bluuebunny/crossref_metadata_2025_split huggingface dataset:
Advanced Technological Pre-College Education Program in Composite Manufacturing
Authors: Abrate Serge , Lindsey Jefferson F. , Weston Alan , Rivers Jon , Dill William 
Published: December 2021

Abstract
This article describes a National Science Foundation sponsored project to promote technological education with a focus on composites manufacturing. This project has four components: (1)the promotion of careers in Technology to students in grades 7–11; (2) summer camps for students grades 7–11; (3) short courses for high school teachers; (4) developing new courses at the undergraduate level. For each component of the project, a rationale, detailed content, delivery methods, and assessment methods will be discussed.
Experience indicates a need to reach secondary school students to make them aware of careers in Technology and related educational opportunities at two-year and four-year institutions and to present a positive and attractive image of the field. Our efforts are directed towards students in grades 7–11. To reach a maximum of students in a large geographic area using several approaches:
1. Presentations using distance learning facilities that allow interactive audio/video presentations at different sites. Faculty members on campus can communicate with six or more sites simultaneously and present computer-based materials, videos, and conduct live demonstrations.
2. School visits. Many schools do not have access to site for interactive video presentations.
3. A web site developed for the project contains regularly updated information about the project, information about composite materials, and the field of technology. Interested parties can register for various programs by filling out the appropriate forms on the web.
4. Special events such as National Engineers Week and Open House Days are used to establish personal contacts.
This paper describes how the presentations are delivered, their contents, and how effective they are in promoting a positive image of technology.
Another important component of this project is that each institution offers summer camps for students in grades 7–11 and short courses for high school teachers. Each of these activities concentrate on one specific technical area and offer both a general view of that area and how it can lead to rewarding careers in industry, and direct hands-on experiences.
A Finite Element Analysis Study of Non-Linear Behavior in a Bolted Connection
Authors: Englund Richard B. , Johnson David H. , Sweeney Shannon K. 
Published: December 2021

Abstract
A finite element analysis (FEA) model of the interaction of a nut and bolt was used to investigate the effects of sliding, friction, and yielding in a bolted connection. The finite element model was developed as a two-dimensional, axisymmetric system, which allowed the study of axial and radial loading and displacements. This model did not permit evaluation of hoop or torsional effects such as tightening or the helical thread form.
Results presented in this paper include the distribution of load between consecutive threads, the relative sliding along thread faces, and the stress distribution and regions of yielding in the model. Finally, a comparison to previous, linear analysis work and to published experimental data is made to conclude the paper.
On Designing an Efficient Deburring Tool Path
Authors: Hassamontr Jaramporn , Dornfeld David A. 
Published: December 2021

Abstract
Due to the lack of edge finishing information on a part, the process planner usually designs a deburring tool path to cover all edges with low feed rates. This is to ensure that all part edges are within tolerance. With the presence of edge finishing information, however, it is possible to design the deburring tool path to cover only certain part edges while still maintaining the tolerance requirement. In this paper, the problem of planning such an efficient deburring tool path is formulated as a Travelling Salesman Problem. A few examples are used to illustrate the concept.
Decision Making in Developing Reconfigurable Manufacturing Center for Programmable Force Fit Insertion
Authors: Zhang Bopeng , Zheng Li , Xu Jiaqu 
Published: December 2021

Abstract
Most papers dealing with insertion related-assembly consider mainly loose fit insertions, but in machine building industries nearly 25–35% insertion operations are force fit insertion and are mainly completed manually, some times with the aid of a press machine. In this paper decision making in developing a reconfigurable manufacturing center for performing force fit insertion is presented. A special force fit insertion end effector and a dual mode fixture are developed then combined with a machining center for performing force fit insertion automatically. Functional requirements generation and descision making for conceptual design are explained. A prototype is established, it can perform programmable force fit insertions successfully.
Chatter Suppression With Multiple Time-Varying Parameters in Turning
Authors: Yang Fulun , Zhang Bi , Yu Junyi 
Published: December 2021

Abstract
This paper presents a new method, multiple time-varying parameter (MTVP) turning for chatter suppression. Compared to the single time-varying parameter (STVP) turning, the new method uses both time-varying spindle speed and time-varying rake angle to suppress chatter. The paper provides theoretical analyses on the MTVP turning and experimental results to justify the analytical results. It compares the effects of chatter suppression between the MTVP and STVP turnings, and discusses the possible mechanisms of chatter suppression. The paper then concludes that the MTVP turning method is more effective in chatter suppression than the STVP turning method because of the combined effect of the multiple time-varying parameters. It is demonstrated that the MTVP turning method can suppress chatter by 80%, and can be applied to suppress all kinds of chatter in a machining process.
Mechanistic Model for Tapping Process With Emphasis on Process Faults and Hole Geometry
Authors: Dogra Ajit Pal S. , Kapoor Shiv G. , DeVor Richard E. 
Published: December 2021

Abstract
A mechanistic approach for modeling the tapping process is presented. A methodology for computing chip load is developed for an arbitrary tap geometry. The mechanics of cutting for tapping is analyzed, considering it as an oblique cutting phenomenon. The effects of tap geometry (tap diameter, thread pitch, number of flutes, flute helix angle, tooth rake angle, and thread type), workpiece geometry (hole diameter and hole depth), process parameters (spindle speed and tap penetration depth), and process faults (tap runout, axis misalignment, and drilled hole geometry) are incorporated in the model. The model is calibrated using drilling experiments and is validated by comparing experimental tapping results for Aluminum 319, Aluminum 356, and Gray Cast Iron. In most cases, the tapping forces were predicted within 10% of the experimental values.
Cutting Force Modeling and Optimization in 3D Plane Surface Machining
Authors: Feng Hsi-Yung (Steve) , Su Ning 
Published: December 2021

Abstract
The prediction and optimization of cutting forces in the finishing machining of 3D plane surfaces using ball-end milling are presented in this paper. The cutting force model is developed based on the mechanistic modeling approach. This improved model is able to accurately predict the cutting forces for non-horizontal and cross-feed cutter movements typical in 3D finishing ball-end milling. Optimization of the cutting forces is used to determine both the tool path and the maximum feed rate in 3D plane surface finishing machining. The objective is to achieve highest machining efficiency and to ensure product quality. Experimental results have shown that the cutting force model gives excellent predictions of cutting forces in 3D finishing ball-end milling. The feasibility of the integrated process planning method has been demonstrated through the establishment of optimized process plans for the finishing machining of 3D plane surfaces.
Parallel-Process (Simultaneous) Machining and its Stability
Authors: Ozdoganlar O. Burak , Endres William J. 
Published: December 2021

Abstract
This paper presents a mathematical perspective, to complement the intuitive or practice-oriented perspective, to classifying machining operations as parallel-process (simultaneous) or single-process in nature. Illustrative scenarios are provided to demonstrate how these two perspectives may lead in different situations to the same or different conclusions regarding process parallelism. A model representation of a general parallel-process machining system is presented, based on which the general parallel-process stability eigenvalue problem is formulated. For a special simplified case of the general system, analytical methods are employed to derive a fully analytical stability solution. Thorough study of this solution through eigenvector analysis sheds light on some fundamental phenomena of parallel-process machining stability, such as dependence of the stability solution on phasing of the initial conditions (disturbances). This establishes the importance, when employing numerical time-domain simulation for such analyses, of specifying initial conditions for the multiple processes to be arbitrarily phased so that correct results are achieved across all spindle speeds.
Modeling of Tool Wear Acceleration in Relation to the Reinforcement Percentage in Cutting of Metal Matrix Composites
Authors: Li Xiaoping , Seah W. K. H. 
Published: December 2021

Abstract
A comprehensive study of the tool wear mechanism in cutting of metal matrix composites (MMCs) and its dependence on the percentage of reinforcement in the MMCs is presented. The results from experimental cutting of Aluminium alloy-Silicon Carbide Metal Matrix Composite (Al-SiC MMC) with tungsten carbide tools show that the main mechanism of tool wear in cutting of Al-SiC MMC includes two-body abrasion and three-body abrasion. The abrasive wear of the tool is accelerated when the percentage of the reinforcement in the MMC exceeds a critical value. The wear acceleration is caused by the interference between the reinforcement particles. The interference is associated with a critical weight percentage of the reinforcement in the MMC. The critical weight percentage of reinforcement is a function of the densities of the reinforcement and the matrix as well as the size of the reinforcement particles and the radius of the tool cutting edge. It does not vary with cutting conditions. An analytical model for the critical reinforcement percentage of MMCs is developed and verified with experimental results. The model is used to develop a map showing the critical reinforcement percentages of MMCs varying with the size of the reinforcement particles and the radius of the tool cutting edge.
Correlation of Acoustic Emission, Scanning Electron Microscopy and 3D Topography Data to Investigate the Ground Ceramic Condition
Authors: Maksoud Talal M. A. , Mokbel Amin A. , Morgan John E. 
Published: December 2021

Abstract
This paper considers the grinding parameters, which affect the initiation and propagation of surface and sub-surface cracks formed during the surface grinding of engineering ceramics. The results given in this paper are chosen from a much larger series of experiments, and can be shown to be representative in correlating the principal grinding parameters with a number of observed and measured properties. During grinding tests, for a range of grinding conditions, acoustic emission (AE) measurements, 3-D surface topography measurements, and scanning electron microscope (SEM) images are brought together in an effort to relate the initiation and propagation of surface and sub-surface cracks with specific grinding parameters. Subsequent results from three point bend tests carried out on ground specimens are also used to confirm the type and extent of sub-surface cracking produced during grinding.
The Application of Titanium Castings for Primary Structure in Commercial Airframes
Authors: Allison Daniel J. 
Published: December 2021

Abstract
As commercial airframers such as Boeing focus on improving profitability, low cost options for primary structure such as titanium castings are being seriously considered. Titanium castings offer nearly equivalent static strength properties as their equivalent wrought competition, but offer a potential for major reductions in machining. In addition to reduced machine time, castings can allow for dramatic design simplifications, employing fewer parts and fasteners and opening the door to more production friendly design philosophies such as Design for Manufacturing (DFM) and Determinant Assembly (DA). [1]
“Design Consultant”: A Network-Based Concurrent Design Environment
Authors: Ahn Sung-Hoon , Roundy Shad , Wright Paul K. , Liou Shuh-Yuan 
Published: December 2021

Abstract
In today’s globally distributed business environment, resolution of the communication problems between team members is a critical issue. A project named the Design Consultant has been launched to improve inter/intra-departmental communications. Leveraging available Internet technology, the Design Consultant enables designers to share design information with other team members including colleague designers, CAE analysts, manufacturing engineers, and marketing engineers. The network accessible DFX modules assist designers to simulate manufacturability and to estimate cost and time for fabrication resulting in faster product development. Building blocks of the Design Consultant were established based on a 3-tier client/server architecture, and feasibility tests were successful. As part of the feasibility tests, the Design Consultant for Part Reuse and the Design Consultant for Rubber Molding were implemented to prove the concept of the network-based Concurrent Engineering.
Geometry Modeling and Adaptation by Infrared and Laser Sensing in Thermal Manufacturing With Material Deposition
Authors: Doumanidis Charalabos , Kwak Yong-Min 
Published: December 2021

Abstract
A lumped-parameter, analytical model of material and thermal transfer is established in this paper for metal deposition by a moving, concentrated source. This is a dynamic description of the distinct width, height, length and temperature of the ellipsoidal molten puddle, expressed with respect to the torch power, material feed and angle, and the source motion. This is established through scalar mass, momentum and energy balances of the puddle control volume, and thermal conduction in the substrate. The model is validated by GMA Welding experiments, through measurements by an infrared camera and a Laser profilometry scanner. These sensors are next employed for real-time identification of the model efficiency parameters. Open-loop testing with parameter adaptation was conducted for the bead cross section profile during changes of the torch velocity, and the applicability of such geometry regulation to geometry control is discussed.
Diagnosis of Multiple Simultaneous Faults in Manufacturing Systems
Authors: Li Wei , Hu S. Jack , Ni Jun 
Published: December 2021

Abstract
In manufacturing systems, multiple faults often occur simultaneously and generate complex fault patterns. However, most of the previous research on multiple fault diagnosis assumes that faults either occur one at a time or have linearly additive fault patterns. In this paper, we present a new approach for multiple simultaneous fault diagnosis. A comprehensive pattern modeling approach is developed for prediction based on functional regression. With the complete set of fault patterns, a minimum distance pattern classifier is designed for diagnosis. The proposed approach is demonstrated to be successful with a simulation study. An example from the resistance spot welding process is also provided. In this case, an 88% success rate for fault classification is achieved based on the predicted fault patterns.
Characteristics of White Layers Formed in Steels by Machining
Authors: Akcan S. , Shah S. , Moylan S. P. , Chhabra P. N. , Chandrasekar S. , Farris T. N. 
Published: December 2021

Abstract
White layers, produced by machining cylinders of AISI 52100, AISI 4340, and AISI M2 steels, are characterized using nano-indentation hardness tests, and microstructural analysis through optical microscopy, transmission electron microscopy and X-ray diffraction. Microstructural observations show that the white layer is composed primarily of martensite. The martensite structure in the white layer is found to have a mean hardness of 12.6 GPa, which is significantly greater than the hardness values of martensite produced by heat treatment or ausforming processes. Furthermore, its grain size is shown to be in the sub-micron range with values ranging, typically, between 50 nm and 500 nm. These two novel characteristics of the white layer martensite distinguish it from martensite structures formed in other operations. The formation of the white layer is promoted by conditions of high cutting speed (100 m/min to 200 m/min) and moderate to large values of tool flank wear. Based on these observations, it is hypothesized that white layer formation involves three steps, austenitization of the steel surface, followed by deformation of the high temperature austenite to large plastic strains, and finally, rapid quenching of the austenite by the bulk of the material to form a martensite structure.
The Tool Life, Mechanics, and Economics in Conventional and Ultraprecision Machining
Authors: Venkatesh V. C. , Awaluddin M. S. , Ariffin A. R. 
Published: December 2021

Abstract
Conventional machining that is discussed here covers the use of the Taylor tool life equations and Merchant’s theory for the machining of aluminum silicon alloy with diamond coated carbide as well as the newly developed diamond coated silicon nitride tools. Gilbert’s economics of machining is described, and its application is extended to grinding to show the advantages of a 4 axis CNC Machining Centre over its 5 axis equivalent. Scattergood et al’s theory of ultra-precision turning of brittle materials for determining the critical depth of cut is highlighted together with the first author’s work on silicon showing how yc, the critical depth of cut, can be experimentally obtained in a much easier and rapid way.
A Self-Calibration Method for Robotic Measurement System
Authors: Gong Chunhe , Yuan Jingxia , Ni Jun 
Published: December 2021

Abstract
Robot calibration plays an increasingly important role in manufacturing. For robot calibration on the manufacturing floor, it is desirable that the calibration technique be easy and convenient to implement. This paper presents a new self-calibration method to calibrate and compensate for robot system kinematic errors. Compared with the traditional calibration methods, this calibration method has several unique features. First, it is not necessary to apply an external measurement system to measure the robot end-effector position for the purpose of kinematic identification since the robot measurement system has a sensor as its integral part. Second, this self-calibration is based on distance measurement rather than absolute position measurement for kinematic identification; therefore the calibration of the transformation from the world coordinate system to the robot base coordinate system, known as base calibration, is not necessary. These features not only greatly facilitate the robot system calibration but also shorten the error propagation chain, therefore, increase the accuracy of parameter estimation. An integrated calibration system is designed to validate the effectiveness of this calibration method. Experimental results show that after calibration there is a significant improvement of robot accuracy over a typical robot workspace.
Prediction of Springback in Straight Flanging Operation
Authors: Cao Jian , Liu Zhihong , Liu Wing Kam 
Published: December 2021

Abstract
A straight flange problem is investigated with the expectation that this will lead to a better understanding of the deformation mechanism and to more complicated flanging problems. The “in-die” shape of the part is subdivided into a number of segments and individual springback of each segment is investigated, by releasing the elastic energy element by element, using the Finite Element Method (FEM). Typical distribution of the springback angle along the blank is obtained and found to be quite different from the widely used constant springback assumption for the curved part of the flange. A new model incorporating a non-uniform moment distribution at the curved part is proposed which reflects the above observation. Explicit analytical formulae are derived and the analytical predictions match with the experimental results very well.
Mathematical Modeling of a Variable Displacement Axial Piston Pump
Authors: Dobchuk Jeff W. , Burton Richard T. , Nikiforuk Peter N. , Ukrainetz Paul R. 
Published: December 2021

Abstract
The variable displacement axial piston pump has been the subject of much research, having been studied from the controls, noise reduction, and design perspectives. The resulting body of research is large and very diverse in content. A review of the available publications was conducted for this paper in order to identify those works that would be most helpful in developing a complete and accurate mathematical model of an axial piston pump.
Most of the available publications can be classified into one of two general groups; those describing a small group of components to understand specific phenomena or those describing the entire pump for control or design purposes. The significant mathematical developments in various publications regarding specific phenomena, particularly those works involving nonlinear friction or pressure transients, were identified by the authors in this paper. When the mathematical developments of the phenomena specific effects are combined with the widely accepted kinematics equations for the pump, an accurate numerical model can be developed.
Works on linearized lumped parameter models and parameter sensitivity were examined for this paper and the limitations of these types of models were addressed. While linearized models offer mathematical simplicity, they suffer from poor accuracy over a wide range of operating conditions and do not reflect instantaneous swashplate dynamics.
This paper offers insight into the required complexity of a mathematical model that is necessary to achieve a desired accuracy as well as providing the appropriate references to develop that model.
Injection Moulding Simulation for Hydraulic Valve-Actuator System Controller Design
Authors: Guerrier Paul K. , Edge Kevin A. 
Published: December 2021

Abstract
In the development of advanced injection controllers and more effective control valves, full scale testing is often too expensive. This paper is concerned with virtual testing using simulation and experimental testing using a ‘hardware-in-the-loop’ technique in which a servovalve-actuator system emulates the moulding process. Simulation results for the purely simulated load and a ‘hardware-in-the-loop’ emulated load are compared with experimental data. Good agreement is achieved. Although the particular case of an hydraulic injection moulding machine has been considered, the model of the moulding process would be equally valid for studies of an all-electric machine.