bluuebunny/crossref_metadata_2025_split huggingface dataset:
Development of a Magnetostrictive Torque Sensor for Milling Process Monitoring
Authors: Ohzeki Hiro , Mashine Akihiro , Aoyama Hideki , Inasaki Ichiro 
Published: March 2022

Abstract
This paper deals with a sensor system based on the magnetostrictive effect, which is installed in a tool holder, for sensing cutting torque in order to monitor the milling process. Changes in the magnetic permeability of ferromagnetic alloy layers formed onto a rotating shaft due to torque are detected by coils as changes in impedance without contacting the rotating shaft. By mounting the magnetostrictive sensor on a tool holder, it became possible to detect cutting torque as close to the cutting point as possible. The accuracy of the proposed sensor system was confirmed through static and dynamic evaluation tests. In order to investigate the relationship between tool failure and cutting torque, side milling tests were performed, which bore out the possibility of estimating flank wear and tool fracture from the cutting torque detected by the proposed sensor system.
A Statistical Study of Factors Affecting Surface Finish in Five-Axis Machining
Authors: White Keith A. , Jensen C. Greg , Helquist Chuck , Smalley Troy 
Published: March 2022

Abstract
A statistical study of factors affecting the surface finish of parts machined on a five-axis mill was performed. The study was a 23 full factorial experiment. The following factors and levels for each factor were selected: cutter type (flat and filleted end mill), feedrate (12 and 20 inches per minute), and angle of inclination (7 and 15 degrees). All factors were statistically significant. Cutter type was the factor which most significantly affected surface finish, followed by feedrate, and angle of inclination. The effect of cutter type was more than four times greater than the other factors. All two-way interactions were also found to be significant, with the magnitude of the interactions involving cutter type approximately four times greater than the interaction between feedrate and angle of inclination. An acceptable mathematical model for predicting surface finish based on these factors was obtained which can be used in five-axis machining research and applications.
Improving the Accuracy of Microscopic Laser Interferometry System for Precision Surface Measurement by Integrated Scanning Motions
Authors: Moon Kee S. , Wang Yiding 
Published: March 2022

Abstract
A new technique for improving the accuracy of microscopic laser interferometry system for precision surface measurement is presented. Laser interferometry creates a fringe pattern which contains information about the surface texture of the specimen and the method provides nanometer resolution for height axis of the reconstructed surface. The resolutions of the lateral axes of the surface, however, relies only on optical magnification capability of the measurement system and this often results in poor resolution. This paper presents a new technique to improve the interferometric system resolution in lateral axes. This method is based on an integrated scanning motion of the specimen and the obtained multiple sets of scanned data are processed to improve the lateral axes resolution. Computer simulations show that the proposed method can be an effective approach to improve the resolution in the lateral axes for commonly used laser interferometric system. It provides a new principle for the design of modern laser interferometric measurement instruments.
Microstructural Effects on the Machining Performance of Dental Ceramics
Authors: Le D. T. , Qi Lixun , Zhang Guangming , Ng Stanley J. 
Published: March 2022

Abstract
Constraints of mechanical, thermal, and chemical properties are making ceramics the material choice for industrial and dental applications. The quality of a machined surface of ceramics is fundamentally dependent on the response of the material to the machining process. This paper presents a combined analytical and experimental study with focus on optimizing the machining performance of dental ceramics — DICOR/MGC — with three distinguished microstructures. The study starts from analyzing the microstructural characteristics to searching for the machining conditions that provide satisfactory performance in terms of acceptable flexural strength. Evidence gained from the cutting force measurements and evaluation of fracture strength degradation indicates that the control of micro-scale fracture formed on the machined surface, with microstructural characteristics being considered, is the key factor which dominates the machining performance.
Current Deburring Methods Used in Industry
Authors: Gillespie LaRoux K. 
Published: March 2022

Abstract
Deburring involves several aspects often overlooked. While over 100 deburring processes exist there is still no universally accepted definition of what the term “deburred” really implies. Deburring and edge standards are available, but are often ignored. The functional requirement probably is to finish edges as opposed to just deburr. Environmental, health and safety issues are important considerations in the selection and use of any edge finishing process. Many of the deburring processes are still laboratory curiosities at this time.
Investigation of the Lead-On-Chip Package’s Reliability
Authors: Tsao P.-H. , Chang L. C. , Chen T. C. , Haung Chender , Chen C. Z. 
Published: March 2022

Abstract
An assembly test chip (ATC), consisting of varieties of test structures, had been utilized to monitor the package integrity of SOJ lead-on-chip (LOC) packages after various reliability tests. Two different types of epoxy molding compounds, namely biphenyl and EOCN epoxies, were chosen to investigate their effects on package’s reliability. After the reliability tests, silicon chip crack was observed in three test samples due to the existence of a large chip backside chipping (−120 μm). Qualitative study about this failure mechanism was carried out by a finite element analysis, and it was found that, due to the higher flexural modulus and CTE of the biphenyl epoxy, the thermally induced stresses developed in the chip encapsulated by this epoxy during reliability tests were more likely to cause the crack propagation in the silicon chip than those induced by using EOCN type epoxy.
Wafer Surface Measurements Using Shadow Moiré With Talbot Effect
Authors: Wu S. , Wei S. , Kao I. , Chiang F. P. 
Published: March 2022

Abstract
In this paper, a modified shadow moiré technique is applied to measure surface topology of wafers. When a wafer is sliced, either by an inner-diameter (ID) saw or wiresaw, the surface needs to be measured to ensure the consistency of quality. Two important characteristics of the wafer surface measurements are the warpage and total thickness variation (TTV). Currently, the most commonly used method of wafer measurement employs a pair of capacitive measuring probes which sample points on the surface of a rotating wafer to obtain the contours of surface. Many sampling points on the surface are needed for more accurate measurements; however, this will require more time for the inspection of wafers during production. An innovative alternative for full-field, whole-wafer measurement is developed using a laser light source and the modified shadow moiré technique. This methodology enables one to examine the whole wafer surface quickly and simultaneously. In this study, a 1000 lines/inch reference grating is employed as the standard to create a shadow moiré pattern. In addition, the Talbot effect is utilized to adjust the gap, or the so-called Talbot distance, between the grating and the wafer surface such that a fringe pattern of good quality can be obtained. By using the phase shifting technique, the resolution (or sensitivity) can be enhanced by two order of magnitude. The results show that not only the full view of whole wafer surface can be obtained, but also enhanced surface resolution and accuracy can be realized. In addition, warpage due to excessive residual stresses can be observed distinctly with fringe patterns because of the global and interconnected moiré fringes. This process is faster, especially when dealing with wafers with diameter larger than 200mm (8″). Experimental results of both 200mm single crystalline and 100 × 90mm polycrystalline wafers are presented. The system can also be fully automated to become an on-line inspection tool.
Constitutive Modeling of Polymer Films From Viscoelasticity to Viscoplasticity
Authors: Qian Zhengfang , Lu Minfu , Liu Sheng 
Published: March 2022

Abstract
A unified constitutive model for polymer films is proposed with viscoelastic characterization at small deformation and viscoplastic characterization at large deformation, based on molecular chain deformation mechanisms. The evolution equations and the temperature dependence of drag stress and back stress are well established from molecular network theories. The material constants are then determined by master curves and a consistent procedure. The excellent agreement between experimental data of polycarbonate film tests and model predictions is achieved.
Prediction of the Solder Joint Configuration Under Various Geometric Parameters
Authors: Chen Wei-Long , Shyu Bor-Lin , Chiang Kuo-Ning 
Published: March 2022

Abstract
Prediction of the shape of solder joint has drawn special attention in the development of electronic packaging for it’s practical engineering application. Many solder joint models have been developed based on energy minimization principle or analytical method. These methods are extensively utilized to the shape design of solder joint. However, one would find It is important to find a suitable method in real case application. In this study, numerical methods used to predict the shape of solder joint are investigated and compared. The change of geometric shape with respect to different parameters of solder joint are also discussed in this paper. The influence of the geometric parameters such as volumes of solder joint, package weight, contact angles, pad sizes, solder surface tension, and gravity forces to the shape of solder joint are investigated. Results presented in this study can be used to determined the optimal balanced stand-off height of Single Ball Module (SBM) or Multiple Ball Module (MBM) solder joint models.
Evaluation of Interfacial Fracture Toughness of a Bi-Material System Under Thermal Loading Conditions
Authors: Wang Jianjun , Zou Daqing , Liu Sheng 
Published: March 2022

Abstract
In this paper, the interfacial fracture toughness of a bi-material (molding compound/silicon) specimen subjected to a series of thermal loads was evaluated using a high density laser moiré interferometry coupled with FEA technique. The moiré interferometry technique was used to monitor and measure the crack length during the test. A finite element technique was simultaneously used to determine the near crack tip displacement fields of the bi-material specimen. The interfacial fracture toughness and phase angle were computed by using these near tip displacement variables through the analytical energy release rate and phase angle expressions derived by authors. The results show that the interfacial fracture toughness of the bi-material specimen considered is strongly related to the phase angle in terms of the defined phase angle expression in this paper. The interfacial fracture toughness Gc and the phase angle ϕ of the tested bi-material specimen at the interface corresponding to the crack length a = 3.0mm under the temperature rise thermal load from room temperature (20° C) to 120° C are 13.64 J/m and −54.28° respectively, while the interfacial fracture toughness Gc and the phase angle ϕ of the tested bi-material specimen at the interface of the molding compound/silicon with the crack length a = 3.3mm under the temperature rise thermal load from room temperature (20° C) to 138° C are 20.02 J/m2 and −54.8° respectively.
Interactive Tutorials on Manufacturing Processes Using Java™
Authors: Klamecki Barney E. 
Published: March 2022

Abstract
A series of tutorials describing some engineering science concepts underlying the development of manufacturing process models has been developed. The tutorials are available over networks so that access is easy. There are two unique aspects of the tutorials. One is the use of computer-independent software so that interactive exercises run on the user’s computer. This makes for fast response to user input and so useful interactive exercises are possible. The other different aspect is the presentation of process models in a non-typical way. Interactive exercises which call for the user to vary process parameter values, observe the effects on process performance and deduce the form of the process model are used. An example of one such computer-based tutorial is described — chip formation in machining. A world wide web location of the tutorial is provided so that individuals can use and evaluate the approach taken to presenting engineering science concepts and process models, http://www.menet.umn.edu/klamecki.
Manufacturing Engineering Education Through Industry/University Cooperative Research: Issues, Challenges, and Strategies
Authors: Lee Jay 
Published: March 2022

Abstract
Today’s globalized manufacturing enterprise necessitates a new imperative for the academe to generate internationally astute engineers to enable manufacturing companies to collaborate in a global market in the 21st century. This paper presents author’s perspectives on manufacturing engineering education system in a changing world. First, issues, challenges, and strategies are discussed. Second, various industry/university cooperative research models in the US, Japan, Germany, and Taiwan are examined. Finally, challenges in education system and research collaboration in moving the innovation to a global marketplace is addressed.
Video Based Manufacturing Courses for Electronics
Authors: Fillo John A. , Sahay Chittaranjan , Srihari Krishnaswami 
Published: March 2022

Abstract
Two product-oriented manufacturing courses, Printed Wire Board Manufacturing and Processes for Electronic Manufacturing have been developed. The mode of delivery is original and unique, pairing manufacturing experts from industry and university faculty to develop video based instructional materials based on real industrial operations and processes. The final product is a new generation of “text books” in the form of video modules for the rapid dissemination of dynamic types of information as encountered in manufacturing. The goal is to educate both defense and commercial sectors to current practices in packaging manufacturing as well as those students who will make up the next work force.
Teaching Manufacturing and Design for Manufacturability to Mechanical Engineering Students
Authors: Nesbit Steven M. , Comer Jess J. 
Published: March 2022

Abstract
The Department of Mechanical Engineering at Lafayette College has implemented an innovative manufacturing laboratory course as part of its mechanical design sequence to give its students a basic understanding of engineering design and the influence of manufacturing in the design process. The course, which is required for all junior mechanical engineering students, teaches basic manufacturing skills and concepts, and design for manufacturability. The laboratory is co-taught by the mechanical engineering faculty and the engineering technicians. The course takes a hands-on approach to teaching these subjects and incorporates two interrelated projects; the manufacture of a pre-designed mechanical system, and the design, manufacture, evaluation, and competition of a semester long design project. This paper discusses the format of the course, the two projects, the role of the faculty and engineering technicians, and how these fit together to create an effective learning experience.
Manufacturing Processes Course With Emphasis on Modeling, Experimentation, and Design
Authors: Moller James C. 
Published: March 2022

Abstract
A sophomore-level Manufacturing Processes course is described. It is the second course in a Design for Manufacturing sequence in the Manufacturing Engineering degree curriculum. Emphasis is placed on prediction of manufacturing results prior to lab sessions to build student confidence with process modeling as well as an understanding of the relations among process conditions and part attributes. The laboratory experience focuses on understanding processes by rational selection of conditions and measurement of attributes for a variety of conditions. The course culminated with a process design project in which teams manufactured product components to be assembled in a subsequent course.
A Continuum Mechanics Model to Predict Shear Angle and Cutting Forces in Orthogonal Cutting
Authors: Zheng Y. , Sutherland J. W. , Olson W. W. 
Published: March 2022

Abstract
The mechanics of the orthogonal cutting process are examined. Under an assumed streamline and shear plane curvilinear system, the Eulerian strain and strain rate tensor in the primary deformation zone are obtained analytically. When the material behavior is dependent on strain, strain rate and temperature, the temperature distribution in machining is numerically estimated using an iterative incremental method. The results obtained are compared with those from the classical shear plane theory. The shear angle as a function of undeformed chip thickness and cutting velocity, and cutting forces in orthogonal cutting are predicted by the total work minimization principle and are seem to agree with the experimental results from the literature.
Dynamic Indentation Hardness of Metals and its Implications to High Speed Machining
Authors: Subhash Ghatu , Koeppel Brian J. , Chandra Abhijit , Huang Yonggang Y. 
Published: March 2022

Abstract
A novel experimental technique for determining the dynamic indentation hardness of materials is described. Unlike the traditional static hardness measurements, the dynamic hardness measurements can capture the inherent rate dependent material response that is germane to high strain rate processes such as high speed machining and impact. The current technique also offers several advantages over the existing dynamic hardness testers. The dynamic hardness of several commonly used engineering materials is found to be greater than the static hardness. The percentage increase in dynamic hardness over its static counterpart is found to be strongly dependent on the crystal structure of the materials used in this study. The significance of dynamic hardness and its implications on high speed machining characteristics of metals is explored.
A Simulation System for Feasibility Study of Single Set-Up Fixtures in Milling and Drilling
Authors: Li Xiaoping , Nee Andrew Y. C. 
Published: March 2022

Abstract
Single set-up fixtures in milling and drilling processes are usually desired because of its high efficiency. One of the main difficulties in designing such fixtures is to estimate the deformation corresponding to the processes under consideration. In this aspect, theoretical calculation of the workpiece deformation has hardly been achieved due to the complication caused by interactions between the cutting forces and clamping forces on the workpiece. Traditionally the workpiece deformation under a fixture is estimated approximately based on the designer’s experience. In this paper, a system for simulation of workpiece deformation in end milling and drilling processes is developed. In the system, from a given plan of fixture setup and machining conditions, the cutting forces and clamping forces acting on the workpiece are firstly predicted using theoretical and empirical models, then the corresponding deformations throughout the workpiece are calculated from the forces and workpiece material properties using the finite element method. As a case study, the system is used to investigate workpiece deformation in end milling a slot and drilling a hole on a workpiece with different configurations of single set-up fixture. It is shown that by using the simulation system the effect of different configurations of single set-up fixture on the deflections of the workpiece can be accurately estimated. In this way the feasibility of a single set-up fixture design can be studied and the design can be optimized on a scientific basis.
Automated Modular Fixture Planning: Accuracy, Clamping, and Accessibility Analysis
Authors: Wu Yufeng , Rong Yiming (Kevin) , Ma Weidong , LeClair Steven R. 
Published: March 2022

Abstract
Automated fixture design has become a research focus in process planning and CAD/CAM integration. An automated fixture configuration design system has been developed where when fixturing surfaces and points are specified, modular fixture components can be automatically selected and placed into position with satisfying assemble conditions. A geometric analysis has been conducted to determine the fixturing surfaces and points which provide feasible geometric constraints and assembly relationships with modular fixtures. This paper presents analyses on fixturing accuracy, clamp planning, fixturing accessibility, and clamping stability. When a fixture planning is determined, the analysis results can be applied to verify the performance of the fixture design.
A Systematic Approach for Fixture Design and Analysis: A Workholding Illustration of Truck Differential Carrier
Authors: Hou Jiang Liang , Trappey Amy J. C. 
Published: March 2022

Abstract
Many factors such as process planning and fixture design contribute to the machining quality of products. Based on the determined operating sequences and the corresponding cutting path and force distribution, fixture design and analysis are proceeded. Further, the result of fixture design and analysis can provide additional information or constraints to be fed-back to the process planning so that the process can be further improved. In this paper, fixture planning of a truck differential carrier is taken as a case study to illustrate how the fixture design and process planning act interactively. By finite element analysis and loading-strain experiments, we explore the effects of fixture system and the dimensional variation of workparts on machining accuracy. The deformation effects of fixturing force are analyzed so that the process planning can be modified for more accurate machining. Moreover, in fixture hardware design, the functional behavior of fixture is verified to ensure the functional requirements are satisfied. Combining the computer-aided engineering (CAE) with experimental verification, this paper presents a systematic approach of fixture design to ensure the workholding accuracy and reliability.
Optimal Selection of Tooling and Cutting Conditions for End Milling Using Microgenetic Algorithms
Authors: Strenkowski John S. , Wei Yi-Min 
Published: March 2022

Abstract
In this paper, a new method is presented for the optimal selection of cutting tools and operating conditions for end milling. An end milling model developed by Armarego is used to determine the cutting forces and power. This model is coupled with a microgenetic algorithm to determine the optimal tooling and operating conditions. Unlike other more conventional optimization techniques, genetic algorithms can be used for discrete data. In this paper, the optimal tool is identified from a manufacturer’s catalog of milling cutters along with the optimal speed and feed to achieve both minimum production cost and minimum production time criteria. In addition, constraints are imposed on the cutting speed, feed, maximum cutting force, and available power to simulate realistic machine tool constraints.