bluuebunny/crossref_metadata_2025 huggingface dataset:
Research on Data Generation Method in Cloud Manufacturing Simulation Platform
Authors: Zhao Chun , Zhang Lin
Published: July 2017

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 related 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.
Simulation Optimization for Computer Models With Multivariate Output
Authors: Kontar Raed , Zhou Shiyu , Horst John
Published: July 2017

This paper explores the potential of Gaussian process based Metamodels for simulation optimization with multivariate outputs. Specifically 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 features of the Multivariate Gaussian process models are then demonstrated in a case study for the optimization of manufacturing performance metrics.
On the Fatigue Performance of Nanoparticles Reinforced Iron by Selective Laser Melting
Authors: Wang Yachao , Shi Jing , Lu Shiqiang , Xiao Weihan
Published: July 2017

Selective laser melting (SLM) is an additive manufacturing process that uses laser beam to melt metal powders and allow the melt to solidify 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 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 regime, 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
Authors: Wang Zhiyu , Saldana Christopher , Basu Saurabh
Published: July 2017

Severe plastic burnishing was investigated as a promising surface severe plastic deformation technique for generating gradient microstructure surfaces. The deformed state of oxygen free high conductivity copper workpieces during the surface deformation process was determined with high-speed imaging, this complemented by microstructure characterization using orientation image microscopy based on electron 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 equiaxed 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 surface with expected mechanical and microstructural responses is suggested.
Study of Living Cell Distribution During Inkjet Printing of Bioink
Authors: Zhang Mengyun , Krishnamoorthy Srikumar , Song Hongtao , Xu Changxue
Published: July 2017

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 constructs with uniform cell distribution.
Investigation on Drilling Performance of Titanium Alloy Ti6Al4V Based on Response Surface Method
Authors: Zhu Zhaoju , Sui Shaochun , Sun Jie , Li Jianfeng , Liu Kai
Published: July 2017

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 significant 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
Authors: Zhu X. P. , Du P. C. , Meng Y. , Lei M. K. , Guo D. M.
Published: July 2017

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 established 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 the material and geometry constraints hindering achievability of a desired surface integrity during conventional manufacturing as well as the complex influence of multiple surface integrity parameters on a final performance. In this study, thermally sprayed WC-10Ni coatings onto stainless steel using high velocity oxy-fuel (HVOF) spraying process are investigated to identify the surface integrity predominantly determining the water-lubricated wear performance of coated steel, and then to correlate it to process parameters. The controllable surface integrity facilitates identifying responsible surface integrity parameters for a required high performance, and subsequently deriving necessary process parameters for achieving the desired responsible surface integrity. Specifically, HVOF process 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 spraying powders and impact velocity of the molten splats onto stainless steel to form the coatings. Surface features including porosity and phase structure, and surface characteristics including hardness, elastic modulus, and fracture toughness were studied with respect to the wear performance. The porosity and WC phase composition of coatings are identified responsible for the wear performance, as two essential surface integrity parameters that in turn greatly affect the surface characteristics including coating hardness, elastic modulus and fracture toughness. Consequently, the process parameter O/F is feasibly correlated to wear resistance through the responsible surface integrity parameters, as elucidating the coating formation mechanism of influence of particle velocity and temperature on the coating porosity and WC decomposition.
Dynamic Manufacturing Scheduling Under Real-Time Electricity Pricing Based on MILP and ARIMA
Authors: Zhai Yuxin , Wang Haiyan , Zhao Fu , Sutherland John W.
Published: July 2017

The scheduling of manufacturing equipment is critical in production facilities. Research on production scheduling has traditionally focused on component throughput and cycle time. However, the increase of electricity price in the United States following the market deregulation in 1990s has led to efforts to reduce 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 maintaining a pre-determined production throughput. A time series model is developed to forecast the hourly electricity price and time-indexed integer programming 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 parts per day, the results suggest that it is possible to reduce the cost by 3.6% using an hourly forecast compared with a schedule based on a day-ahead price forecast.
Tool-Chip Interface Temperature Measurement in Interrupted and Continuous Oblique Cutting
Authors: Kesriklioglu Sinan , Morrow Justin D. , Pfefferkorn Frank E.
Published: July 2017

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 protective layer to obtain temperature data 1.3 μm below the tool-chip interface. Oblique interrupted cutting tests on AISI 12L14 steel were performed 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
Authors: Kim Dong Min , Kim Do Young , Jo In Su , Song Tae Jin , Paik Kyung Soo , Park Hyung Wook
Published: July 2017

The hard turning process is widely used in automobile and heavy machinery industries. Extreme cutting conditions like high temperature and tool wear rate, are associated with the hard turning process. Cubic boron nitride (CBN) cutting tool is generally preferred for hard machining operations. However, higher tool cost, and tool failure due to thermal shock limits its widespread usage. In machining performance analysis, tool wear is an important parameter which is directly related to the cost of the machining process. Previous studies have reported the improvement in tool life by using cryogenic coolant as a cutting fluid. Objective of this paper is to investigate the effect of cryogenic cooling on the tool wear of CBN and Ti-coated alumina ceramic cutting tools used in the hard turning of AISI 52100 hardened steel. High pressure cryogenic jet (HPCJ) module was optimized and configured to use it for hard turning case. Computational fluid dynamics (CFD) based simulation was used to test and optimize the nozzle design for the flow of cryogenic coolant. It was validated by fundamental heat removal test. Ceramic and CBN cutting tools were then used for hard turning of parts using HPCJ module. Flank wear lengths for various cooling conditions were measured and analyzed. It was observed that the higher tool life of a Ti-coated alumina ceramic can be achieved under cryogenic cooling technique, as compared to the CBN insert under dry conditions. Cost analysis of these hard turning cases was also conducted to check the feasibility of its usage under realistic shop floor conditions. It was observed that the machining using Ti-coated ceramic under cryogenic jet may reduce the total tooling cost compared to CBN cutting tool conducted under dry conditions.
Joint Production and Maintenance Decision-Making in Mixed-Model Assembly Systems
Authors: Gu Xi , Guo Weihong
Published: July 2017

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
Authors: Arinez Jorge , Zou Jing , Chang Qing , Lei Yong
Published: July 2017

For multi-stage manufacturing system, considerable amount of energy may be wasted and energy efficiency may be hindered due to idleness 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
Authors: Heigel J. C. , Lane B. M.
Published: July 2017

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.
Process Development for a Robotized Laser Wire Additive Manufacturing
Authors: Akbari Meysam , Ding Yaoyu , Kovacevic Radovan
Published: July 2017

Additive manufacturing has attracted the attention of industries such as aerospace and automotive as well as the medical technology sectors 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 complicated geometries.
Simulation Based On-Line Evaluation of Singulation Plans to Handle Perception Uncertainty in Robotic Bin Picking
Authors: Kumbla Nithyananda B. , Thakar Shantanu , Kaipa Krishnanand N. , Marvel Jeremy , Gupta Satyandra K.
Published: July 2017

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 singulation plan may fail during execution. In such cases, the singulation process will need to be repeated. We are interested in selecting singulation plans that minimize the expected task completion time. In order to estimate the expected task completion time for a proposed singulation 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 computationally efficient simulations for on-line evaluation of singulation plans. Results from physical experiments match well with predictions obtained from simulations.
Evaluation of Environmental Sustainability for Additive Manufacturing Batch Production
Authors: Yang Yiran , Li Lin
Published: July 2017

Additive manufacturing (AM), owning to the unique layer-by-layer manufacturing method and its associated advantages, has been implemented 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., energy 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 production 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
Authors: Sasahara Hiroyuki , Goto Masato , Takahashi Wataru , Yamamoto Hiromasa , Muraki Toshiyuki
Published: July 2017

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. Results 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 on Key Methods of On-Machine Micro Milling Cutter Condition Inspection Based on Machine Vision
Authors: Zhang Xi , Zhang Benzheng , Shi Yuanyuan , Shang Bo
Published: July 2017

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.
Design of a Tip Based In-Line Metrology System for Roll-to-Roll Manufactured Flexible Electronic Devices
Authors: Connolly Liam G. , Cullinan Michael
Published: July 2017

The development of accurate, noncontact surface imaging is key to implementing an effective metrology strategy to manage defect detection in high volume flexible electronic device fabrication. This paper presents the design of a compound, double parallelogram flexure-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 device for roll-to-roll (R2R) electronics manufacturing and shown in Fig. 1 [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 μm line scans every 0.15 seconds for a total throughput of over 75 μm2/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 reliably measure and analyze nanofeatured, R2R manufactured, flexible electronics in a cost-effective manner and provide fast, continuous defect identification.
Enhancing Mechanical Properties of Thin-Walled Structures Using Non-Planar Extrusion Based Additive Manufacturing
Authors: Alsharhan Abdullah T. , Centea Timotei , Gupta Satyandra K.
Published: July 2017

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 deposition method and orientation has on the failure mode.
Effect of Binder Content on Hybrid Magnetic Tool Behavior
Authors: Stein Max , Yamaguchi Hitomi
Published: July 2017

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.
An Energy Saving Scheduling Method for Just in Time Material Handling in Mixed-Model Assembly Line
Authors: Hu Liman , Zhou Binghai , Li Yang
Published: July 2017

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.
Effect of Needle Diameter on Scaffold Morphology and Strength in E-Jetted Polycaprolactone Scaffolds
Authors: Bhargav Aishwarya , Rosa Vinicius , Wen Feng Lu , Fuh Jerry Y. H.
Published: July 2017

Electro-hydrodynamic Jetting or E-Jetting is a process in which a polymer, dissolved in a solvent and extruded through a needle onto a substrate. A potential difference is applied between the needle and the substrate to facilitate the homogeneous extrusion of the fiber. 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

Scaffolds are dependent on the cell type, as each type of cell has a different set of requirements depending on the functionality. Bone cells are smaller than soft tissue cells, hence a common scaffold design may not be suit either of the applications. Thus, a one size fits all approach is not suitable for the scaffold [9]. As seen in Figure 1, the Red Blood Cells are a fraction of the size of the fibroblasts and bone marrow stem cells [20–22]. Similarly, the stiffness of the cells is also different.

Electro Hydrodynamic Jetting (E-jetting) is a process that is used to fabricate such 2D scaffolds by extruding a polymer solution through a needle and forming a fiber by applying a 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 database. The purpose of creating this database is to choose a select needle for a selected biomedical application.
The Development of a Novel Positioning System to Improve Pulmonary Outcomes in Critically Ill Patients
Authors: Hennigan Kalie , Miller Scott , Kabbur Prakash , Woo Russell
Published: July 2017

An automated inflatable repositioning device was created in this study for use in the developmentally supportive care of premature neonates. 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 multi-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.
Effects of Tool Nose Corner Radius and Main Cutting-Edge Radius on Cutting Temperature in Micro-Milling Inconel 718 Process
Authors: Lu Xiaohong , Wang Hua , Jia Zhenyuan , Si Likun , Liang Steven Y.
Published: July 2017

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 verified 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
Authors: Lu Xiaohong , Zhang Haixing , Jia Zhenyuan , Feng Yixuan , Liang Steven Y.
Published: July 2017

Micro-milling tool breakage has become a bottleneck for the development of micro-milling technology. A new method to predict micro-milling tool breakage based on theoretical model is presented in this paper. Based on the previously built micro-milling force model, 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 provides a new method for the prediction of micro-milling tool breakage, and therefore guides the cutting parameters selection in micro-milling.
Manufacturing and Computational Fluid Dynamics Modeling of a Patient-Specific Fistula Model
Authors: Liu Yang , Zheng Yihao , Pitre John , Weitzel William , Bull Joseph , Shih Albert
Published: July 2017

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 estimate 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 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.
Experimental and Numerical Analysis of Burn Marks and Shrinkage Effect on Injection Molding
Authors: Beheshtian Mesgaran Saeed , Elhami Nik Farzad , Seyyed Mousavi Seyyed Emad
Published: July 2017

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 proposed 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. Furthermore, 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
Authors: Lynn Roby , Louhichi Wafa , Parto Mahmoud , Wescoat Ethan , Kurfess Thomas
Published: July 2017

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 medium-size enterprises need efficient and easily deployable methods for data collection and analysis. This paper presents three broad solutions to data collection from machine tools, all of which rely on the open-source and royalty-free MTConnect protocol: the first is a machine 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 real-time data from a machining process.
Development of an Integrated Melt Modulation System to Manipulate Cold-Runner Injection Molding Processing Parameters and Their Effects on Final Product Physical and Optical Properties
Authors: Alsarheed Majed E.
Published: July 2017

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 during 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.
Laser Surface Engineering of Hierarchy Hydroxyapatite Aerogel for Bone Tissue Engineering
Authors: Parandoush Pedram , Fan Hanxiong , Song Xiaolei , Lin Dong
Published: July 2017

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.
Interoperability in Cloud Manufacturing and Practice on Private Cloud Structure for SMEs
Authors: Wang Xi Vincent , Wang Lihui
Published: July 2017

In recent years, Cloud manufacturing has become a new research trend in manufacturing systems leading to the next generation of production 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 interoperability 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 challenges 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.
Analysis of Cryogenically Treated Sheet Nylon 6/6
Authors: Shaffer Derek , Reinstadtler Cody , Roth John T. , Ragai Ihab
Published: July 2017

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 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 resulted in decreases in the Nylon’s natural response at the structure’s dominate mode. These initial findings indicate that the conventional 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.
Turning Force Prediction of AISI 4130 Considering Dynamic Recrystallization
Authors: Pan Zhipeng , Feng Yixuan , Ji Xia , Liang Steven Y.
Published: July 2017

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 mechanical and thermal loads. The model is validated by comparing the predicted machining forces with experimental measurements.
A Desktop Application for Sustainability Performance Assessment of Composed Unit-Based Manufacturing Systems
Authors: Smullin Matteo M. , Iman Zahra , Haapala Karl R.
Published: July 2017

Life cycle assessment software packages such as SimaPro, GaBi, and Umberto have become well-established tools for conducting environmental impact analysis. However, applications for broader sustainability assessment are limited. Recent research has developed an information modeling framework to compose models of unit manufacturing processes for sustainability assessment and has led to the definition of unit manufacturing process information modeling concepts. An engineer can use the framework to conduct manufacturing system-level sustainability assessments by composing models of unit manufacturing processes. Assessment results can aid engineers in selecting the superior manufacturing process flow for a given product. To demonstrate usefulness of the information framework, a prototype desktop application has been 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 follow the framework and are read by the application, which produces a sustainability assessment for the manufacturing process flow. A manufacturing process flow for an automobile-like metal product acts is used to demonstrate the software application.