part quality and reduced scrap rates. This paper proposes a probabilistic method based on particle learning by building a linear system transition function whose parameters are updated by online in‐process observations of the machining process. By applying Particle Learning (PL), the method helps to avoid devel‐ oping the closed form formulation for a specific tool wear model. It increases the robustness of the algorithm and reduces the time com‐ plexity of the computation. The application of the particle learning method is demonstrated using experiments performed on a typical milling machine. We have demonstrated one‐step and two‐step look ahead tool wear state prediction using online indirect measurements from vibration signals. Additionally, the study also estimates remaining useful life (RUL) of the cutting tool inserts.

Finish Turning of Ti‐6Al‐4V with the Atomization‐Based Cutting Fluid (ACF) Spray System Technical Publication. NAMRC2017‐71 Chandra Nath, Hitachi America, Ltd., Shiv Kapoor, University of Illinois at Urbana‐Champaign, and Anil Srivastava, The Uni‐ versity of Texas Rio Grande Valley Product quality and productivity are important factors in manufacturing industries, especially when dealing with cumbersome materials like titanium. Cooling and lubrication effects offered by the associated metalworking fluid application system play a vital role in determining these factors, especially during finish cutting. Recently, the atomization–based cutting fluid (ACF) spray system has shown promising cool‐ ing and lubrication effects during rough turning of titanium at the macro–scale, but yet to be examined during finish cutting (e.g., depth of cut and feed rate 0.2 mm or lower). This paper aims to study the effect of the ACF spray system on machining performance during finish turning of Ti‐6Al‐4V. In the first set of experiments, two spray parameters (viz., gas velocity and flow rate) and cutting parameters (viz., cutting speed, feed rate and depth of cut) are varied to select the most suitable condition for the application of the ACF spray system. Ma‐ chining outputs are evaluated in terms of nose wear, cutting temperature, surface roughness, roundness error, chip morphology, and part hardness. A separate set of experiments is then performed to compare the performance of the ACF spray system against compressed air (dry) and flood coolant conditions. It is found that, even a lower fluid flow rate of 1.5 mL/min (10 vol.%) at a lower gas velocity of the spray system outperforms the other two coolant conditions, thus further enhancing the performance of environmentally‐friendly manufacturing process.

Reduction of Friction using Electrospun Polymer Composite Microbeads Emulsified in Mineral Oil Technical Publication. NAMRC2017‐72 Danny Wong, University of Calgary, Jesus Resendiz, University of Calgary, Philip Egberts, University of Calgary, and Simon Park, University of Calgary The tribological properties of electrospun polymer‐based microbeads dispersed in mineral oil were investigated. Microbeads composed of polyvinypyrrolidone, oxide and multi‐walled carbon nanotubes (MWCNTs) were generated using an electrospinning apparatus. The influence of various electrospinning parameters such as voltage, injection rate and concentration were investigated. The friction reducing ability of microbeads enhanced lubricants were evaluated using a reciprocating tribometer system. In the tribometer, a hemispherical ruby counter surface was slid against an aluminum 6061 workpiece in the presence of a mineral oil‐based lubricant. Friction was reduced by 13% to 27% when the composite microbeads were emulsified in the base mineral oil.

High‐Resolution Electrohydrodynamic (EHD) Direct Printing of Molten Metal Technical Publication. NAMRC2017‐73 Yiwei Han, North Carolina State University and Jingyan Dong, North Carolina State University In this paper, we developed a high‐resolution direct printing process for molten metal using Elctrohydrodynamic (EHD) printing technology. We characterized and verified the effect of the electric field on the printing process, which can continuously print fine molten metal fila‐ ment from nozzle without requiring any pneumatic pressure. By comparing direct extrusion with pneumatic pressure and EHD printing with a voltage, we found that the EHD printing can effectively reduce the printed filament dimension down to less than 50μm and achieve better quality of the printed features. We successfully applied EHD printing to print high‐resolution 2D patterns and some high aspect‐to‐ratio 3D structures, which demonstrated the potential capabilities of EHD printing process in producing fine metal structures and microelectronic fabrication.

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A Virtual Sensing Based Augmented Particle Filter for Tool Condition Prognosis Technical Publication. NAMRC2017‐74 Jinjiang Wang, China University of Petroleum, Beijing, Yinghao Zheng, China University of Petroleum, Beijing, Peng Wang, Case Western Reserve University, and Robert X. Gao, Case Western Reserve University Timely evaluation and prediction of tool condition is critical to establish optimized maintenance plans in order to enhance production, minimize costly downtime. This paper presents an augmented particle filter based on virtual sensing technique with support vector regres‐ sion (SVR) model to account for uncertainties in the tool condition degradation process. Tool condition is predicted by recursively updating a physics‐based tool condition degradation model with virtual measurement approximately estimating tool degradation condition through virtual sensing technique, following a Bayesian inference scheme. Additionally, in order to improve estimation accuracy of virtual sensing model, different state‐of‐the‐art dimension reduction techniques including principal component analysis (PCA) and its kernel version (KPCA), locality preserving projection (LPP) method have been investigated for feature fusion in a virtual sensing model, and the KPCA method performs best in terms of sensing accuracy. Afterwards, virtual measurement is then incorporated into particle filter. The effec‐ tiveness of the developed method is experimentally validated in a set of machining tool run‐to‐failure tests on a computer numerical con‐ trol (CNC) milling machine.

Amplitude Ratio: A New Metric for Milling Stability Identification Technical Publication. NAMRC2017‐76 Mark Rubeo, University of North Carolina at Charlotte and Tony Schmitz, University of North Carolina at Charlotte This paper describes a metric referred to as the “amplitude ratio” for evaluating the stability of milling operations via time domain simula‐ tion. The amplitude ratio is used to generate contour diagrams that identify stability behavior over a range of spindle speeds and axial depths of cut. The suitability of the amplitude ratio stability metric is evaluated through comparison to independently published results obtained using semi‐analytical techniques.

Corrosion Behavior of Titanium Implant with Different Surface Morphologies Technical Publication. NAMRC2017‐77 Guisen Wang, Shandong University, Yi Wan, Shandong University, and Teng Wang, Shandong University Titanium, as one of vital biomaterials to implant, was widely used for the repairing or replacement of bone in clinic. In order to improve the interaction of biomaterials surface with tissue, various surface structures were fabricated by surface medication methods in previous re‐ searches. However, the corrosions of biomedical metallic materials were inevitable and the release of ions from their surfaces can lead to toxicity and allergen after which were implanted into the human body. Therefore, the corrosion behavior of titanium with different surface morphologies was evaluated in Ringer's solution at ambient temperature in this study. In terms of surface morphologies, four groups of samples (smooth surface (P), microstructure surface (M), micro/nanostructure surface (MN) and functionalized micro/nanostructure with sliver nanoparticles (Ag‐PDA)) were prepared and their corrosion behaviors were measured by using electrochemical workstation. Through comparing to electrochemical parameters in Ringer's solution, surface functionalization of micro/nanostructure showed the best corrosion resistance with respect to others. In addition, the corrosion behavior of microstructure surface sample was lower than smooth sample. Titanium with various surface morphologies all displayed out good corrosion resistance except for microstructure sample and the order of their corrosion resistance were Ag‐PDA>MN>P>M. The results indicated that the suitable surface morphologies were important to improve the corrosion resistance of titanium via applying surface modification methods. In particular, the corrosion resistance of titanium would be significantly increased after covering a layer of barrier.

Tool Temperature in Slotting of CFRP Composites Technical Publication. NAMRC2017‐78 Mohamed El‐Hofy, University of Birmingham, Sein Leung Soo, University of Birmingham, David Aspinwall, University of Birmingham, Wei‐Ming Sim, Airbus Operations UK, David Pearson, Seco Tools UK, Rachid M'Saoubi, Seco Tools UK and Peter Harden, University of Birmingham Following a brief review on the effects of process parameters on cutting temperatures and associated workpiece integrity when machining carbon fibre reinforced plastic (CFRP) composites, the paper details experimental work to assess tool temperature regimes and machinabil‐ ity when slot milling CFRP. This involved variation in workpiece lay‐up, tool geometry, cutting environment and operating levels. Typically, cutting temperatures varied between ~180‐350˚C with fibres orientated at 0˚ and 45˚ producing the highest temperatures and cutting forces. Worn tooling and dry cutting also produced less favourable results. Increasing cutting speed from 200 to 350 m/min caused a rise in temperature by an average of ~25% while increasing feed rate from 0.03 to 0.06 mm/tooth produced a reduction of ~18%.

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The Effects of Welding Parameters and Backing Plate Diffusivity on Energy Consumption in Friction Stir Welding Technical Publication. NAMRC2017‐82 Woongjo Choi, University of Wisconsin – Madison, Justin Morrow, University of Wisconsin – Madison, Frank Pfefferkorn Uni‐ versity of Wisconsin – Madison, and Michael Zinn, University of Wisconsin ‐ Madison The objective of this work is to investigate the effects of welding parameter variation and backing plate diffusivity on energy consumption in friction stir welding (FSW). FSW is a solid‐state welding process, where joints are created below the solidus temperature of the work‐ piece. As a result, FSW is known for being energy efficient and environmentally friendly. However, a method of quantifying the energy consumption in FSW, for a variety of operating conditions, has not been well established. In order to fully understand the energy consump‐ tion of FSW, both process power and wall plug power were measured on a 3‐axis CNC mill at various feed rates, spindle speeds, and with different backing plates. The results of monitoring the process power suggest that using a low thermal diffusivity backing plate has a bene‐ ficial effect on the instantaneous power consumption and on the total energy consumption during a weld. Conversely, tensile tests also showed that welds over a high thermal diffusivity backing plate consistently failed inside the weld zone, corresponding to a lower welding temperature and lack of penetration in the weld zone. These results suggest that using a low thermal diffusivity backing plate can both reduce energy consumption during FSW while also helping to achieve full penetration welds, while high feed rate is good for both welding productivity and reducing energy consumption per length of weld.

Maximizing Operating Room Performance Using Portfolio Selection Technical Publication. NAMRC2017‐83 Vivek Reddy Gunna, University of Kentucky, Amin Abedini, University of Kentucky, and Wei Li, University of Kentucky The operating room (OR) is responsible for most hospital admissions and is one of the most cost and work intensive areas in the hospital. From recent trends, we observe an ironic parallel increase among expenditure and waiting time. Therefore, improving OR scheduling has become obligatory, particularly in terms of patient flow and benefit. Most of the hospitals rely on average patient arrivals and processing times in OR planning. But in practice, variations in arrivals and processing times causes high instability in OR performance. Our model of optimization provides OR schedules maximizing patient flow and benefit at a fixed level of risk using portfolio selection. The simulation results show that the performance of the OR has a direct relationship with the risk.

Selective Laser Sintering of Phase Change Materials for Thermal Energy Storage Applications Technical Publication. NAMRC2017‐84 Malek Nofal, University of Illinois at Chicago, Yayue Pan, University of Illinois at Chicago, and Said Al‐Hallaj, AllCell Technolo‐ gies With a global concern about energy and carbon dioxide emissions, renewable energies have attracted extensive attentions. One of the crucial aspects is waste heat recovery and thermal energy storage. Phase change materials have unique merits in latent heat thermal ener‐ gy storage, due to its capability of providing a high energy density storage by solidifying/melting at a constant temperature. The increased global demand for phase‐change‐materials‐enabled energy storage systems exposed limitations of established manufacturing methods in terms of processing speed, material waste, and flexibility. In this research, a phase change composite was developed by mixing paraffin wax with a thermal conductive expanded graphite. Using a layer‐by‐layer laser sintering method, these two materials combined at a mi‐ cro‐scale, forming a phase change composite that possesses good thermal conductivity, superior latent heat, and good mechanical strength. This work investigated the key parameters for successful production of paraffin wax/expanded graphite composite using laser sintering technique. In particular, the paraffin wax is melted and then impregnated into the inter‐particle pores of expanded graphite through capillaries. It serves as a binder that bonding the expanded graphite molecules together as into a solid form‐stable object in the laser sintering process. To validate the developed sintering process, both single‐layer and multi‐layer samples with various geometries have been fabricated and tested. Results showed good structural integrity and functionality of the printed parts. The produced thermal conduc‐ tivity was in the range of 1.4 ‐ 1.9 W/m.K for single‐layer and 0.75 – 0.80 W/m.K for multi‐layer, and the latent heat of fabricated samples is in the range of 161‐166 kJ/kg for both single‐layer and multi‐layer structures. These experimental results verified that the developed laser sintering process could be used as an effective nontraditional manufacturing technique for fabricating phase change materials for thermal energy storage applications.

Characterization of Weld Attributes in Ultrasonic Welding of Short Carbon Fiber Reinforced Thermoplastic Composites Technical Publication. NAMRC2017‐85 Kaifeng Wang, University of Michigan, Daniel Shriver, University of Michigan, Yang Li, University of Michigan, Mihaela Banu, University of Michigan, S. Jack Hu, University of Michigan, Guoxian Xiao, General Motors R&D Center, Jorge Arinez General Motors R&D Center, and Hua‐Tzu Fan, General Motors R&D Center

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Ultrasonic welding is a well‐known technique for joining thermoplastics and has recently been introduced for joining carbon fiber rein‐ forced thermoplastic composites. However, there is a lack of understanding on how weld quality attributes develop under different welding conditions. In this paper, ultrasonic welding of an injection molded short carbon fiber reinforced composite is tested to investigate three important weld attributes, degree of bonding, weld area, and horn indentation. To understand the effects of the welding parameters on the weld attributes, only the welding energy is varied while the other weld variables, trigger force, welding speed, holding time, and ampli‐ tude, are kept constant. After examining the microstructure of the cross sections and the fracture surface of the welded joints, several ob‐ servations were obtained. First, the bonding mechanism for the carbon fiber reinforced composite is mainly through the polymer‐polymer interface healing of the composites, which is the same as the bonding mechanism for ultrasonic welding of thermoplastics. Second, the degree of bonding and weld area increase with an increase in welding energy until they reaches a threshold. As welding energy continues to increase, the degree of bonding will decrease due to material degradation as pores develop, but weld area will remain unchanged. Final‐ ly, there are three different failure modes by analyzing the joint fracture: interfacial separation, nugget shear fracture, and nugget pull‐out fracture. The failure mode changes with the change of welding energy. These observations provide insights toward development of a ro‐ bust ultrasonic welding process for fiber reinforced composites.

General Motor Family Flexibility Design based on NICA‐II Technical Publication. NAMRC2017‐86 Wei Wei, School of Mechanical Engineering and Automation, Beihang University, Pingyuan Wang, School of Mechanical En‐ gineering and Automation, Beihang University, Zhenyu Tian, School of Mechanical Engineering and Automation, Beihang University, Jun Ji, Information Center of China North Industries Group Corporation, and Cui Jin School of Mechanical Engi‐ neering and Automation, Beihang University This paper proposes a product family optimum design method based on a Novel Immune Clonal Algorithm (NICA‐II) to realize product fam‐ ily flexibility design. Firstly, the product family dynamic uncertain requirements analysis and forecasting techniques is researched in this paper, aims to improve the dynamic response ability of the product family to the change of the market demand in the future. Afterwards an improved immune clonal algorithm was proposed to solve the general motor family flexibility design optimization problem. At last the Pareto‐optimal solution was obtained via NICA‐II, then the Fuzzy Optimization Method (FOM) is presented to extract the optimal solution of multi‐objective optimization problem. The design of a family of general motor is used as an example to benchmark the efficiency and superiority of the proposed approach.

Thin‐Slots Machining of Compliant Needles for Vibration‐assisted Medical Insertion Technical Publication. NAMRC2017‐87 Yuan‐Shin Lee, North Carolina State University, Yi Cai, North Carolina State University, and Jason Moor, Pennsylvania State University This paper presents a geometric analysis modeling and control of micro‐slots manufacturing for compliant needles fabrication and biomed‐ ical applications. In medical applications, the insertion accuracy of medical needles is closely related with the insertion forces encountered during the relative motion between needle and tissue. This paper presents a new design of compliant needle featured by 4‐bevel tip and shaft slots for vibratory needle insertion, whose capability in reducing insertion force has been demonstrated in our earlier works. The ef‐ fects of the design variables of the slots on needle tip vibration pattern are studied using harmonic analysis with a focus on slot width and slot depth. This paper presents a method of using harmonic analysis to identify the effects of the design variables of the slots on needle tip vibration pattern with a focus on slot width and slot depth. Based on the analysis results, an analytical model is presented and validated for accurate calculation of slot depth in the EDM‐based (electrical discharge machining) fabrication process. To use slot width to fine tune the tip vibration, a methodology involving additional electrode motions after initial slot cutting is proposed to increase slot width. This paper provides practical design and manufacturing guidance for vibration‐assisted medical insertion devices. Examples and experimental results are presented in the paper for demonstration and validation. The presented geometric analysis model and manufacturing techniques can be used for micro‐slots fabrication and biomedical applications.

A Universal Velocity Limit Curve Generator Considering Abnormal Tool Path Geometry for CNC Machine Tools Technical Publication. NAMRC2017‐88 Mo Chen, Shanghai Jiao Tong University, Xue‐Cheng Xi, Shanghai Jiao Tong University, Wan‐Sheng Zhao, Shanghai Jiao Tong University, Hao Chen Shanghai Jiao Tong University, and Hong‐Da Liu, Shanghai Jiao Tong University Non‐linear parametric curves, such as B‐spline curves, are becoming increasingly available in modern CNC (Computer Numerical Control) systems. The smoothness of parametric curves offers higher order of continuity and thus invokes less vibration in machines as compared to short line segments. Nevertheless, the computations for velocity limit curves, velocity profiles and interpolation points are quite compli‐ cated and time‐consuming and therefore approximation methods are applied. Unnecessary accelerations and decelerations, which cost additional time of motion, can be caused by inaccurate computations of the velocity limits around tiny corners. To overcome the problem, the unit arc length increment scanning method (UALISM) is proposed to reduce the time of movement and to improve the efficiency. The 149 scanning interval is fixed at 1 BLU (basic length unit) which is irrelevant to the type, size and shape of the tool path curve. The constraints of chord height errors and axis accelerations are considered and the velocity limit for the specified scanning point is computed using the coor‐ dinates of multiple scanning points near the specified scanning point. Simulation results show that the unnecessary accelerations and de‐ celerations can be avoided and thus the total motion time can be reduced by UALISM.

Fabrication and Electrical Characterization of Multi‐Layer Capacitive Touch Sensors on Flexible Substrates by Additive E‐jet Printing Technical Publication. NAMRC2017‐89 Hantang Qin, Georgia Southern University, Jingyan Dong, North Carolina State University, and Yuan‐Shin Lee, North Carolina State University Current consumer electronics, in particular touch displays and flexible electronics, were limited by the properties of existing commercial transparent conductor materials used as electrodes both in flat panel display and capacitive touch sensors. In this paper, an alternative fabrication technique using silver nanoink that can be used for rapid prototyping of high‐resolution electrode arrays to replace indium tin oxide (ITO) for flexible electronics was presented. By direct printing silver nanoparticles on flexible substrates, capacitive touch sensors were fabricated onto polyethylene terephthalate (PET) film. Experiments were conducted to study the feasibility of electrohydrodynamic inkjet printing (e‐jet printing) of high‐resolution electrodes for touch sensors. Sensitivity of sub‐20 µm capacitance sensor array was inves‐ tigated in the study for droplet and humidity detection applications. The rapid prototyping method makes a significant impact in enabling simultaneously (1) customized and flexible touch sensors, (2) cost‐effective manufacturing, and (3) high resolution and good sensitivity. The presented techniques can be used for the on‐demand fabrication of customized conductive patterns for flexible and wearable electronics.

Operations Status and Bottleneck Analysis and Improvement of a Batch Process Manufacturing Line using Discrete Event Simulation Technical Publication. NAMRC2017‐91 Sriram Velumani, Eastern Michigan University and He Tang, Eastern Michigan University There are many product and process variations in the production systems of batch processing. Planning and executing such manufacturing operations are a significant and challenging task. Discrete Even Simulation is an effective tool to consider the complex product and process variations and predict the operations status and bottlenecks of an existing system, which is critical to the operation planning, execution, and improvement. This study simulates the first stage of tire manufacturing in batch process involving product variation and process vari‐ ants. The study analyses the operations status, bottlenecks, and the interdependence of the manufacturing activities. In the simulation, the efficiency of machines, reliability, maintenance, and setup time are considered. The simulation identifies the operation bottleneck and proposes process changes for the improved production efficiency. The buffer status are analyzed in different scheduling operations to re‐ veal the requirement/necessity of changes or addition of the buffer into the system. The effects of increasing the number of machines and other resources are also reviewed for throughput improvement.

Adaptive Learning Control for Thermal Error Compensation of 5‐Axis Machine Tools Technical Publication. NAMRC2017‐92 Philip Blaser, IWF ETH Zurich, Florentina Pavliček, IWF ETH Zurich, Kotaro Mori, MMCL Kyoto University, Josef Mayr, Inspire AG, Sascha Weikert Inspire AG, and Konrad Wegener, IWF ETH Zurich The research presented in this paper shows an adaptive approach for long‐term thermal error compensation of 5‐axis machine tools (MT). A system of differential equations is used to compute the model based compensation values. The model can predict thermal displacements of the tool center point (TCP) based on changes in the environmental temperature, load‐dependent changes and boundary condition changes and states, like machining with or without cutting fluid. The model based compensation of the rotary axis of a 5‐axis MT is then extended by on‐machine measurements. The information gained by the process‐intermittent probing is used to adaptively up‐date the model parameters, so that the model learns how to predict thermal position and orientation errors and to maintain a small residual error of the thermally induced errors of the rotary axis over a long time. This approach not only increases the MT accuracy but also reduces the amount of time spent on preproduction model parameter identifi‐ cation. Additionally an algorithm has been developed to dynamically adjust the length of the on‐machine measurement intervals to maintain a high productivity and a constant deviation of the machined parts. Experimental results confirm that the adaptive learning con‐ trol (ALC) for thermal errors shows a desirable long‐term prediction accuracy.

On the Fracture Characterization in Double‐Sided Incremental Forming of Ti6Al4V Sheets at Elevated Temperatures Technical Publication. NAMRC2017‐93 Beatrice Valoppi, University of Padua – DII, Zixuan Zhang, Northwestern University, Muyang Deng, Northwestern University, Andrea Ghiotti, University of Padua – DII, Stefania Bruschi, University of Padua – DII, Kornel F. Ehamnn Northwestern Univer‐ 150 sity, and Jian Cao, Northwestern University In this paper, the characteristics of fracture arising in Ti6Al4V sheets deformed using the Double‐Sided Incremental Forming (DSIF) strategy are investigated and related to the stress state characteristics of the process. Due to the limited material formability of Ti6Al4V at room temperature, Electrically‐assisted Double‐Sided Incremental Forming (E‐DSIF) experiments were performed under different current intensi‐ ties, and the resulting fracture surfaces were investigated by means of Scanning Electron Microscopy (SEM) observations. To classify the fracture characteristics and identify the corresponding stresses leading to failure in E‐DSIF, tests characterized by simpler stress states, i.e., uni‐axial tensile and pure shear, were also carried out at different temperatures. The comparison of the related fracture surfaces demon‐ strates the prominent contribution of the shear effect in E‐DSIF. Furthermore, the mechanisms controlling fracture occurrence in E‐DSIF were analysed, proving that Mode I (tearing) was responsible for the occurrence fracture and that cracks start from the outer surface of the sheet.

Investigation on Grindability of Medical Implant Material Using Vitreous Bond Silicon Carbide Grinding Wheel Technical Publication. NAMRC2017‐94 Suya Prem Anand P, Indian Institute of technology Madras, Arunachalam N Indian Institute of technology Madras, and Vijayaraghavan L, Indian Institute of technology Madras Zirconia is the preferred material used in many applications including biomedical implant. As the pre‐sintered form is easy to machine, the zirconia in a pre‐sintered form is used to get the required shape and avoid the chipping of the material during grinding in a sintered form. In this paper, the performance of fine grit vitreous bond silicon carbide wheel was evaluated in terms of force ratio, grinding ratio, specific energy and surface finish under both wet and MQL cooling conditions. The forces produced during the grinding of pre‐sintered zirconia minimized in the MQL technique due to the reduction of friction, when compared to the wet cooling condition. The surface finish obtained from the wet cooling condition gives a better performance due to the reduction of wheel loading. The percentage difference of the grinding ratio between both the wet and MQL cooling conditions was observed to be 24 percent. This was due to the active participation of grains and less wheel loading in wet grinding condition, as compared to the MQL condition. The ground surfaces obtained from the wet cooling condition were smooth and regular, compared to the MQL grinding condition

Fabrication of Functionally Graded Porous Polymer Structures Using Thermal Bonding Lamination Techniques Technical Publication. NAMRC2017‐95 Ying Zhang, Texas A&M University, and Jyhwen Wang, Texas A&M University Functionally graded porous materials (FGPMs) are porous structures with porosity gradient distributed over volume. They have many po‐ tential applications in aerospace, biomedical, and other industries. Despite significant efforts have been made to fabricate FGPMs, the ex‐ isting manufacturing techniques are either complex, expensive, unable to control exact porosity distribution, or unable to create closed cell structures. This paper presents an additive approach to manufacturing polymer FGPMs with both closed cell and open cell structures using thermal‐bonding lamination techniques. Under applied compressive load, controlled heating, and appropriate holding time, it was shown that this thermally induced bonding technique can bond layers of polymer sheets to create porous three‐dimensional objects. An investiga‐ tion on effects of various factors on the bonding shear strength was performed. It was found that the bonding strength can be controlled by properly setting the pressure, temperature, and time in the process. The fabricated FGPMs specimens with different porosity configura‐ tions were further characterized using compression test in the normal and transverse directions. The results show that the developed tech‐ niques can be used to obtain FGPM with various effective moduli.

Grain‐based Support Architecture Design for Additive Manufacturing Technical Publication. NAMRC2017‐96 Ahasan Habib, North Dakota State University and Bashir Khoda, North Dakota State University Supporting the overhang section, restraining the model deformation or warping, minimizing the residual stress and controlling the cooling rate are some common functions of support structure in multiple additive manufacturing (AM) process. Since it needs to be removed at the post processing stage of fabrication, it is a considerable waste in terms of material, energy and time employed for their construction. Hence, it is advantageous to minimize the amount of support which eventually can improve the overall efficiency of the AM process. In this paper, a novel support architecture design methodology is proposed considering the amount of support volume, maximum contact inter‐ face, lower fabrication time, and ease of fabrication. First, the support needed points on the object surface are identified considering their normal direction. The points are clustered with a weighted algorithm considering their uniform curvature and location. Afterward, each cluster of points is segmented iteratively into closed‐convex regions i.e. grain boundary, considering the geometric factors such as aspect ratio, fill factor, and contour area to ensure the ease of fabrication and supportability. These convex grains are the model‐support interface segments. Finally, self‐supported slanting and pillar support structures are generated that minimizes support material consumption and consequently saving build time. The proposed research is implemented on free‐form objects and the results are evaluated with the availa‐ ble support generator software.

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Parameter Optimization On Surface Roughness During Milling Of Woven Kenaf Fiber Reinforced Epoxy Composite Technical Publication. NAMRC2017‐97 Azmi Harun, School of Manufacturing Engineering, University Malaysia Perlis, Che Hassan Che Haron, The National University of Malaysia, Jaharah A.Ghani UNIVERSITI KEBANGSAAN MALAYSIA, and Suhaily Mokhtar, Universiti Kebangsaan Malaysia The surface roughness of a milled kenaf reinforced epoxy (woven kenaf fiber) is depending on the milling parameters (spindle speed, feed rate and depth of cut). Therefore, a study was carried out to investigate the relationship between the milling parameters and their effects on a kenaf reinforced epoxy. Response surface (Box‐Behnken) in Design of experiments (DOE) was used to determine the number of ex‐ periments. The responses for each experiment are the surface roughness. Analysis of variance (ANOVA) was then performed to identify the significance of factors. At the end, an optimum setting of milling parameters and modeling equations were obtained by practicing response surface methodology (RSM) for minimizing the surface roughness value. The spindle speed and feed rate contributed the most in affecting the surface roughness of the kenaf fiber reinforced epoxy composite. The modeling equation for optimizing surface roughness was in quadratic form.

Effect of Vibration on Surface Texture During Machining Multiphase Micro‐Alloyed Steel Technical Publication. NAMRC2017‐98 Sivaraman Vijayakumaran, IITMadras, Vijayaraghavan L, IITMadras, and Sankaran S, IITMadras Multiphase (ferrite‐bainite‐martensite) microalloyed steel produced through two step cooling procedure was turned and compared with ferrite‐pearlite microstructure and tempered‐martensite microstructure to study the effect of vibration on surface finish. The cutting pa‐ rameters like cutting speed, feed and depth of cut were varied to understand the parameter influence on surface finish due to vibration. The result shows that FBM microstructure steel gives better performance interms of lower surface roughness and lower vibration com‐ pared to FP and TM microstructure steel.

Prediction of Forming Forces in Single Point Incremental Forming Technical Publication. NAMRC2017‐99 Ankush Bansal, Indian Institute of Technology Hyderabad, Rakesh Lingam, Indian Institute of Technology Hyderabad, Sateesh Kumar Yadav Indian Institute of Technology Kanpur, and N Venkata Reddy, Indian Institute of Technology Hyderabad Incremental sheet forming (ISF) is a cost effective die‐less forming process for low volume production. Achieving good accuracy using this process is a challenging task. Bending between clamped boundary and component opening, tool deflection, sheet spring‐back and rigid body displacements are the major reasons for geometric inaccuracy in components formed using ISF process. In order to achieve desirable geometric accuracy, accurate prediction of sheet thickness, tool‐sheet contact area and forming forces is important. In this article, modified analytical model is presented to accurately predict formed component thickness, contact area and forming forces during single and mul‐ ti‐stage incremental forming. Predictions of models presented in this work are compared with experimental work carried out during this work as well as experimental results available in the literature and they are in good agreement. Prediction models developed during the present work require very less computational resources compared to finite element analysis.

Experimental Study on Mechanical Properties of Single‐ and Dual‐Material 3D Printed Products Technical Publication. NAMRC2017‐100 Heechang Kim, UNIST, Eunju Park, UNIST, Suhyun Kim, UNIST, Bumsoo Park, UNIST, Namhun Kim, UNIST, and Seungchul Lee, UNIST The recent increase in application of Additive Manufacturing (AM) products has resulted in new demands throughout the industry. Alt‐ hough FDM‐based products are used in various fields, the mechanical properties of such products still tend to be weaker than that of the products manufactured through conventional manufacturing processes. Therefore, improving the mechanical properties of FDM‐printed products is a key factor that can greatly contribute to the manufacturing industry. In this study, tensile tests are conducted on a single ma‐ terial specimen to analyze the influence of various experiment variables that may add up to the enhancement of the mechanical properties of 3D printed products. Additional experiments are conducted with respect to the structural arrangement and material ratio of dual mate‐ rial 3D printing in order to investigate the effectiveness of dual material printed products. Studies on improving such mechanical properties are expected to contribute to the enhancement of the strength for single material printed products, and provide some guidance when manufacturing dual material printed products by considering the optimum efficiency of each material.

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Development of Novel CBN Cutting Tool for High Speed Machining of Inconel 718 Focusing on Coolant Behaviors Technical Publication. NAMRC2017‐101 Tatsuya Sugihara, Osaka University, Haruki Tanaka Osaka University, and Toshiyuki Enomoto, Osaka University Nickel‐based superalloys such as Inconel 718 are known as one of the most difficult‐to‐cut materials due to their mechanical and chemical properties and the tool life is extremely short. Recently, Cubic‐Boron‐Nitride (CBN) has received considerable attention as a material for cutting tools and has already established itself in many areas of machining. However, the performance of CBN tools is still insufficient in practical use, especially in the high speed machining of Inconel 718. To overcome this problem, cutting experiments on Inconel 718 at a wide range of cutting speeds (100 m/min ‐ 500 m/min) were conducted and the performance of CBN cutting tools under dry and wet cut‐ ting conditions was evaluated. Based on the result, we newly developed a CBN cutting tool with a textured flank face with the aim to en‐ hance the effect of cutting fluid at the tool‐workpiece interface. Experimental results showed that the textured flank face improved the wear resistance of the CBN cutting tool in the high speed machining of Inconel 718.

Economic Evaluation of Lignocellulosic Biofuel Manufacturing Considering Integrated Lignin Waste Conversion to Hydrocarbon Fuels Technical Publication. NAMRC2017‐102 Yuntian Ge, University of Illinois at Chicago, Fadwa Dababneh University of Illinois at Chicago, and Lin Li University of Illinois at Chicago Although lignin accounts for 20%‐25% of the total weight of dry lignocellulosic feedstock, it is largely wasted in the lignocellulosic ethanol industry due to the challenging nature of decomposing lignin polymers. In fact, through a series of chemical processes, lignin can be con‐ verted into hydrocarbon biofuels with a very low oxygen content; thus making them suitable to be combined with conventional fossil fuels for transportation fuel applications. In this paper, we present a framework to guide biofuel manufacturers seeking to extend traditional lignocellulosic biofuel manufacturing processes to process lignin waste and convert it to hydrocarbon biofuels. Additionally, we conducted an economic viability assessment on such integrated production processes by comparing to the baseline case based on the NREL 2011 bio‐ethanol process design. The findings show that using lignin waste, the integrated manufacturing processes can produce 16 million gal‐ lons of hydrocarbon fuel in addition to the 67 million gallons of ethanol from baseline case. In addition, the economic evaluation shows that the production cost per unit energy produced increases only by 2.3%, which indicates the integrated production scheme has great potential to be economically viable.

Quasistatic Error Modeling and Model Testing for a 5‐Axis Machine Technical Publication. NAMRC2017‐103 Hua‐Wei Ko, Mechanical Science and Engineering, University of Illinois at Urbana‐Champaign, Patrick Bazzoli, Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, J. Nisbett, Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Le Ma, Department of Mechanical and Aero‐ space Engineering, Missouri University of Science and Technology, Douglas Bristow, Department of Mechanical and Aero‐ space Engineering, Missouri University of Science and Technology, Robert Landers, Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Yujie Chen, Innovation and Technology Development Division (ITDD), Caterpillar Inc, Shiv Kapoor, Mechanical Science and Engineering, University of Illinois at Urbana‐Champaign, and Placid Ferreira, Mechanical Science and Engineering, University of Illinois at Urbana‐Champaign This paper presents an approach to modeling the quasistatic errors of a 5‐axis machine tool with one redundant axis. By introducing errors to the ideal joints and shape transforms of the kinematics of the machine, an error model is obtained. First order error characteristics are used to parameterize the introduced errors. It is found that of the 52 introduced error parameters, only 32 have a linearly independent effect on the volumetric errors observed in the machine’s workspace. To identify these error parameters, the volumetric error components at 290 randomly chosen points are measured with a laser tracker. The unknown parameters are obtained by least‐squares estimation, and the resulting model able to reduce average magnitude of the volumetric error vectors at these points by an average of 90% of their original values. Further, the identified model was used to predict the errors observed in two independent test point sets (each set consisting of 48 points). A 75% reduction in the average magnitude of the error vectors was observed. A large fraction of the residual errors was found to be attributable to the thermal drift of the machine during the experiments where were not conducted in a thermally controlled environ‐ ment and the positioning repeatability of the machine.

Dexterous Printing and Fabrication of Multi‐Functional Parts: Sentiments in Science and Engineering Education Technical Publication. NAMRC2017‐106 Jolie Frketic, Florida State University, Sean Psulkowski, Florida State University, Alexander Sharp, Florida State University, and Tarik Dickens, Florida A&M University 153

With the introduction of precision additive manufacturing techniques, the complexity of a particular fabricated part rivals that which is possible with conventional manufacturing alternatives. The drawback to this however is the time investment required to bring a part to its completion, which limits the practicality of an otherwise advantageous shift in manufacturing. To counteract this, an ambidextrous multi‐ purpose hybrid machine (DEXTER), operating dual SCARA has been developed to reduce the time of single and multi‐material builds. While the SCARA functionality brings forth new obstacles not inherent in conventional gantry setups, optimization studies were performed to minimize the irregularities in print performance. Ensuring a natural lateral movement in manufacturing practices between the traditional and dual arm approach. During prototyping, the current DEXTER model is being used to train the next generation in additive thinking, and to educate them on current manufacturing methods and devices. Doing so creates a generation with the skill set to join the workforce ready to take on the new revolution in manufacturing.

Benchmark Burnishing with Almen Strip for Surface Integrity Technical Publication. NAMRC2017‐107 Z.Y. Liu, The University of Alabama, C.H. Fu, The University of Alabama, M.P. Sealy University of Nebraska, Lincoln, and Y.B. Guo The University of Alabama Burnishing is a surface treatment process widely used in aerospace, navy and other industries to improve fatigue and corrosion resistance by introducing a compressive residual stress layer. The measurement of residual stress by XRD is expensive, time consuming, and tedious. This work presented a quick method to determine the residual stress by using Almen strips. Inspired by the application of Almen strips in , deflections of burnished Almen strips under different burnishing conditions were measured. It was found that the deflection of Almen strip reflects the magnitude and penetration depth into subsurface of induced stress. Higher burnishing force, smaller feed, and smaller ball diameter tend to produce more deflection, which indicates more compressive residual stress.

Surface Integrity and Corrosion Performance of Biomedical Magnesium‐Calcium Alloy Processed by Hybrid Dry Cutting‐Finish Burnishing Technical Publication. NAMRC2017‐108 M. Salahshoor, The University of Alabama, Y.B. Guo The University of Alabama, and C. Li The University of Alabama Biodegradable magnesium‐calcium (MgCa) alloy is a very attractive orthopedic biomaterial compared to permanent metallic alloys. How‐ ever, the critical issue is that MgCa alloy corrodes too fast in the human organism. Compared to dry cutting, the synergistic dry cut‐ ting‐finish burnishing can significantly improve corrosion performance of MgCa0.8 (wt %) alloy by producing a superior surface integrity including good surface finish, high compressive hook‐shaped residual stress profile, extended strain hardening in subsurface, and little change of grain size. The measured polarization curves, surface micrographs, and element distributions of the corroded surfaces by bur‐ nishing show an increasing and uniform corrosion resistance to simulated body fluid.

Evaluation of Quenching Methods for the Purpose of Acoustic Data Collection Technical Publication. NAMRC2017‐109 Travis Roney, Penn State University, Samantha Muhhuku, Penn State University, Chetan Nikhare, Penn State University, Ihab Ragai Penn State University, and David Loker, Penn State University Using data pertaining to the audible emission of processes has become a growing area of research in recent years. This principle has been applied to the monitoring of the heat treatment process during quenching. This work highlights the importance of a proper testing meth‐ odology when collecting such data. The primary purpose of this research paper is to compare and contrast three different methodologies for controlling this process. The first method is manual quenching, the second method automates the process by lowering the sample into the quenching medium, and the third method automates the process by raising the quenching medium container while the sample to be quenched remains fixed. In each of these methods, an acoustic spherical array was used as a beam former directed at the location in which the sample entered the quenching medium. The comparisons in this work indicate that the third option yields the most consistent and repeatable results.

Experimental Study on the Porosity of Electrochemical Nickel Deposits Technical Publication. NAMRC2017‐110 Abishek B. Kamaraj, University of Cincinnati, Hirdayesh Shrestha, University of Cincinnati, Emily Speck University of Cin‐ cinnati, and Murali Sundaram, University of Cincinnati Porous metal parts offer unique advantages over traditional parts as they have excellent specific mechanical properties at lesser weight. In this paper, the effect of the electrical parameters of deposition such as voltage and pulse duty cycle during pulsed electrodeposition on the current density and porosity of the manufactured parts was studied. Porosity at the micron scale, with pore size between 1 – 10 µm was identified while using a 250 µm anode (tool). It is demonstrated that the porosity during these depositions occurs due to the kinetics of the electrochemical deposition, nucleation and crystal growth mechanisms. Through the study, it was found that the pulse duty cycle and 154 voltage influence the porosity of the part. Higher duty cycle and higher voltage result in lower porosity in deposits, except in the case of 50% duty cycle when the double layer capacitance confines the deposit.

Machinability for Dry Turning of Laser Cladded Parts with Conventional vs. Wiper Insert Technical Publication. NAMRC2017‐112 P.R. Zhang, Shandong University, Z.Q. Liu Shandong University, and Y.B. Guo, The University of Alabama Laser cladding has been developed for rapid manufacturing of complex and functional parts. The process chain combining both laser clad‐ ding and machining is necessary when a laser cladded part requires high precision and surface integrity. Turning with the conventional cut‐ ting insert to machine laser cladded part is time consuming and generates average surface integrity. In this paper, the machinability for dry turning of laser cladded parts with wiper vs. conventional inserts is investigated. The experimental results show that both material removal rate (MRR) and machined surface finish can be improved by using the wiper insert. An innovative model has been developed using the Monte Carlo method to predict MRR. The key advantage by combining laser cladding and turning is to produce both high surface quality and high MRR when a wiper insert is used as finish cutting tool. However, rapid tool wear and built‐up‐edge (BUE) are prone to occur in turning with the wiper inserts, which leads to tensile residual stress on the machined surface. This research will provide insights to deter‐ mine an optimal process window of the hybrid laser cladding‐turning for functional surfaces.

Effect of Robot Dynamics on the Machining Forces in Robotic Milling Technical Publication. NAMRC2017‐114 Lejun Cen Georgia Institute of Technology, and Shreyes Melkote, Georgia Institute of Technology This paper analyzes the effect of robot structural dynamics on the forces produced in robotic milling. For this purpose, a dynamic milling force model incorporating the effect of robot dynamics and the effect of external forces on the robot stiffness is implemented. The force model leverages prior work on dynamic modeling of milling forces where the influence of system compliance on the equilibrium or “steady state” uncut chip thickness is accounted for using an iterative computation process. The effect of milling forces on the robot arm stiffness is accounted for using the Conservative Congruence Transformation (CCT). Robotic milling experiments show ~50% to 75% reduction in the predicted errors for key characteristics of the resultant milling forces with the above dynamic model. The paper also analyzes the signifi‐ cance of the robot dynamics effect on the resulting forces as a function of robot configuration (pose) and cutting conditions.

Manufacturing of Smart Composites with Hyperelastic Property Gradients and Shape Memory Using Fused Deposition Technical Publication. NAMRC2017‐115 Kevin Estelle, Washington State University, Dylan Blair, Washington State University, Kent Evans Washington State Universi‐ ty, and Arda Gozen Washington State University In this paper, we demonstrate two studies where fused‐deposition modelling (FDM) is used to fabricate composites with (1) controlled hyperelastic property gradients and (2) shape‐memory behaviour. In the first study, we fabricate thermoplastic elastomer scaffolds con‐ sisting of freely suspending fibers is first fabricated through FDM and then encapsulated with soft silicone elastomers. We first present our studies on how the scaffold geometry is correlated with the printing speed and flow rate. Next, through tensile testing, we demonstrate the capability of the method in generating structures with (1) different hyperelastic properties through scaffold design and printing parameter control and (2) controlled spatial gradients of such properties. In the second study, we use multi‐material FDM to manufacture composite structures consisting of a thermoplastic elastomer shell and polycaprolactone (PCL) core. Owing to the lower melting point and higher room temperature modulus of the PCL, these composites exhibit shape memory behaviour if subjected to thermal cycling between the room temperature and the melting point of the PCL. We evaluate the geometry and temperature dependence of this behaviour. We also demonstrate the reprogrammability of the memorized shape by introducing a silicone encapsulation for the composites.

Micro‐Milling Machinability of DED Additive Titanium Ti‐6Al‐4V Technical Publication. NAMRC2017‐117 Giuseppe Bonaiti, Politecnico di Milano, Paolo Parenti, Politecnico di Milano, Massimiliano Annoni Politecnico di Milano, and Shiv Kapoor, University of Illinois at Urbana‐Champaign The use of Ti‐6Al‐4V in Direct metal deposition (DMD) in particular with the laser engineered net shaping (LENS) technology has been wide‐ ly investigated and utilized for making aerospace components and biomedical products with small dimensions. This work investigates the micro‐milling machinability of LENS‐processed Ti‐6Al‐4V, giving a specific focus on surface quality, cutting forces and burr formation. The effect of additive deposition parameters is also investigated since the material thermal histories during processing can affect porosity and mechanical behavior of the samples, giving different milling performance. The aim is to prove in what entity the LENS deposition parame‐ ters are related to mechanical properties and, consequently, how they interact with the machining process. Microstructure of the samples are analyzed through micrographs, hardness tests and porosity. The achieved roughness on the cut surfaces shows a statistical distinction between additive and wrought titanium. The same do the cutting forces which increase with an increase of hardness of the AM samples, 155 but decrease in wrought titanium, even when hardness is similar. Another evidence is the increased tendency of AM titanium in burr for‐ mation with respect to standard titanium machined at constant cutting parameters. The future prospective is to take into account the ma‐ chinability properties as a functional material characteristics during the deposition process by controlling both material thermal laws and the melt pool.

Thermo‐Mechanical Design Optimization of Conformal Cooling Channels using Design of Experiments Approach Technical Publication. NAMRC2017‐118 Suchana Akter Jahan, Purdue School of Engineering and Technology, IUPUI, Tong Wu, Purdue School of Engineering and Technology, IUPUI, Yi Zhang, Purdue School of Engineering and Technology, IUPUI, Jing Zhang, Purdue School of Engineer‐ ing and Technology, IUPUI, Andres Tovar Purdue School of Engineering and Technology, IUPUI, and Hazim El‐Mounayri, Pur‐ due School of Engineering and Technology, IUPUI Plastic injection molding is a versatile process and a major part of the present plastic manufacturing industry. Traditional die design is lim‐ ited to straight (drilled) cooling channels, which don’t impart optimal thermal (or thermo‐mechanical) performance. With the advent of additive manufacturing technology, injection molding tools with conformal cooling channels are now possible. However, optimum confor‐ mal channels based on thermo‐mechanical performance are not found in the literature. This paper proposes a design methodology to gen‐ erate optimized design configurations of such channels in plastic injection molds. Design of experiments (DOEs) technique is used to study the effect of critical design parameters of conformal channels. In addition, a trade‐off technique is utilized to obtain optimum design con‐ figurations of conformal cooling channels for “best” thermo‐mechanical performance of a mold.

Feasibility Exploration of Superalloys for AISI 4140 Steel Repair Using Laser Engineered Net Shaping Technical Publication. NAMRC2017‐119 Zhichao Liu, Texas Tech University, Weilong Cong, Texas Tech University, Hoyeol Kim, Texas Tech University, Fuda Ning, Tex‐ as Tech University, Qiuhong Jiang, Texas Tech University, Tao Li, Dalian University of Technology, Hong‐Chao Zhang Texas Tech University, and Yingge Zhou Texas Tech University Due to high strength and ductility, AISI 4141 alloy steel is widely used in many industrial applications, such as gears and blades. When it is composed to harsh working environment, severe mechanical failures may happen. In order to save the high added value of the compo‐ nents, necessary repairing techniques are required to recover their functionality. Laser Engineered Net Shaping (LENS) is an innovative technology for metal parts repairing and rebuilding due to its metallurgical bonding and exhibit heat affected zone (HAZ). Compared to other repairing processes, LENS cannot only reduce the manufacturing time and cost, increase material utilization, but also provide an out‐ standing as‐fabricated mechanical properties. Considering the compatibility and availability of powder materials, the selection of to‐be‐fabricated materials are important and decisive to the mechanical properties and the quality of the deposits. In this investigation, nickel‐based and cobalt based superalloys are deposited onto AISI 4140 steel substrate using laser engineered net shaping (LENS) process to verify the feasibility of these superalloys for repairing of AISI 4140 workpieces. The micro‐hardness, tensile strength, fracture and wear resistance are analyzed to testify the resistance of deformation, tension and anti‐friction performance of deposited materials.

Design Optimization of Plastic Injection Tooling for Additive Manufacturing Technical Publication. NAMRC2017‐120 Tong Wu, Purdue School of Engineering and Technology, IUPUI, Suchana Akter Jahan, Purdue School of Engineering and Technology, IUPUI, Yi Zhang, Purdue School of Engineering and Technology, IUPUI, Jing Zhang, Purdue School of Engineering and Technology, IUPUI, Hazim El‐Mounayri Purdue School of Engineering and Technology, IUPUI, and Andres Tovar Purdue School of Engineering and Technology, IUPUI This work presents a systematic and practical finite element based design optimization approach for the injection tooling adaptive to addi‐ tive manufacturing (AM) technology using power bed fusion (PBF). First a thermo‐mechanical optimization of conformal cooling is im‐ plemented to obtain the optimal parameters associated with conformal cooling design. Then, a multiscale thermomechanical topology optimization is implemented to obtain a lightweight lattice injection tooling without compromising the thermal and mechanical perfor‐ mance. The design approach is implemented to optimize a real design mold and the final optimal design is prototyped in SLA and demon‐ strated can be manufactured in PBF.

A Novel Modification to the Incremental Forming Process, Part 1: Multi‐Directional Tooling Technical Publication. NAMRC2017‐121 Tyler Grimm, Penn State Erie, The Behrend College, Ihab Ragai Penn State University, and John Roth Penn State Erie, The Behrend College 156

Incremental forming (IF) is a novel sheet material forming technique, which has the ability to eliminate the need for die sets. The IF method forms sheet material by use of a non‐cutting tool, which gradually deforms the sheet material into the desired shape. In the following works, this research proposes a range of novel tool geometries that allows forming of the sheet material in multiple directions at a rapid rate, allowing for greater formability, improved surface finish, and reduced springback. Additionally, several tool features are proposed which achieve this forming motion. Part 1 of this research describes the design of the tooling, as well as variations that are possible with the tool’s geometry. In part 2 of this research, the proposed forming method is validated.

A Novel Modification to the Incremental Forming Process, Part 2: Validation of the Multi‐Directional Tooling Method Technical Publication. NAMRC2017‐122 Tyler Grimm, Penn State Erie, The Behrend College, Ihab Ragai Penn State University, and John Roth Penn State Erie, The Behrend College Incremental forming (IF) is a novel sheet material forming technique, which has the ability to eliminate the need for die sets, forms sheet material through the use of a non‐cutting tool that gradually deforms the sheet material into the desired shape. Generally, the shape of the tool tip is a hemisphere. In the following works, the authors validate a novel tool shape, presented in Part 1 of this research, that allows forming of the sheet mate‐ rial in multiple directions at a rapid rate. The works described herein demonstrate that a more complex tool tip can result in greater forma‐ bility, improved surface finish, and reduced springback. The tested tool tip shape described herein is that of two hemispherical tips, re‐ volved about a common radius from a single axis, vertically offset to half of the tool path’s step size.

Al‐TiB2 Nanocomposites Produced by Flux‐Assisted Liquid‐State Processing Technical Publication. NAMRC2017‐124 Abdolreza Javadi, University of California, Los Angeles, Chezheng Cao University of California, Los Angeles, and Xiaochun Li, University of California, Los Angeles Aluminum matrix nanocomposites (AMNCs) materials are of a great candidate for various structural and functional applications for auto‐ motive, aerospace, and military. In this study pure aluminum (Al) with one and two volume percent (vol.%) of TiB2 nanoparticles were produced via flux‐assisted liquid‐state processing. Adding flux during nanoparticle feeding can significantly improve nanoparticle incorpora‐ tion into molten Al. TiB2 nanoparticles as small as 100 nm were successfully incorporated into pure Al using KAlF4 (potassium aluminum fluoride) flux. TiB2 nanoparticles were fairly distributed and dispersed in the Al‐2 vol.% TiB2 nanocomposite. Vickers hardness of the Al‐2 vol.% TiB2 nanocomposite was higher than the pure Al. While KAlF4 flux is proven to enhance the nanoparticle incorporation efficiency in Al system, further study is needed to clean the flux remnant inside Al matrix, possibly due to the mechanical mixing, to enhance the effect of the TiB2 nanoparticle reinforcement.

3D Finite Element Modeling Based Investigations of Micro‐Textured Tool Designs in Machining Titanium Alloy Ti‐6Al‐4V Technical Publication. NAMRC2017‐125 Alaa Olleak, Rutgers University and Tugrul Ozel, Rutgers University Surface texturing on cutting tools is considered a potential improvement to the tool performance both in dry machining with use of solid lubricants and in wet/cryogenic machining. This paper presents investigations on the effects of micro‐textured tool designs that include grooves that are parallel, perpendicular, and diagonal to the main cutting edge as well as with pitted and diagonal pitted forms in the case of dry cutting titanium alloy Ti‐6Al‐4V by using 3D Finite Element modelling based simulations. The results include predicted forces, stress, temperature, and wear rate distributions which possess certain advantages of micro‐texture tool designs.

Numerical Investigation of Ultrashort Laser Interaction with Dielectric Materials Based on a Plasma‐Temperature Com‐ bined Model Technical Publication. NAMRC2017‐126 Xiao Jia Clemson University and Xin Zhao, Clemson University Numerical study of ultrashort laser‐induced ablation of dielectric materials is presented based on a one‐dimensional plasma‐temperature model. Plasma dynamics including photoionization, impact ionization, relaxation and electronic diffusion are considered through an im‐ proved single‐rate equation. Material decomposition is captured by a temperature‐based ablation criterion. Dynamic description of abla‐ tion process has been achieved through instant material removal. Behaviors of laser‐induced ablation threshold, transient optical proper‐ ties and ablation depth have been investigated with respect to incident fluence and pulse duration. Good agreements are shown between numerical predictions and experimental observations. Fast increase of ablation depth, followed with saturation, are observed with the in‐ crease of the incident fluence. The ablation efficiency decreases with fluence after reaching the peak value at the fluence twice of the abla‐ tion threshold. Material processing at low laser fluence and short pulse duration is proved to be able to provide higher ablation efficiency

157 and reducing thermal damage. The divergence of tightly focused in transparent materials has been revealed to significantly affect the ablation process, particularly at high laser fluence. This effect is found negligible in laser processing of metals.

Streaming Machine Generated Data to Enable a Third‐Party Ecosystem of Digital Manufacturing Apps Technical Publication. NAMRC2017‐127 Shaurabh Singh, North Carolina State University, James Barkley, UI Labs, Yuan‐Shin Lee, North Carolina State University, Paul Cohen, North Carolina State University, Binil Starly North Carolina State University, and Atin Angrish, North Carolina State University The digital factory of the future will be driven by the integration of physical smart machine tools and cyber‐enabled software, working seamlessly to increase manufacturing intelligence, flexibility, agility and production efficiency. The objective of this study is develop and demonstrate a middleware software architecture to interface physical machines on a shop floor with client manufacturing applications. We have connected both legacy and modern ‘smart’ machines to a highly scalable database capable of storing streaming time‐series data gen‐ erated by on‐board sensors and machine controllers. Three client applications were developed to demonstrate the mechanism through which apps can be written without detailed physical knowledge of the type of machines on the floor. The first, is an application that re‐ sides within the Digital Manufacturing Commons (DMC) which demonstrates the ability to query data from any physical machine on the floor; the 2nd application demonstrates a python app which compares digital data with machine generated data; and the 3rd application demonstrates building a LabView app built to interface with the middleware service. This proposed architecture enables an ecosystem of smart manufacturing applications to be built and deployed on the shop‐floor through open‐sourced software and hardware devices.

Effects of Hot Isostatic Pressing on Copper Parts Fabricated via Binder Jetting Technical Publication. NAMRC2017‐128 Ashwath Yegyan Kumar, Virginia Polytechnic Institute and State University, Blacksburg, VA 24060, Yun Bai, Virginia Polytech‐ nic Institute and State University, Blacksburg, VA 24060, Anders Eklund Quintus Technologies, LLC, Lewis Center, OH, 43035, and Christopher Williams, Virginia Polytechnic Institute and State University, Blacksburg, VA 24060 Binder Jetting, an Additive Manufacturing process that fabricates parts via selective inkjet deposition of binder into a powder bed, is capa‐ ble of cost‐ effectively producing complex metal and ceramic components without the need for support structures or anchors. Printed green parts are then sintered for added densification and strength. However, printed parts typically suffer from porosity due to the use of large powders and a loosely packed powder bed. While researchers have investigated many techniques (e.g., process parameter optimiza‐ tion and powder morphology selection and sizing) for achieving full theoretical density in binder jetted parts, 100% density has not been achieved without infiltration of a secondary lower melting point material. In this work, the authors investigate the use of Hot Isostatic Pressing (HIP) as a post‐process heat treatment of printed parts to evaluate its effect on printed parts’ density, porosity, and shrinkage. The authors conduct this investigation in the context of printed copper. It is demonstrated that the use of HIP can improve the final part density from 92% (following sintering) to 99.7% of theoretical density.

Experimental Evaluation of Direct Laser Assisted Turning through a Sapphire Tool Technical Publication. NAMRC2017‐129 Yuan Wei, University of Calgary, Chaneel Park University of Calgary, and Simon Park University of Calgary Laser assisted machining (LAM) techniques have been investigated to improve the efficiency and quality of machining operations by ther‐ mally softening hard to cut materials. Traditionally, the techniques were applied in such a way that the heating zone was in front of the cutting tool, softening materials prior to chip formation. In order to reduce energy consumption and prevent unwanted phase changes in the materials, we propose a direct laser assisted machining technique where a laser beam is applied through a transparent sapphire tool, directly affecting the tool‐workpiece contact surface. The sapphire tool has a high hardness compared to conventional tungsten carbide tools, while its transparency allows for the direct application of the laser through the tool. In this study, we investigated the effects of ap‐ plying a direct laser assisted machining technique, and we observed changes in cutting behaviors including cutting forces, surface finish, and adhesion. Aluminum and bulk metallic glass workpiece materials were examined to investigate how crystalline and amorphous materi‐ als behave under direct laser assisted machining techniques. Experimental results showed that the proposed technique reduced forces and improved surface finish.

Virtualization and Deep Recognition for System Fault Classification Technical Publication. NAMRC2017‐130 Peng Wang, Case Western Reserve University, Ananya Ananya, Case Western Reserve University, Ruqiang Yan Case Western Reserve University, and Robert Gao, Case Western Reserve University

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Efficient gearbox health monitoring and effective representation of diagnostic results of dynamical systems have remained challenging. In this paper, a new approach to using deep learning for translating diagnostic results of one‐dimensional time series analysis into graphical images for fault type and severity illustration is presented, with gearbox as a representative example. Specifically, time sequences are first converted by wavelet analysis to time‐frequency images. Next, a deep convolutional neural network (DCNN) learns the underlying features in the time frequency domain from these images and performs fault classification. Experiments on gearbox data demonstrates effective‐ ness and efficiency of the developed approach with a classification accuracy better than 99.5%.

Rotary Ultrasonic Surface Machining of CFRP Composites: A Comparison with Conventional Surface Grinding Technical Publication. NAMRC2017‐131 Fuda Ning, Texas Tech University, Hui Wang, Texas Tech University, Yingbin Hu, Texas Tech University, Weilong Cong, Texas Tech University, Meng Zhang Kansas State University, and Yuzhou Li, Texas Tech University Rotary ultrasonic machining (RUM), a hybrid nontraditional process technology combining ultrasonic machining and grinding, has been proven to be a promising method for hole making of CFRP. Due to its advanced capabilities, RUM has been further extendedly applied in surface machining: rotary ultrasonic surface machining (RUSM). Carbon fiber reinforced plastic (CFRP) composites have found extensive applications in areas such as aerospace, automotive, and sports due to their superior material properties. CFRP components are usually near net shaped after molding processes, however, additional surface machining is still required to generate the final dimensions and func‐ tional surfaces of the advanced CFRP components especially with three‐dimensional features. However, the investigations on RUSM of CFRP are very limited and there are no reported studies on comparisons between RUSM and conventional surface grinding (CSG) of CFRP. In this paper, for the first time, a comparative study between these two processes of CFRP in the aspects of axial and infeed‐directional cutting forces, torque, and surface roughness is conducted. In order to better understand the material removal differences between these two processes, the kinematic motions of the abrasive grains are also analyzed and compared.

An Investigation of Side Flow during Chip Formation in Orthogonal Cutting Technical Publication. NAMRC2017‐132 Rui Liu, Rochester Institute of Technology, Elijah Eaton Rochester Institute of Technology, Mendy Yu Rochester Institute of Technology and Jason Kuang, Rochester Institute of Technology Orthogonal cutting is a simplified two‐dimensional model that neglects many geometric complexities, which describes complicated three‐dimensional cutting process quite well in most cases. The orthogonal cutting should satisfy the plane strain assumption to prevent the extensive deformation perpendicularly to the cutting direction due to the pressure between the cutting tool and the workpiece, which is named as the side flow. To satisfy this assumption, the depth of cut needs to be much greater than the feed with a certain ratio. Howev‐ er, the criterion is not valid all the time. This paper presents an experimental study of the side flow with different cutting conditions by comparing the profiles of the cross section of the machined chip in machining of aluminum alloy. It is shown that the higher ratio between the uncut chip width and the uncut chip thickness (chip width‐to‐thickness ratio) and the lower cutting speed can prevent the side flow during chip formation. And the new criterion for plane strain assumption has been proposed in this study as well.

Geometric Complexity based Process Selection for Hybrid Manufacturing Technical Publication. NAMRC2017‐134 Anay Joshi University of Cincinnati and Sam Anand, University of Cincinnati Hybrid manufacturing (HM), which combines additive manufacturing (AM) and subtractive manufacturing (SM) operations in a single ma‐ chine is gaining popularity among engineers because of its capability of leveraging the advantages of both processes. As a result, a part with complex geometries and organic designs can be manufactured with the desired surface finish with minimal setup. However, there is a need for choosing the correct manufacturing method for a given product and developing the optimum process plan. This paper presents a novel approach for decision making between the three manufacturing processes, along with an optimal part splitting methodology for HM. The proposed process plan minimizes geometric complexities and optimizes the manufacturing resources. A novel metric, called complexity score, has also been developed for quantifying the part’s geometric complexities which includes various parameters based on Design for Manufacturing (DFM) rules. The proposed methodology will be useful for detecting potential manufacturing difficulties before the actual fabrication of a product and identifying the best manufacturing process for fabrication. Three case studies representing different manufac‐ turing methods are presented for validating the practical application of the research.

Surface Grinding of Ti‐6Al‐4V Alloy with SiC Abrasive Wheel at Various Cutting Conditions Technical Publication. NAMRC2017‐135 Rosemar Batista Da Silva, Federal University of Uberlandia, Antonio Vitor de Mello, Federal University of Uberlandia, Alisson Rocha Machado, Mechanical Engineering Graduate Program, Pontifícia Universidade Católica do Paraná ‐PUC‐PR, Rogerio Valentim Gelamo, Federal University of Triangulo Mineiro, UFTM, Institute of Technological and Exact Sciences, 159

Anselmo Eduardo Diniz State University of Campinas, UNICAMP, Department of Materials and Manufacturing Engineering, and Rodolfo Fischer Moreira de Oliveira, Saint‐Gobain Abrasivos América do Sul, Saint‐Gobain do Brasil Produtos Industriais e para Construção Ltda Ti‐6Al‐4V alloy is mostly used in biomedical and aerospace industries, as well as in automotive and cutting implements, like scissors and knives due to its high strength‐to‐weight ratio and excellent resistance to corrosion in many environments. However, Ti‐6Al‐4V alloy is re‐ ferred as difficult‐to‐cut material due to its unique combination of low thermal conductivity and high chemical reactivity with most cutting tools, especially with ceramics, and rapid work hardening during machining,. This will accelerate tool wear and generally adversely affects surface quality of the component. This becomes more critical in grinding operation due to conventional abrasive wheels that have poor thermal conductivity and small dimension of chips, which in turn contributes to more heat to be concentrated in the cutting zone. Depend‐ ing on the temperature gradient and workpiece, this heat can cause damage to the component surface. So, it is important to control the amount of heat entering the workpiece and prevent damages like burning, surface cracks and other metallurgical alterations in the work‐ piece. In this context, this work investigates the surface quality of the Ti‐6Al‐4V alloy in terms of surface roughness e micro‐hardness, after surface grinding with silicon carbide wheel under various cutting conditions. The morphology of the machined was also analyzed in a Scan‐ ning Electron Microscope to understand the cutting mechanisms. Conventional and MQL coolant delivery techniques were tested. A spe‐ cially designed nozzle was tested in the experiments with the MQL. Results showed that surface roughness is dependent on both radial depth of cut and coolant system; and the lowest results were recorded after machining with the combination of the lowest depth of cut and MQL technique. With respect to micro‐hardness, little variation was observed after machining with the MQL technique, unlike when machining with conventional method, irrespective the depth of cut employed.

Effect of Bottom Shape on Acoustic Streaming in Ultrasonic Processing of Metal Matrix Nanocomposites (MMNCs) Technical Publication. NAMRC2017‐136 Saheem Absar, Clemson University, Pavan Pasumarthi Grupo Antolin, and Hongseok Choi, Clemson University Acoustic streaming is a non‐linear physical effect associated with ultrasonic processing of liquid media. The fluid flow patterns induced by acoustic streaming effects can assist in effective distribution of nanomaterials within a liquid medium. In this study, a time‐dependent non‐linear computational model was developed to study the effect of geometrical parameters on the transient acoustic streaming flow during ultrasonic processing. Three different geometric configurations related to the size of the ultrasonic processing cell and the immer‐ sion depth of the ultrasonic probe were used for the study. The acoustic streaming flow patterns were compared to that of a baseline ge‐ ometric configuration for a flat‐bottomed straight cylindrical ultrasonic processing cell obtained from a parametric acoustic cavitation study. It was observed that the baseline configuration provided the most well‐developed flow pattern compared to other cases, showing formation and interaction of multiple acoustic vortices in the liquid medium. A sedimentation study of ultrasonically processed carbon nanofibers (CNFs) in water was performed and the settling of CNFs was observed after 43 hours. The baseline geometric configuration showed the best dispersion of CNFs in the sedimentation study, compared to the other cases. Microstructural analysis of a metal matrix nanocomposite (MMNC) composed of an with CNFs and silicon carbide microparticles indicated that ultrasonically pro‐ cessing of the MMNC exhibited uniform distribution of the nanomaterials across the base matrix along with refinement of the grains of the matrix. Finally, ultrasonic processing cells with three different bottom shapes were used in the computational model to study their influ‐ ence on acoustic cavitation and acoustic streaming. The acoustic cavitation zone size is considerably affected by the shape of the bottom surface, originating from variations in interference patterns of the acoustic waves reflecting off the boundaries of the ultrasonic processing cell. The study further indicated that flow entrainment by the acoustic vortices during acoustic streaming is significantly affected by the shape of the bottom surface and its transition toward the sidewalls of the ultrasonic processing cell.

Sensor Data and Information Fusion to Construct Digital‐Twins Virtual Machine Tools for Cyber‐Physical Manufacturing Technical Publication. NAMRC2017‐137 Yi Cai, Binil Starly, North Carolina State University, Shaurabh Singh, North Carolina State University, Paul Cohen North Carolina State University, and Yuan‐Shin Lee, North Carolina State University This paper presents sensor data integration and information fusion to build “digital‐twins” virtual machine tools for cyber‐physical manu‐ facturing. Virtual machine tools are useful for simulating machine tools’ capabilities in a safe and cost‐effective way, but it is challenging to accurately emulate the behavior of the physical tools. When a physical machine tool breaks down or malfunctions, engineers can always go back to check the digital traces of the “digital‐twins” virtual machine for diagnosis and prognosis. This paper presents an integration of manufacturing data and sensory data into developing “digital‐twins” virtual machine tools to improve their accountability and capabilities for cyber‐physical manufacturing. The sensory data are used to extract the machining characteristics profiles of a digital‐twins machine tool, with which the tool can better reflect the actual status of its physical counterpart in its various applications. In this paper, techniques are discussed for deploying sensors to capture machine‐specific features, and analytical techniques of data and information fusion are pre‐ sented for modeling and developing “digital‐twins” virtual machine tools. Example of developing the digital‐twins of a 3‐axis vertical milling machine is presented to demonstrate the concept of modeling and building a digital‐twins virtual machine tool for cyber‐physical manu‐ facturing. The presented technique can be used as a building block for cyber‐physic manufacturing development.

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Weight Reduction of Heavy Duty Truck Components through Hollow Geometry and Intensive Quenching Technical Publication. NAMRC2017‐138 James Lowrie, North Carolina State University, Department and Aerospace Engineering, Hao Pang North Carolina State University, Department and Aerospace Engineering, and Gracious Ngaile, North Carolina State University, Department and Aerospace Engineering Increasing environmental awareness has put pressure on heavy duty truck manufacturers to improve the fuel economy and reduce the emissions of their vehicles. Light weighting efforts are a useful tool in meeting these goals and so this paper outlines how a heavy duty rear axle shaft may have its weight reduced. Two methods are focused on, i) hollow shaft geometry and ii) intensive quenching, as possi‐ ble avenues to shed mass from the shaft. Load mapping is used to establish a finite element model which can be used to evaluate the light weight designs and techniques proposed in the paper. It is discovered that weight savings of around 26% can be achieved by chang‐ ing the traditionally solid axle shaft into a hollow shaft. The intensive quenching process is shown to be superior to the oil quenching process in regards to both residual stresses and strength, allowing for material removal accounting for 3% of the shaft weight. Addition‐ ally, the compressive residual stresses created on the surface of the part during the intensive quenching process may also serve to slow crack initiation and increase fatigue life. Further optimization of the intensive quenching process may provide additional weight reduction opportunities.

Coated Tool Performance in Dry Turning of Super Duplex Stainless Steel Technical Publication. NAMRC2017‐140 Rajaguru J Indian Institute of Technology, and Arunachalam N, Indian Institute of Technology Madras Super duplex stainless steels (SDSS) are widely used in marine environments because of their excellent mechanical properties and corrosion resistance. The presence of different alloying elements and their two phase microstructure makes it difficult to machine material. The use of multilayer coated cutting tools is an effective strategy to improve the cutting performance during dry machining of this material. In this work, the performance of four different coated tools made either by PVD or CVD has been investigated during dry turning of SDSS. Their performances were evaluated in terms of tool wear, cutting force, cutting temperature and surface tegrity. Results indicated that [MT‐TiCN]‐Al2O3 coating provided relatively performance better than other coatings in terms of tool wear, cutting force and surface integ‐ rity. Their combined properties of higher hardness and oxidation stability make them an effective coating during machining. TiN‐[MT‐TiCN]‐Al2O3 coating exhibited higher tool wear, poor surface finish and less tensile residual stress among the other surfaces ma‐ chined, which could be due to the dominance of plastic deformation by mechanical load over temperature effects.

Micro‐Scale Texture Fabrication Using Immersed Surface Accumulation Technical Publication. NAMRC2017‐142 Xiangjia Li, University Of Southern California and Yong Chen, University Of Southern California Most additive manufacturing (AM) processes such as stereolithography (SLA) and selective laser sintering (SLS) use a layer‐by‐layer fabrica‐ tion approach. They cannot be used to fabricate geometric features on the surfaces of a pre‐existing three‐dimensional (3D) object. In addition, existing AM processes are mainly based on a single size scale, e.g. macro‐scale or micro‐scale, and cannot be used to build a mac‐ ro‐scale object with micro‐scale features on its surfaces. In this paper, we present a novel immersed surface accumulation process that can fabricate micro‐scale features on macro‐scale surfaces. In the process, a surface‐based light guide tool is immersed inside liquid resin to fabricate high‐resolution features on the surfaces of a pre‐existing object. The system design and process settings to fabricate 3D features are presented. The relation between process control and related building quality is also discussed. Two test cases are presented to demon‐ strate the effectiveness and efficiency of the newly developed immersed surface accumulation process.

Investigation of Chip Thickness and Force Modelling of Trochoidal Milling Technical Publication. NAMRC2017‐144 Abram Pleta, Clemson University International Center for Automotive Research, Farbod Akhavan Niaki Clemson University International Center for Automotive Research, and Laine Mears Clemson University With the ever increasing pressure to reduce processing time and cost, researchers in machining have begun to develop a body of work cen‐ tred around increasing the throughput of machining operations. While standard toolpaths exist, such as raster and zig‐zag, alternative toolpaths have been developed to achieve beneficial kinematics and dynamics for the cutting tool to better achieve high‐speed machining conditions. One such toolpath, trochoidal milling, has been identified to decrease machining process time and increase overall tool life. Understanding the undeformed chip thickness produced utilizing trochoidal milling is critical to developing advances in the field. This paper presents a novel approach to modelling the chip thickness of the process for low to medium range cutting speeds. It has been found that the tool path cannot be described as a purely circular path, instead requiring the model of a true trochoid, which is presented in this work. Utilizing efficient, numerical method, the instantaneous chip thickness is solved for and validated experimentally with cutting force meas‐ urement, using a semi‐mechanistic force model, where the experimental cutting forces find good agreement with the simulated results.

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Optimization of StepLock® Orthotic Knee Joint Design Technical Publication. NAMRC2017‐145 Omar Castiblanco Bradley University and Iqbal Shareef, Bradley University Concurrent and early application of DFM, DFMA, FEA, and DFE methodologies in biomedical products can yield significant benefits to com‐ panies involved in the design and development of products such as orthotics. In these cases, nearly 70‐80% of the orthotic cost is already committed during the design phase leaving much less than 20% of product cost for optimization during the manufacturing phase. Thus, attempts to reduce orthotic cost, and increase robustness of product performance become an uphill task due to limited scope for optimiza‐ tion during the manufacturing phase. This paper presents the integration of DFM, DFMA, FEA, and DFE principles early in the design phase of orthotics, coupled with the use of CREO® for generation of CAD models, DFM‐Pro® for improving manufacturability, CustomPart.Net for cost reduction, and Sustainable Minds® for reducing carbon footprint. In this study StepLock® orthotic knee joint design optimization re‐ sulted in a 50% reduction in number of features, 37% reduction in number of parts, 2% reduction in weight, 50% reduction in Von‐Mises stresses, 44% reduction in maximum shear stresses, 47% reduction in cycle time, 49% reduction in manufacturing cost, and 95% reduction in carbon footprint

Measurement of Operator‐Machine Interaction on a Chaku‐Chaku Assembly Line Technical Publication. NAMRC2017‐146 Matthew Krugh, Clemson University ‐ International Center for Automotive Research, Ethan McGee, Clemson University ‐ School of Computing, Stephen McGee, Clemson University ‐ School of Computing, Laine Mears, Clemson University ‐ Interna‐ tional Center for Automotive Research, Andrej Ivanco, Clemson University ‐ International Center for Automotive Research Kenneth Podd Robert Bosch LLC., and Barbara Watkins Robert Bosch LLC. Assembly operations in the automotive industry represent a substantial proportion of overall manufacturing time and total manufacturing cost. With product complexity increasing year after year, humans continue to remain a cost‐effective solution to the needs of flexible man‐ ufacturing. The human element is largely marginalized in Manufacturing 2.0 and necessitates a better understanding of the human’s impact on the future of manufacturing. The work herein illustrates a method through the use of the Industrial Internet of Things (IIoT) to capture ubiquitous data streams from human and automated machinery with the intention to make available the data necessary and elucidate the potential to deepen the understanding of the human impact on Industry 4.0 assembly systems.

Highly Removable Water Support for Stereolithography Technical Publication. NAMRC2017‐147 Jie Jin, University Of Southern California and Yong Chen, University Of Southern California Current stereolithography (SL) technology can print there‐dimensional (3D) objects with high precision and fast speed. However, for a com‐ plex computer‐aided design (CAD) model, the fabricated structures have a significant amount of additional support structures that are re‐ quired in order to ensure the model can be fabricated. However, these support structures may be difficult to remove. Even worse, the re‐ moval of the support structures may cause unexpected damage to delicate features and leave undesired surface marks. Although some special materials have been utilized in support structures such as water‐soluble materials for the fused deposition modeling (FDM) process and wax for the multi‐jet modeling (MJM) process, such support materials have not been available for the SL process. In this paper, a novel SL process using highly removable and widely available water as supports is presented. The process uses solid ice to surround the built parts in the layer‐by‐layer fabrication process. A cooling device is used to freeze the water into ice for each layer. The photocurable resin is spread on ice surface and then solidified by a projection image. Accordingly, a complex 3D object can be fabricated without using tradition‐ al support structures. After the fabrication process, the additional ice structure can easily be removed leaving no undesired marks on the bottom surfaces. Two test cases are presented to show the effectiveness of the presented highly removable water support method.

Scalable Manufacturing of 10 nm TiC Nanoparticles through Molten Salt Reaction Technical Publication. NAMRC2017‐148 Chezheng Cao, UCLA, Weiqing Liu, Harbin Institute of Technology, Abdolreza Javadi, UCLA, Haonan Ling, UCLA, and Xiao‐ chun Li, UCLA Titanium carbide (TiC) particle is a good candidate material for strengthening metals to manufacture metal matrix nanocomposites (MMNCs) as it has high hardness, high Young’s modulus, good conductivity and excellent wear resistance. Moreover, originated from its partial metallic bonds, it normally has a good wettability with molten metals. To enable effective Orowan strengthening effect, smaller TiC nanoparticles (e.g. < 10 nm) is highly preferred. However, small TiC nanoparticles (< 10 nm) are not available in market. Current production method cannot produce 10 nm TiC nanoparticles in a scalable manufacturing way. Here we explored a molten salt based reaction method that can enable us manufacture TiC nanoparticles below 10 nm. Diamond nanoparticles (<10 nm) work as the carbon source and reaction template. Titanium can dissolve in molten salt and deposit on the diamond nanoparticles before titanium reacts with diamond to form TiC nanoparticles. The size of the reacted TiC particles is determined by the size of diamond nanoparticles. This method provide a simple and

162 inexpensive pathway to manufacture TiC nanoparticles below 10 nm and open up the opportunity for making high performance MMNCS reinforced by TiC nanoparticles.

Thermal Effect on Clad Dimension for Laser Deposited Inconel 718 Technical Publication. NAMRC2017‐149 Jennifer Bennett, Northwestern University, DMG MORI, Sarah Wolff, Northwestern University, Gregory Hyatt, DMG MORI, Kornel Ehmann Northwestern University, and Jian Cao Northwestern University Additive manufacturing of nickel‐based components with materials of high strength, such as Inconel 718, is gaining traction in industry. However, prediction and control for volume change of the component due to tool path acceleration and deceleration among other sus‐ pected causes are a remaining challenge in laser deposition. The dimensional integrity of a completed laser deposited structure is depend‐ ent on the uniformity of each individual clad track. This study investigated the relationship of clad track dimension and process parameters and solidification cooling rate for laser deposited INCONEL 718. In‐situ infrared camera captured the thermal history of each localized point. A focus variation metrology tool measured the clad heights at varying points of the clads relative to the tool path. Based on these results, there was a clear relationship between process parameters, cooling rate and the volume change of the clad, which will allow for a better understanding and therefore control of the laser deposition process.

Solid State Electrochemical Direct Writing of Copper Nanostructures on an Ion Conductive using Atomic Force Microscopy Technical Publication. NAMRC2017‐150 Shama Barna, University of Illinois at Urbana Champaign, Arun Ramanathan, University of Illinois at Urbana Champaign, Kyle Jacobs, University of Illinois at Urbana Champaign, Glennys Mensing, University of Illinois at Urbana Champaign, Daniel Shoemaker University of Illinois at Urbana Champaign, and Placid Ferreira University of Illinois at Urbana Champaign In this paper, we report a solid state direct writing method for fabricating copper nanostructures in seconds using atomic force microscopy. Under ambient conditions, a dendritic electrochemical reaction on the surface of a super‐ionic (CuI)x (CuPO3)(1‐ x) glass surface is demon‐ strated by negatively biasing an atomic force microscopy (AFM) probe relative to a Cu film counter electrode. Energy dispersive X‐ray spectroscopy (EDS) is then used to characterize the dendrite and confirm electrochemical extraction of copper on the glass surface. To implement controlled electrochemical extraction, the copper growth process is then localized by realizing a ~pA level current controlled electrochemical extraction process with a stationary AFM tip. Line patterns with ~200 nm line‐width are then generated in seconds over areas tens of microns in diameter by moving the AFM tip along the desired pattern while supplying a constant current to the tip. To the best of our knowledge, this is the first demonstration of a solid state direct writing approach for making copper nano‐patterns on an ion conductive glass substrate.

Study of Ultrasonically Processed Polymer‐Nanoparticle Solutions for Electrospinning Technical Publication. NAMRC2017‐151 Stephanie Hulsey, Clemson University, Saheem Absar Clemson University, and Hongseok Choi, Clemson University A systematic investigation was performed to compare the electrospinnability of polymer solutions processed by ultrasonication and me‐ chanical stirring. Aqueous PEO solutions were prepared using two different mixing methods: ultrasonic processing and mechanical stirring. Electrospinning experiments were performed to observe the ability to produce nanofibers from solutions processed using each mixing method. The electrospinning process parameters were kept constant for all the experiments. It was found that, for a given polymer con‐ centration, the viscosity of ultrasonically processed solutions was lower compared to mechanically stirred solutions and had also an effect on electrospinnability of the solution. Together these results provide important insights into selecting a polymer concentration for electro‐ spinning nanofibers from PEO solutions prepared by ultrasonically processing and mechanical stirring. The transition from electrospraying to electrospinning of each solution was determined by studying the morphology of produced nanofibers using scanning electron microsco‐ py (SEM).The shear viscosity of each solution was measured using a cone/plate viscometer. For mechanically stirred PEO solutions, nano‐ fibers were successfully electrospun beginning with polymer concentrations of 6 wt% but no higher than 9 wt%. The concentration range for producing nanofibers was between 8 and 15 wt% for solutions prepared by ultrasonic mixing. A further study was conducted regarding the dispersion of 2 wt% silicon carbide (SiC) nanoparticles in PEO solutions using mechanical stirring and their corresponding electrospinna‐ bility. An increase in bead frequency throughout the length of the nanofiber was observed with the addition of SiC nanoparticles. Similar to the neat PEO solutions, a higher polymer concentration is required to obtain a sonicated PEO‐SiC solution possessing sufficient viscosity suitable for electrospinning.

Direct Bio‐printing with Heterogeneous Topology Design Technical Publication. NAMRC2017‐152 Amm Nazmul Ahsan, North Dakota State University, Ruinan Xie, North Dakota State University, and Bashir Khoda, North 163

Dakota State University Bio‐additive manufacturing is a promising tool to fabricate porous scaffold structures for expediting the tissue regeneration processes. Un‐ like the most traditional bulk material objects, the microstructures of tissue and organs are mostly highly anisotropic, heterogeneous, and porous in nature. However, modelling the internal heterogeneity of tissues/organs structures in the traditional CAD environment is difficult and oftentimes inaccurate. Besides, the de facto STL conversion of bio‐models introduces loss of information and piles up more errors in each subsequent step (build orientation, slicing, tool‐path planning) of the bio‐printing process plan. We are proposing a topology based scaffold design methodology to accurately represent the heterogeneous internal architecture of tissues/organs. An image analysis tech‐ nique is used that digitizes the topology information contained in medical images of tissues/organs. A weighted topology reconstruction algorithm is implemented to represent the heterogeneity with parametric functions. The parametric functions are then used to map the spatial material distribution. The generated information is directly transferred to the 3D bio‐printer and heterogeneous porous tissue scaf‐ fold structure is manufactured without STL file. The proposed methodology is implemented to verify the effectiveness of the approach and the designed example structure is bio‐fabricated with a deposition based bio‐additive manufacturing system.

Hierarchical Scanning Data Structure for additive manufacturing Technical Publication. NAMRC2017‐153 Ahasan Habib North Dakota State University and Bashir Khoda, North Dakota State University In additive manufacturing, the digital information of required object model is transferred to additive manufacturing (AM) machine using a technology‐independent de facto file format called STL. The approximation of the actual object surface employing STL file causes loss of geometrical and topological information and introduces error to the digital model. This may also limit the manufacturing repeatability be‐ tween AM machine and processes. This research focuses on building a common data generation platform directly from the commonly used parametric surface model (B‐rep). The generic data structure named as Hierarchical Scanning Data Structure (HSDS) is proposed in this research. HSDS will store the actual digital scanning information systematically and sequentially. A common application program interface (API) platform is also proposed in this research, which can access the HSDS and generate machine readable file for different existing AM control systems. The data stored in HSDS can be retrieved remotely and be used by different existing AM controller supporting the cloud/cyber manufacturing process and ensure the platform‐independent object repeatability. The proposed framework is implemented with examples and results are compared with the existing system.

Enabling Non‐Expert Sustainable Manufacturing Process and Supply Chain Analysis during the Early Product Design Phase Technical Publication. NAMRC2017‐154 Kamyar Raoufi, Oregon State University, Karl Haapala, Oregon State University, Kathy Jackson, Pennsylvania State Universi‐ ty, Kyoung‐Yun Kim, Wayne State University, Gul Kremer Iowa State University, and Carolyn Psenka, Wayne State University Consumers are pressuring companies to produce products with superior sustainability performance, yet educators are disadvantaged in training students about sustainable engineering and many engineers are often not well‐positioned to perform product sustainability as‐ sessments. In particular, quantifying environmental impacts is a key aspect of achieving improved product sustainability performance that has garnered much attention over the past two decades, but tools remain deficient to assist manufacturing decision making. In light of efforts undertaken to develop sustainability assessment methodologies, we review recent developments in quantifying a widely adopted environmental performance metric, carbon footprint, in manufacturing processes and supply chain networks. We also present a method‐ ology to address the deficit identified from this review for simple, easy‐to‐use sustainability assessment methods and tools. We suggest a questionnaire‐based methodology to provide non‐experts with a better understanding of sustainability performance, specifically during the product design phase. An application of the methodology is demonstrated to quantify and compare environmental impacts for the produc‐ tion of two quadcopter upper shell designs. The review presented can help the sustainable design and manufacturing community in identi‐ fying research gaps, while non‐expert engineers and engineering students can benefit from application of the presented methodology in learning and in practice.

Quality Enhancement with Ultrasonic Wave and Pulsed Current in Electrochemical Machining Technical Publication. NAMRC2017‐156 Wayne Hung, Texas A&M University, Jigar Patel, Texas A&M University, Zhujian Feng, Texas A&M University, and Pedro Villanueva, COMIMSA This paper presents the results of the novel enhancement in Electrochemical Machining (ECM) by providing pulsed current to an electrode while embedding ultrasonic wave into flowing electrolyte through an electrode. Teflon coated stainless steel tubes were used as electrodes to produce deep holes in 6061‐T6 aluminum. Material removal rate and hole quality were measured on a 3D optical profiler to study the effect of pulsed current amplitudes and frequencies, machining times, and ultrasonic wave amplitudes. Although pulsed current improves the removal rate, cavitation induced microjet suppresses the ionization process. The shockwaves from busting of cavitated bubbles break the aluminium tri‐bromide by‐product into fine powder that flows and polishes the workpiece surface. Although ultrasonic wave at 40 KHz compromised material removal rate, it significantly enhance the part quality when reducing surface roughness from 2.5 µm to 1 µm. The combined effect of pulsed current and ultrasonic wave reduces taper angle of ECM’ed holes sidewall from ~10° to 1°. 164

Numerical Investigation of CP‐Ti/Cu110 Impact Welding using Smoothed Particle Hydrodynamics and Arbitrary Lagrangian‐Eulerian Methods Technical Publication. NAMRC2017‐157 Ali Nassiri, The Ohio State University, Shunyi Zhang, University of New Hampshire, Taeseon Lee, The Ohio State University, Tim Abke, Honda R&D, North America, Anupam Vivek, The Ohio State University, Brad Kinsey University of New Hampshire, and Glenn Daehn, The Ohio State Univesity To support the lightweighting aim in the automotive industry, high‐velocity impact welding (HVIW) can be used to join dissimilar metals. The manufacturing industry often relies on numerical simulations to reduce the number of trial‐and‐error iterations required during the process development to reduce costs. However, this can be difficult in high strain rate manufacturing processes where extremely high plas‐ tic strain regions develop. Thus, a traditional Lagrangian analysis is not able to accurately model the process due to excessive element dis‐ tortion. In order to further understand the science behind HVIW processes and benefits of various numerical simulation methodologies, two methods were utilized to simulate CP‐Ti/Cu110 bimetallic system. First, a Smoothed Particle Hydrodynamics (SPH) model of two im‐ pacting plates was created. Using SPH method, metal jet emission was investigated which previously was impossible. The results then were compared with an Arbitrary Lagrangian‐Eulerian (ALE) method. Finally, the numerical results were compared with experimental tests using a Vaporizing Foil Actuator Welding process.

Environmental Performance Evaluation of Direct Metal Laser Sintering through Exergy Analysis Technical Publication. NAMRC2017‐158 Hari Prashanth Narayan Nagarajan Oregon State University and Karl Haapala Oregon State University Additive manufacturing is rapidly emerging as an alternative to traditional, subtractive metal manufacturing processes, often attributed to its claim for sustainable product development, e.g., reduced cost, reduced energy and material use, and the distributed production of tai‐ lored consumer products. We posit that exergy analysis can be applied to better evaluate the environmental performance of additive man‐ ufacturing processes. A cradle‐to‐gate characterization of direct metal laser sintering (DMLS) of iron metal (Fe) powder is conducted. A thermodynamic evaluation of resources and energy utilized and lost in the process is performed. It is found that only 6% of total process inputs contribute to material processing, while 94% is lost as bulk waste, heat, and work. Environmental assessment is performed to char‐ acterize the impacts of these losses using the ReCiPe 2008 and Global Warming Potential (GWP) impact assessment methods. The results show that the GWP of the DMLS process and its upstream processes due to electricity use is 6.2 kg CO2 equivalent. The ReCiPe method indicates impacts on human health outweigh those to ecosystem quality and resource availability.

In‐situ Droplet Inspection and Control System for Liquid Metal Jet 3D Printing Process Technical Publication. NAMRC2017‐160 Tianjiao Wang, University at Buffalo, the State University of New York, Tsz‐Ho Kwok, Concordia University, and Chi Zhou, University at Buffalo, the State University of New York Liquid Metal Jet Printing (LMJP) is a revolutionary metal 3D printing technique. The driving force is produced by magneto‐hydrodynamic property of liquid metal in an alternating magnetic field. Due to its integrated melting and inkjeting process, it can fabricate complex metal parts 10x faster at 1/10th of cost compared to current metal 3D printing techniques. However, the jetting process may be influenced by many uncertain factors, which imposes a significant challenge to its process reliability and product quality. To address this challenge, we present a closed‐loop control mechanism using vision technique to inspect droplet behaviours. This system automatically tunes the drive voltage applied to compensate the uncertain influence based on vision inspection result. To realize this, we first extract multiple features and properties from both frozen and dynamic images to capture the droplet behaviour. Second, we use a voting‐based decision making technique to determine how the drive voltage should be adjusted. We test this system on a piezoelectric‐based inkjeting emulator, which has very similar jetting mechanism to the LMJP. Results show that much more stable and precise jetting behaviour can be obtained in re‐ al‐time. This system can also be applied on other droplet related applications due to its universally applicable characteristics.

Iso‐Scallop Tool Path Building Algorithm based on \Tool Performance Metric" for Generalized Cutter and Arbitrary Milling Zones in 3‐Axis CNC Milling of Free‐Form Triangular Meshed Surfaces Technical Publication. NAMRC2017‐161 Andrey Balabokhin University of South Carolina and Joshua Tarbutton University of North Carolina Charlotte In order to generate a tool path, the scallop height should be under the given precision requirement and the tool path should not be longer than necessary. The iso‐scallop tool path generation method is commonly used to generate an effective tool path. This paper discusses a new method to generate an iso‐scallop and contour‐parallel oset tool path for generalized cutter geometry and an arbitrary area on a free‐form surface in 3‐Axis CNC milling. The milling surface (originally represented as a triangular mesh), and the generalized cutter surface are converted into voxel‐based depth maps. A milling zone map with the same resolution as the part depth map is used to define an arbi‐ trary milling area. The points on the boundary of milling area are marked in order to build the tool path that can follow a boundary line. Different cutter location positions are explored in order to satisfy the following conditions: the ability to mill the material from the selected 165 boundary points within the tolerance limit and while having the maximum material removal rate. The algorithm is repeated until the whole zone to mill is finished. The result of the algorithm is a tool path set that can traverse the provided milling zone. Graphics processing units are employed for the most time consuming operations, due to the high demand of computational power.

Periodic Error Compensation in Fiber‐coupled Heterodyne Interferometry Technical Publication. NAMRC2017‐162 Chao Lu, University of South Carolina, Jon Ellis, University of Rochester, Ethan Burnam‐Fay, University of Rochester, Tony Schmitz University of North Carolina at Charlotte, and Joshua Tarbutton, University of North Carolina at Charlotte This paper extends the application of a novel wavelet‐based periodic error compensation algorithm in fiber‐coupled heterodyne interfer‐ ometry. In this case, the amplitudes of periodic error may be fluctuating and traditional digital algorithms are not well‐suited. The wave‐ let‐based method, however, has the ability to compensate non‐stationary periodic error. In this work, the algorithm is used to compensate periodic error in a non‐constant velocity motion and to reduce the error by approximately 81.2%.

Phase Transformation and Shock Sensor Response of Additively Manufactured Piezoelectric PVDF Technical Publication. NAMRC2017‐163 Joshua Tarbutton, University of North Carolina Charlotte, Tue Le, University of South Carolina, Greg Helfrich University of South Carolina, and Max Kirkpatrick University of South Carolina Recently the authors discovered the ability to print electroactive PVDF using a modified FDM printer. This paper discusses the results from investigating the phase change during printing using FTIR and DSC measurements. FTIR and DSC data was collected on the filament before the print, the printed filament without an applied electric field and the printed filament with a 30MV/m field applied during the print. The results show a definitive phase change during the print and indicate that the alpha phase of the PVDF was significantly modified. The FTIR results do not indicate a significant change in the beta phase of the polymer which is the dominant electroactive phase. Therefore it is likely that the bulk amorphous polymer phases have been aligned in the process. The response of the printed and poled PVDF demonstrates piezoelectric behaviour when subjected to impulse.

Micromilling of Poly(methyl methacrylate, PMMA) using Single‐Crystal Diamond Tools Technical Publication. NAMRC2017‐165 Emrullah Korkmaz, Carnegie Mellon University, Recep Onler, Carnegie Mellon University, and Burak Ozdoganlar, Carnegie Mellon University This paper presents an experimental investigation on micromachinability characteristics of Poly(methyl methacrylate) (PMMA, with the common trade names of Acrylic® or Plexiglass®) when using single‐crystal diamond micro‐endmills towards enabling rapid, accurate, and reproducible fabrication of PMMA parts for a broad range of applications. An experimental study with a full factorial design is conducted using a straight single‐crystal diamond micro‐endmill with a diameter of 450 μm. A set of full‐immersion micromilling tests are performed within a custom‐made miniature machine tool under varying spindle rotational speeds (90, 120, and 150 krpm), feed rates (5, 10, and 15 μm/flute), and axial depth of cuts (50 and 100 μm). The effects of cutting conditions on process forces, surface roughness, burr formation and shape retention (of the fabricated channel) are analyzed, and the material removal rate (MRR) is calculated in each case. It is shown that micromilling using single‐crystal diamond micro‐endmills reduces surface roughness, burr formation and force magnitudes, while cre‐ ating high‐quality features as compared to those obtained when using commercially available tungsten carbide micro‐endmills. Favorable cutting parameters and machining strategies for effective creation of micro‐scale features on PMMA can be identified using the presented micromachinability study.

A Modular‐Architecture Controller for CNC Systems Based on Open‐Source Electronics. Technical Publication. NAMRC2017‐166 Jorge E. Correa, University of Illinois at Urbana‐Champaign, Nicholas Toombs University of Illinois at Urbana‐Champaign, and Placid M. Ferreira University of Illinois at Urbana‐Champaign Open control architectures regain relevance with the new revolution of open source electronics. This paper presents the general ideas, examples of implementation and latest advances of a new, open architecture controller for CNC systems based on open source electronics. The multiprocessor and distributed architecture of this controller leverages the power of platforms like Arduino or TI Launchpad to realize CNC systems of increased computational resources, closed‐loop position of the tool, smother motions and higher feeds. Additionally, this work demonstrates the first steps in the development of virtual machine as a new software component of the architecture. A “tight bind‐ ing” between the real and virtual machines will delineate the path for realistic, machine monitoring, remote operation and process plan‐ ning environment.

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On The Analysis of Metal Droplets during Cold Metal Transfer Technical Publication. NAMRC2017‐171 Chen Zhou, General Motors Research and Development, Hongliang Wang, General Motors Research and Development, Thomas Perry General Motors Research and Development, and James Schroth, General Motors Research and Development Cold metal transfer (CMT) is an advanced gas metal arc welding (GMAW) process that features a reduced thermal input and improved sta‐ bility of arc. This report examines the correlations between welder parameters and droplet properties in a one‐cycle CMT characteristic where a single droplet was transferred. Through design of experiment and statistical analysis, it is revealed that the weight of the deposited metal droplet has a linear relationship with the output energy of CMT, and the weight can be precisely controlled by adjusting CMT param‐ eters. The droplet surface contact angle is independent of the output energy and has no clear correlation with CMT parameters due to the relatively large thermal conductivity of copper and the heat capacity of the coupon. However, when the thickness of the copper coupon was reduced, the substrate temperature did increase, and the droplet had a smaller contact angle. In addition, the metal droplet transfer during the CMT process is subjected to a phenomenon known as magnetic arc blow which affects the landing position. When the ground connection was not in line with the electrode, the bent electric current path deflected the welding arc away from the ground connection. When the ground connection was attached underneath the projection path of the electrode, the droplet deflection disappeared. The knowledge obtained in this study is crucial to optimizing the CMT process and improving the quality of the subsequent copper joining pro‐ cesses.

Mapping the Digital Manufacturing & Design Ecosystem and Preparing for the Jobs of Future Factories Technical Publication. NAMRC2017‐172 Lory Antonucci, ManpowerGroup, Michael Fornasiero Digital Manufacturing Design and Innovation Institute, and Haley Ste‐ vens Digital Manufacturing Design and Innovation Institute With the rapid pace of technological change in manufacturing and increasing labor costs in key overseas markets, American manufacturing appears poised to surge in coming years. Adopting digital manufacturing and design technologies enables enterprises to connect the manufacturing life‐cycle through data, and utilize that information to make smarter more efficient business decisions. However, manu‐ facturers face a talent shortage as training programs struggle to keep pace and enterprises restructure to utilize advanced technologies, ultimately threatening a $2.1 trillion sector of the economy. The Digital Manufacturing & Design Innovation Institute (part of Manufac‐ turingUSA) in partnership with ManpowerGroup has brought together leading manufacturers, educators, policymakers, and workforce experts to identify the key job roles and technological interactions to drive the digital manufacturing revolution throughout the United States. The work presented creates a common language to define the emerging roles, skills, and interactions that are advancing enter‐ prises and shaping our Future Factories. These materials aim to align industry and academia on training and hiring, and to provide insight on future careers in American manufacturing enterprises, large and small. Critical strategies must be developed to prepare both our fu‐ ture and existing workforces aimed at emerging and existing technologies that challenge current models and approaches.

Machinability Study of Unidirectional CFRP Laminates by Slot Milling Technical Publication. NAMRC2017‐173 Jianbo Sui, United Technologies Research Center (China) Ltd., Wenping Zhao, United Technologies Research Center, and Changle Li, United Technologies Research Center (China) Ltd. Slot milling of unidirectional CFRP laminates in four directions relative to fiber orientation is conducted to effectively study the machinabil‐ ity of CFRP composites with respect to process parameters and fiber orientation. First, slot milling experiments with a full factorial design are conducted to include all fiber orientation angles from 0 to 180 degree. Then the cutting forces with respect to fiber orientation angle and chip thickness are decoupled and results are analyzed. The results show that both fiber orientation angle and chip thickness have sig‐ nificant effect on cutting forces and the specific force energies with respect to chip thickness are governed by power law for fiber orienta‐ tion angle lower than 135 degree.

Thermo‐Physical Modelling of Track Width During Laser Polishing of H13 Tool Steel Technical Publication. NAMRC2017‐174 Shirzad Mohajerani, Western University, Joshua D. Miller, Western University, O. Remus Tutunea‐Fatan Western University, and Evgueni Bordatchev, National Research Council of Canada A three‐dimensional CFD model has been developed to predict track width during laser polishing (LP) of H13 tool steel. The developed model incorporates several different mechanisms for heat transfer such as conduction, convection, and radiation as well as temperature dependencies for relevant material properties. Experimental calibration was carried out to obtain adequate absorptivity value. After per‐ forming the mesh‐sensitivity assessment, simulation results have been validated against experimental data. The relatively low errors ob‐ tained suggest that the developed model is capable to accurately describe the effect of process parameters on molten pool dimensions and/or geometry.

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Data Analytics Framework for Semi‐continuous Manufacturing Process – Implementation Vision with a Use Case Technical Publication. NAMRC2017‐176 Parikshit Mehta, Arconic Inc, Christopher Seaman Arconic Inc, and Sergio Butkewitsch‐Choze, Arconic Inc This paper discusses some of the challenges and opportunities involving implementation of data analytics frameworks for semi‐continuous manufacturing processes. With the concurrent efforts in process modeling, data collection and on‐line process control, process perfor‐ mance has been continually improving over the years. On a modern production center, there are hundreds of sensors continuously collect‐ ing process information along with the product quality information available post‐process. These data contain vital process insights yet organization, filtering and contextualization challenges prohibit the widespread use of the data to gain valuable insights about the process. The first part of this paper discusses data requirements and pre‐processing necessary to utilize data for process insights discovery. The second part of the paper presents a use case of a data analytics framework to diagnose a particular process fault using multiple data forms and timescales. The paper concludes with thoughts on wide‐spread deployment of such techniques.

Error Compensation and Accuracy Improvements in 5‐axis Machine Tools Using the Global Offset Method Technical Publication. NAMRC2017‐178 Jie Gu, General Motors, John Agapiou, General Motors, and Sheri Kurgin, General Motors To enhance the machine tool accuracy, the Global offset method is developed for compensating the five‐axis machine tool errors based on the measurement results of one or more identical machined parts. The machined features of a part are measured in a CMM and evalu‐ ated by a compensation processor, based on which the Global offset parameters, representing the machine tool errors, are estimated. The methodology is capable of compensating the overall effect of all position‐dependent and position‐independent systematic errors which contribute to particular workpiece accuracy. The developed technique and software are based on the Global offset method which inter‐ prets the computed deviations between the measured and nominal dimensions of the part through the analysis, synthesis and modeling of a fixture and rotary tables errors. The proposed model‐based error compensation method is simple enough to be implemented in five‐axis CNC machine tools. Production results exhibit effective compensation and remarkable improvement in the workpiece accuracy of the five‐axis machine tools.

Experimental Analysis of Laser and Scanner Control Parameters During Laser Polishing of H13 Steel Technical Publication. NAMRC2017‐179 Joshua Miller, Western University, Tutunea‐Fatan Western University, and Evgueni Bordatchev National Research Council of Canada Laser polishing is a manufacturing process in which a small amount of material is melted via laser irradiation and molten pool is then redis‐ tributed to create a smoother surface finish/superior surface quality. The focus of this study is to generate more comprehensive under‐ standing of the effects that laser and scanner control parameters have on the formation of laser polished lines. A parameter known as “la‐ ser on/off delay” is varied along with the laser power to study the impact that these parameters have on the synchronization between laser power and beam scanning velocity. It was determined through experimental analysis, that the “laser on delay” parameter plays a signifi‐ cant role on the formation of the laser polished lines, essentially in a region that is outside to the widely characterized “steady state” zone of constant track width. A set of experiments was conducted to identify the combined effect of transient (acceleration/ deceleration) phas‐ es for laser power and speed on the terminal geometry of the polished line. When the optimal transient combination of power and speed was used, surface quality improvement by 83% (areal surface roughness (Sa) reduction from 1.35 µm to 0.23 µm) was obtained.

Longitudinal Milling and Fine Abrasive Finishing Operations to Improve Surface Integrity of Metal AM Components Technical Publication. NAMRC2017‐180 Ashif Iquebal, Texas A and M University, Skander Amri, Texas A and M University, Sanjay Shrestha Youngstown State Univer‐ sity, Guha Manogharan, Pennsylvania State University, Satish Bukkapatnam Texas A and M University, and Zimo Wang Growing market of additive manufacturing and in particular, metal AM has allowed the manufacturers to produce a wide variety of com‐ plex designs with near‐net shape in minimum time without the need for custom tooling. However, the application of additive manufactured components in various application e.g., biomechanical contacts, naval and aerospace components, etc. are limited due to its poor surface integrity and part feature tolerance limits. Traditional methods, e.g., milling, do provide solution to some of the post‐processing needs, however, results in poor material utilization, requires custom tooling or may be completely infeasible for complex geometries. In the cur‐ rent work, we focus on developing a post‐processing strategy by coupling traditional machining processes with non‐traditional fine abrasive finishing methods. Preliminary results on 316 L stainless steel components fabricated via laser powder‐bed fusion suggests that the pro‐ posed post‐processing strategy can be used to (a) selectively impart surface finish Sa < 25 nm, and (b) reduce the surface porosity by 89% when compared to the as‐fabricated sample.

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Experimental investigation of Droplet Impact on Metal Surfaces in Reduced Ambient Pressure Technical Publication. NAMRC2017‐181 Benjamin Mitchell, University of New Hampshire, Teagan Bate, University of New Hampshire, Joseph Klewicki, University of New Hampshire, Yannis Korkolis University of New Hampshire, and Brad Kinsey, University of New Hampshire Impacting water droplets are capable of eroding steam turbine blades, high speed aircraft and even metal surfaces (i.e., a machining opera‐ tion). In this latter process, high velocity (~100m/s) water droplets impact a solid surface under conditions in which the ambient air pres‐ sure is sub‐atmospheric. Past research has shown that droplet splashing is suppressed when the ambient air pressure is reduced, but the effects on the associated impact force are unknown. Thus, the physics of this erosion mechanism are not completely understood. To begin to unravel this phenomenon, the impact force of 3.5mm diameter, low velocity (~4m/s) droplets in a reduced pressure environment (23.3kPa) are presented in this paper. A 38x38x50cm vacuum chamber was developed for these studies with a unidirectional piezoelectric force sensor to measure the transient force of impacting droplets. The results confirm that while the droplet collapse is significantly differ‐ ent between the two ambient pressure cases, the impact force and impulse are relatively unchanged (except for magnitude variations due to slight differences in the impact velocity due to reduced drag forces).

Time‐Averaged and Instantaneous Mechanistic Models using Artificial Force Synthesis in Helical End Milling Technical Publication. NAMRC2017‐182 Raja Kountanya, United Technologies Research Center, Changsheng Guo, United Technologies Research Center, and Daniel Viens, United Technologies Research Center This paper aims to develop field‐deployable mechanistic milling models with the aid of the Virtual Machining Simulation Environment (VMSE). Stabler’s rule and sharp tool hypotheses were adopted. VMSE force components for artificial materials with unit normal Kn and friction Kf force coefficients were least‐squares‐fit to experimental values to obtain actual Kn and Kf and then functionally fit to chip thick‐ ness h, speed and normal rake angle. The new approach was tested with a simple ball end mill tool. Both time‐averaged (MMa model)and location‐averaged instantaneous (MMi model)force components from a subset of experimental data were used. Physical force components reported by the VMSE with both MMa and MMi for the com‐ plete test matrix agreed with their experimental counterparts. MMi significantly expanded the range of h and was identical to MMa in the common range.

Training the Workforce in Advanced Composites and Processes Oral Presentation. NAMRC2017‐ORAL1 Joannie A. Harmon, IACMI – The Composites Institute IACMI – The Composites Institute is the fifth Institute in the National Network of Manufacturing Innovation, supported by the US Depart‐ ment of Energy’s Advanced Manufacturing Office. Our collaboration of industry, research institutions and state partners is committed to accelerating development and adoption of cutting‐edge manufacturing technologies for low‐cost, energy‐efficient manufacturing of ad‐ vanced polymer composites for vehicles, wind turbines, and compressed gas storage. One of IACMI’s goals is to prepare the current and future workforce directly affected by new composites technologies. IACMI develops training programs to prepare them before new compo‐ sites technologies are fully integrated into industry.

During 2016 a series of four workshops in advanced composite materials and closed mold processes were delivered across the United States serving over 540 participants from industry, academia, government and others. As a member of the Closed Mold Alliance (CMA), IACMI – The Composites Institute and partners, Composites One, Magnum Venus Products, and RTM North Technologies, designed work‐ shops to help participants become more adept in advanced and closed mold processing, out‐of‐autoclave production, additive manufac‐ turing (3D printing) light‐weighting of products, prototyping, selecting systems and equipment, advancements in composites and high per‐ formance materials, data acquisition, modeling and simulation. Sessions were led by experienced process experts.

Becoming a Global Hub of Manufacturing Talent: Florida’s Greater Gainesville Region Oral Presentation. NAMRC2017‐ORAL2 Staci Bertrand, Gainesville Area Chamber of Commerce and Council for Economic Outreach Manufacturing represents a sizable economic anchor to local, state and federal economies and is therefore vital to competitiveness of each region throughout North America. As visionary organizations, it is now critical for economic development organizations and Chambers of Commerce to assist in developing a reliable talent pipeline for manufacturers convening industry leaders, educational institutions and workforce development partners. The Chamber’s Advanced Manufacturing Council, one of several industry councils at the Gainesville Area Chamber of Commerce, is the region’s unified voice to communicate the needs of manufacturers for education, workforce and advocacy as the community endeavors to retain and expand existing manufacturers, attract new manufacturers to the region and assist manufacturing start‐up companies. Through the Council’s efforts, educational and workforce programs are now in existence within K‐12 to post‐secondary education. Key initiatives of the Council for the Greater Gainesville, FL Region include building regional awareness of the manufacturing industry, enhancing educational partnerships with the K‐12 school board, Santa Fe College ‐ the #1 community college in the nation, and University of Florida, the state’s preeminent university. 169

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