ABSTRACTS, cont.

ABSTRACTS

TABLE OF CONTENTS
TUESDAY, JUNE 11 CONCURRENT SESSIONS A
Simulation and experiment on warm hydroforming of AZ31 magnesium alloy tube..............................................................1
An approach for increasing branch height of a hydroforming t-joint with smaller branch diameter.............................2
An investigation of sheet metal deformation behavior during electro-hydraulic forming (EHF).......................................3
Inclined ball end milling of micro-dimpled surfaces for polymeric components........................................................................4
Modulation-assisted high speed machining of compacted graphite Iron (CGI)...........................................................................5
Helical plate machining in whirling...........................................................................................................................................................................6
Effect of silver coating on silicon ingot slicing by wire-EDM process..................................................................................................7
Understanding the material removal process and heat-affected zone in nano-metric electro-machining of
graphene....................................................................................................................................................................................................................................8
Fabrication of high aspect ratio micro holes in glass by micro electrochemical discharge machining.........................9
Cutting force of hollow needle insertion in soft tissue..................................................................................................................................10
Feasibility of laser surface texturing for friction reduction in surgical blades.................................................................................11
Development of a multi-arm bioprinter for hybrid tissue engineering..............................................................................................12
Ablation dynamics of silicon by femtosecond laser and the role of early plasma.......................................................................13
Energy efficiency in thermally assisted machining of titanium alloy: a numerical study........................................................14
A new application of cryogenic machining for advanced manufacturing.......................................................................................15
Measuring dynamic 3D micro-structures using a superfast digital binary phase-shifting technique............................16
Computed tomography in metrology.....................................................................................................................................................................17
Visual inspection of free form glossy surfaces using phase shifted deflectometry.....................................................................18
Extreme hardness achievements in binderless cubic boron nitride tools........................................................................................19
Folding and transitions in plastic deformation in metal sliding and machining...........................................................................20
A new approach for a simulation-based prediction of torsional chatter in deep hole drilling with extra-long twist
drills................................................................................................................................................................................................................................................21
Chatter stability model of micro-milling with process damping............................................................................................................22
TUESDAY, JUNE 11 CONCURRENT SESSIONS B
Analysis of fiber optic sensor to measure velocity during electromagnetic forming and welding..................................23
An investigation of anisotropic behavior on 5083 aluminum alloy using electric current.....................................................24
Characterization of flow stress for commercially pure titanium subjected to electrically-assisted deformation.....25
Applicability of various cutting tool materials to the machining of spheroidal cast iron........................................................26
Investigation of the machinability of aluminum alloys of the 6xxx series.........................................................................................27
Machinability analysis of Ti10.2.3 titanium alloy using ANOVA................................................................................................................28
Resistance mash welding for joining of copper conductors for electric motors..........................................................................29
Advanced FEM modeling of friction stir welding of Ti6Al4V: Microstructural evolutions........................................................30
Laser autogenous brazing of biocompatible, dissimilar metals in tubular geometries............................................................31
Microcellular injection molding of thermoplastic polyurethane (TPU) scaffold using carbon dioxide and water as
co-blowing agents...............................................................................................................................................................................................................32
Characterization of printable vessel-like cellular micro-fluidic channels towards organ printing.....................................33
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TABLE OF CONTENTS, cont.
Characterization of bioprinting induced cell damage in cellular micro-fluidic channel fabrication................................34
Modeling of thin-film single and multi-layer nanosecond pulsed laser processing...................................................................35
Remote fiber laser processing of zinc coated steels for automotive applications.......................................................................36
Curvature estimation for metrology of fixtureless non-rigid parts........................................................................................................37
Reconciling the differences between tolerance specification and measurement methods................................................38
Optimal motor location for the reduction of residual vibrations in mode-coupled ultra-precision
manufacturing machines.................................................................................................................................................................................................39
Sustainability indicators for discrete manufacturing processes applied to grinding technology......................................40
Assisting sustainable manufacturing enterprise through system dynamics: A conceptual model..................................41
Understanding life cycle social impacts in manufacturing: A processed-based approach....................................................42
Finite element modeling on dislocation density and grain size evolution in machined surface.......................................43
Simulation of surface roughness effects on residual stress in laser shock peening....................................................................44
TUESDAY, JUNE 11 CONCURRENT SESSIONS C
Austenite-martensite phase transformation of biomedical NI50.8TI49.2 alloy by ball burnishing....................................45
A novel hybrid process for drawing operation...................................................................................................................................................46
A study on friction and wear characteristics of sliding guideways finished by cbn milling and conventional
grinding.......................................................................................................................................................................................................................................47
Methodology for shape optimization of ultrasonic amplifier using genetic algorithms and simplex method........48
Force measurement characteristics of multi-axis dynamometers..........................................................................................................49
Integrated electrohydrodynamic jet printing: A flexible deposition approach for micro/nano-manufacturing......50
Hybrid hierarchical fabrication of three-dimensional scaffolds...............................................................................................................51
Multi-nozzle array electrohydrodynamic jet (Ejet) printing........................................................................................................................52
A comprehensive model for laser hardening of carbon steels.................................................................................................................53
Investigation and optimization of laser welding of Ti-6Al-4V titanium alloy plates....................................................................54
Laser beam forming: Experimental investigation and statistical analysis of the effects of parameters on
bending angle.........................................................................................................................................................................................................................55
Experimental study on micro-scale milling process using electro-hydro-dynamic (EHD) spray lubrication
with chilly air............................................................................................................................................................................................................................56
Characterization of fluid film produced by an atomization-based cutting fluid (ACF) spray system during
machining..................................................................................................................................................................................................................................57
Enhancing adaptive production using IEC 61499 event-driven function blocks.........................................................................58
An integrated CNC accumulation system for automatic building-around-inserts......................................................................59
Feature selection for manufacturing process monitoring using cross-validation........................................................................60
An empirical model for the coefficient of friction in injection molding of thermoplastics....................................................61
Evaluation of fiber orientation prediction of moldflow using an injection molded IP panel................................................62
WEDNESDAY, JUNE 12 CONCURRENT SESSIONS D
Die wear and galling in stamping DP980 steel...................................................................................................................................................63
Experimental study of biaxial load-unload behavior of DP590 steel sheets....................................................................................64
ii MSEC 2013 NAMRC 41

Analytical design and implementation of a uniform pressure actuator for electromagnetic forming and
welding........................................................................................................................................................................................................................................65
Machining depth regulation and friction reduction in AFM-based ultrasonic vibration assisted
nanomachining......................................................................................................................................................................................................................66
Process parameters effect on cutting forces and geometrical quality in thin wall micromilling........................................67
Feed rate optimization issues in micro-milling...................................................................................................................................................68
Vibration tissue cutting for blunt hollow needles............................................................................................................................................69
Investigation of friction in needle to soft tissue interaction.......................................................................................................................70
A haptic position measurement system for compliant objects and an application in guidewire stitching of
soft tissue....................................................................................................................................................................................................................................71
Micro-laser assisted feasibility test on soda-lime-glass.................................................................................................................................72
Picosecond and nanosecond pulsed laser ablation of aluminum foil.................................................................................................73
Application of laser in joining aluminum foam hybrid materials............................................................................................................74
The state of the art of cloud manufacturing and future trends...............................................................................................................75
Development and implementation of cloud manufacturing: An evolutionary perspective................................................76
Cloud manufacturing platform: Operating paradigm, functional requirements, and architecture design..................77
Characterizing energy consumption of the injection molding process............................................................................................78
A parametric study on micro-drilling process with nanofluid minimum quantity lubrication using
nanodiamond particles.....................................................................................................................................................................................................79
Effect of inter-particle interaction on particle deposition in a cross-flow microfilter.................................................................80
Modeling of the influence of sample preparation sequences when measuring selectively induced
residual stress depth profiles..........................................................................................................................................................................................81
Performance evaluation of multi-scale data fusion methods for surface metrology domain..............................................82
Study of factors impacting remote fault diagnosis performance on a PLC based automated system...........................83
Dual-scale cascaded adaptive stochastic resonance for rotary machine health monitoring...............................................84
Statistical monitoring for broaching processes using energy features extracted from cutting force signatures.....85
Polycrystalline diamond turning of rock.................................................................................................................................................................86
Statistical cutting force model for orthogonal cutting of polytetrafluoroethylene (PTFE) composites..........................87
WEDNESDAY, JUNE 12 CONCURRENT SESSIONS E
Product-oriented sustainability aspects of abrasive processes................................................................................................................88
Multi-constraint optimization for grinding nickel-based alloys...............................................................................................................89
Removal mechanism and defect characterization for glass-side laser scribing of CdTe/CdS multilayer in
solar cells.....................................................................................................................................................................................................................................90
Pulsed laser assisted exfoliation of hydrogen ion implanted single crystalline SiC thin layers............................................91
Application of picosecond laser for polishing of AISI H13 tool steel sample prepared by micro-milling.....................92
Multi-objective optimization of microturning process parameters using particle swarm technique............................93
Burr formation and surface quality in high speed micromilling of titanium alloy (TI6AI4V).................................................94
Correlation between mechanical properties in standard test specimens and injection molded thin-wall
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TABLE OF CONTENTS, cont.
parts...............................................................................................................................................................................................................................................95
Microcellular injection molding of gas-laden pellets using nitrogen and carbon dioxide as co-blowing
agents...........................................................................................................................................................................................................................................96
Prediction of mechanical properties of microcellular plastics using the variational asymptotic method for
unit cell homogenization (VAMUCH) method....................................................................................................................................................97
Unit process life cycle inventory models of hot forming processes......................................................................................................98
Dilute acid pretreatment of wheat straw: A predictive model for energy consumption using response
surface methodology.........................................................................................................................................................................................................99
Unit process life cycle inventory models of hot forming processes......................................................................................................100
Hole making technology of honeycomb sandwich materials.................................................................................................................101
Effect of tool wear on hole quality when drilling CFRP with coated tools........................................................................................102
Mechanism governing cutting of polycrystalline cubic boron nitride (pCBN) with transformation induced
fracture.........................................................................................................................................................................................................................................103
Spindle dynamics identification using particle swarm optimization...................................................................................................104
Compensation of thermally caused position and orientation errors of rotary axes....................................................................105
LDV-based spindle metrology for ultra-high-speed micromachining spindles............................................................................106
Stability analysis and finite element simulations of superplastic forming in the presence of hydrostatic
pressure.......................................................................................................................................................................................................................................107
Three dimensional finite element analysis of staggered backward flow forming process.....................................................108
Bayesian-based probabilistic force modeling in cold rolling.....................................................................................................................109
WEDNESDAY, JUNE 12 CONCURRENT SESSIONS F
The correlation of abrasive grain dimensional derivation with grinding performances from simulation
perspective................................................................................................................................................................................................................................110
Force modeling for generic profile of drills...........................................................................................................................................................111
Effect of blank holder force schemes on weld-line movements in u-draw bending of tailor welded blanks............112
Examining tool shapes in single point incremental forming.....................................................................................................................113
Evaluation of ionic fluids as lubricants in manufacturing............................................................................................................................114
An investigation on electrochmical discharge micro-drilling of glass.................................................................................................115
Line-based laser induced plasma micro-machining (L-LIPMM)...............................................................................................................116
Embedding information on metal surfaces by micro-milling...................................................................................................................117
Requirements for moving towards liquid molding of large composite structures for aerospace.....................................118
Study of biobased shape memory polylactic acid/thermoplastic polyurethane (PLA/TPU) blends................................119
Synthesis and characterization of high performance polymer nanocomposite using carbon nanotubes
as fillers.........................................................................................................................................................................................................................................120
Research progress of cloud manufacturing in China: A literature survey..........................................................................................121
Lifecycle management of knowledge in a cloud manufacturing system.........................................................................................122
Requirements and concept for a manufacturing service management and execution platform for
customizable products......................................................................................................................................................................................................123
iv MSEC 2013 NAMRC 41

Virtual enterprise architectural framework: Collaboration towards small and medium enterprises................................124
A framework model for characterizing the carbon emissions dynamics of manufacturing system................................125
Energy savings opportunities of an integrated facility and production line...................................................................................126
Real-time milling force control and tool wear monitoring using constraint-based feedrates.............................................127
Process damping coefficient identification using bayesian inference................................................................................................128
Adaptive tool wear estimation using on-machine touch probes...........................................................................................................129
Finite element simulation of micro-end milling titanium alloy: Comparison of viscoplastic and
elasto-viscoplastic models...............................................................................................................................................................................................130
Finite element modeling of microstructural changes in dry and cryogenic machining AZ31B magnesium
alloy for enhanced corrosion resistance.................................................................................................................................................................131
Determination of constitutive material model parameters in FE-based machining simulations of
Ti-6Al-4V and IN-100 alloys: An inverse methodology...................................................................................................................................132
WEDNESDAY, JUNE 12 CONCURRENT SESSIONS G
Evaluation of ductile fracture models on finite element simulation of metal cutting process............................................133
Fatigue properties and life prediction of 8630 cast steel in the presence of weld repair and porosities......................134
Interface delamination of diamond-coated carbide tools considering coating fractures by XFEM.................................135
Ductile fracture limits of the CuZn40Pb2 brass alloy deformed at elevated temperature.....................................................136
Development of a biaxial loading frame for sheet metal.............................................................................................................................137
A motion study of a manipulator for transferring microparts in a multi stage former..............................................................138
Fabrication of chitosan porous structure and applications on artificial photosynthesis device.........................................139
A critical factor in enhancement of MQL lubricants: Platelet thickness..............................................................................................140
Corotating or codeforming models for thermoforming: Free forming...............................................................................................141
Constant temperature embossing of PEEK films...............................................................................................................................................142
Cloud manufacturing: Drivers, current status, and future trends............................................................................................................143
Virtualize manufacturing capabilities in the cloud: Requirements and architecture..................................................................144
Study on the multi-granularity virtualization of manufacturing resources......................................................................................145
A product configurator for cloud manufacturing.............................................................................................................................................146
Effects of ultrasonic vibration-assisted pelleting of biomass on sugar yield in biofuel manufacturing
with different pretreatment methods......................................................................................................................................................................147
Numerical modeling of specific energy consumption in machining process................................................................................148
Analytic stochastic modeling of dynamic wheel topography in superabrasive grinding.......................................................149
Aluminum oxide nanoparticle mixed UV-curable resin study in fabrication of lapping plate.............................................150
The effect of thermal softening on the ductile-to-brittle transition of sapphire..........................................................................151
Experimental investigation and modeling of milling burrs........................................................................................................................152
An improved empirical constitutive model for gamma prime-strengthened nickel-based superalloys......................153
Analysis of variance based predictive model for surface roughness in end milling of IN 718..............................................154
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TABLE OF CONTENTS, cont.
THURSDAY, JUNE 13 CONCURRENT SESSIONS H
Time-dependent effects of contact perturbation in machining.............................................................................................................155
An experimental study on edge chipping in ultrasonic vibration assisted grinding of bio-ceramic materials.........156
Analysis of 1D abrasive vibratory finishing using acoustic emission....................................................................................................157
Low volume aluminum forging using metal based rapid prototyping of dies..............................................................................158
Innovative hybrid process in metal forming........................................................................................................................................................159
Experimental study of electro-plastic effect on advanced high strength steels...........................................................................160
Melt pool flow and surface evolution during pulsed laser micro polishing of Ti6Al4V............................................................161
Residual stress analysis and weld bead shape study in laser welding of high strength steel...............................................162
Effects of interfacial geometry on laser joining of dissimilar NiTi-SS wires.......................................................................................163
Mechanical behavior of Ti-6Al-4V manufactured by electron beam additive fabrication.......................................................164
Characterizations of sintered Ti-6Al-4V powders in electron beam additive manufacturing...............................................165
Improving densification of zirconium tungstate with nano tungsten trioxide and sintering aids....................................166
Modeling of multi-cell lithium-ion battery packs for electric vehicles considering effects of manufacturing
processes....................................................................................................................................................................................................................................167
Modeling, analysis and improvement of door production line at an automotive body shop.............................................168
Beneficial effects of solid lubricant mixture assisted machining.............................................................................................................169
Cooling capability of cutting fluids in grinding.................................................................................................................................................170
Effect of fluid concentration in titanium machining with an atomization-based cutting fluid (ACF) spray
system..........................................................................................................................................................................................................................................171
Chip segmentation in machining: A study of deformation localization characteristics in Ti6Al4V...................................172
The establishment of coupled electromagnetic-thermal analytical model of induction heating system with
magnetic flux concentrator and the study on the effect of magnetic permeability to the modeling...........................173
Progressive modeling: Introducing a new system modeling and optimization paradigm and its application
to the reconfiguration and operations planning problem part I............................................................................................................174
THURSDAY, JUNE 13 CONCURRENT SESSIONS I
Joint maintenance and production planning by maintenance-optimal swapping...................................................................175
Multi-zone proportional hazard model for a multi-stage degradation process............................................................................176
Methodology for ball screw component health assessment and failure analysis........................................................................177
An integrated approach to metrology.....................................................................................................................................................................178
Alternative control of an electrically-assisted tensile forming process using current modulation....................................179
Empirical modeling of direct electric current effect on machining cutting force........................................................................180
Ultrasonic cavitation peening of stainless steel and nickel alloy.............................................................................................................181
Quality evaluation of multistage manufacturing systems by jointly considering the incoming part quality
and system conditions.......................................................................................................................................................................................................182
Monitoring multistage surface spatial variations using functional morphing...............................................................................183
Automated part inspection using 3D point clouds.........................................................................................................................................184
Effect of mechanical alloying on Al6061-graphene composite fabricated by semi-solid powder processing.........185
vi MSEC 2013 NAMRC 41

The effect of warm accumulative roll bonding and post process treatment on microstructure a
mechanical behavior of CP-TI........................................................................................................................................................................................186
Numerical evaluations of thermal property effects in electron beam additive manufacturing.........................................187
Material shrinkage modeling and form error prediction in additive manufacturing processes.........................................188
Numerical simulation of dilution in laser metal deposition by powder injection........................................................................189
Phase transformation affected quench crack study using finite element analysis......................................................................190
Prediction of distortion in quenching-tempering processes for a SM256 steel component with internal
thread...........................................................................................................................................................................................................................................191
THURSDAY, JUNE 13 CONCURRENT SESSIONS J
Key technologies of embedded gear machining CNC system................................................................................................................192
Developing an agility model for maximum responsiveness to the changes in customer requirements for
SMEs...............................................................................................................................................................................................................................................193
Manual precedence mapping and application of a novel precedence relationship learning technique
to real-world automotive assembly line balancing.........................................................................................................................................194
Nanostructural evolution of hard turning white layer during machining of through hardened 52100 steel............195
Thermally assisted high efficiency ductile machining of brittle materials: A numerical study............................................196
High speed ball nose end milling of hardened AISI A2 tool steel with PCBN and coated carbide tools.......................197
A new velocity estimator for motion control systems...................................................................................................................................198
Comparison of electrically-assisted and conventional friction stir welding processes by feed force and torque...199
Characterization of vacuum brazing of Ti6Al4V and alumina with Cu-Ag brazing alloy via substrate-induced
reactive mechanism............................................................................................................................................................................................................200
Analytical modeling and experimental validation of force ripple and friction force for general direct
drive systems............................................................................................................................................................................................................................201
Adaptive robust control of circular machining contour error using global task coordinate frame...................................202
A model-based computationally efficient method for on-line detection of chatter in milling...........................................203
Micro-milling responses of hierarchical graphene composites...............................................................................................................204
Ultrasound induced synthesis of CdS nanocrystals under continuous flow...................................................................................205
An experimental study of the phenomenon of surface alloying by EDM process using inconel tool
electrode.....................................................................................................................................................................................................................................206
Experimental investigations on microchanelling through ECDM using different electrolytes............................................207
FRIDAY, JUNE 14 CONCURRENT SESSIONS K
Design of a 3-DOF compliant parallel mechanism for displacement amplification...................................................................208
A study of the impact of workpiece location on machining performance of a 2-DoF PKM based machine
tool.................................................................................................................................................................................................................................................209
GPGPU accelerated 3-axis CNC machining simulation.................................................................................................................................210
Investigation on performance of various ceramic tooling while milling nickel-based superalloy....................................211
Correlating acoustic emission to calibration phenomena for possible measurement standard........................................212
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TABLE OF CONTENTS, cont.
Remaining useful tool life predictions using bayesian inference............................................................................................................213
Uncertainty analysis of tool wear and surface roughness...........................................................................................................................214
High speed turning of AISI4140 steel using nanofluids through twin jet SQL system..............................................................215
Diluted acid pretreatment and enzymatic hydrolysis of woody biomass for biofuel manufacturing:
Effects of particle size on sugar conversion..........................................................................................................................................................216
Alignment of carbon nanofibers through shear forces.................................................................................................................................217
Study of the effect of anode/cathode geometry on the yield rate and quality of the MWCNTs synthesized
by submerged arc discharging.....................................................................................................................................................................................218
Fabrication and characterization of photonic crystals by two-photon polymerization using a femtosecond
laser................................................................................................................................................................................................................................................219
A new additive manufacturing file format using bezier patches............................................................................................................220
Adaptive layering in additive manufacturing using a k-d tree approach..........................................................................................221
A reactionary process planning algorithm for an unconstrained hybrid process integrating additive,
subtractive and inspection processes......................................................................................................................................................................222
Mechanics of modulation assisted machining...................................................................................................................................................223
Experimental investigation of chip formation and surface topology in ultrasonic-assisted milling of X20Cr13
stainless steel...........................................................................................................................................................................................................................224
Novel high pressure sealing system for tube hydroforming operations............................................................................................225
FRIDAY, JUNE 14 CONCURRENT SESSIONS L
Effect of ball nose end mill geometry on high speed machining of Ti6Al4V..................................................................................226
Machining of VP20ISOF steel with resharpened carbide tools in end milling................................................................................227
Rapid finite element prediction on machining process...............................................................................................................................228
Analytical cut geometry prediction for free form surface during semi-finish milling................................................................229
Model learning in a multistage machining process: Online identification of force coefficients and model
use in the manufacturing enterprise........................................................................................................................................................................230
Estimation of milling forces from compliant sensors using a harmonic force model and kalman filter........................231
Combined temperature and force control for robotic friction stir welding.....................................................................................232
Video event fault detection with STVs: Application to a high speed assembly machine........................................................233
Assembly system configuration design for a product family....................................................................................................................234
AFM-based nanofabrication: Modeling, simulation, and experimental verification...................................................................235
All solution based fabrication of CIGS solar cell.................................................................................................................................................236
Paper based lithium magnesium oxide battery.................................................................................................................................................237
Review and analysis of vibration assisted machining.....................................................................................................................................238
Mechanism of fatigue performance enhancement in a superhard nanoparticles integrated nanocomposites
by a hybrid manufacturing technique.....................................................................................................................................................................239
Modeling of focused ultrasound propagation in water towards a solid target and comparisons to experimental
observations on ultrasonic cavitation......................................................................................................................................................................240
viii MSEC 2013 NAMRC 41

INDEX OF AUTHORS
Abdullah, Amir................................................................................ 224
Abdullah, Arif M......................................................................... 69, 70
Abele, Eberhard................................................................................. 21
Abell, J.A................................................................................................. 60
Abu-Farha, Fadi............................................................................... 186
Adams, David................................................................................... 113
Adamson, Göran....................................................................... 58, 75
Agapiou, John..................................................................................... 29
Agarwal, Kuldeep.......................................................................... 158
Agarwal, Mangilal................................................................236, 237
Aidibe, Ali............................................................................................... 37
Akinlabi, Stephen.............................................................................. 55
Alfieri, Vittorio...................................................................................... 54
Aliahmad, Nojan............................................................................. 237
Allavarapu, Santosh...................................................................... 220
Almuhtady, Ahmad...................................................................... 175
Altintas, Yusuf...................................................................................... 22
Amarasinghe, Voshadhi................................................................ 91
Anand, Sundararaman...........................................188, 220, 221
Anandan, K. Prashanth............................................................... 106
Annoni, Massimiliano..................................................................... 67
Ansari, Faraz....................................................................................... 207
Antani, Kavit R.................................................................................. 194
Arentoft, Mogens........................................................................... 138
Ascari, Alessandro..................................................................... 53, 74
Aurich, Jan C........................................................................................ 88
Awadallah, Osama M................................................................... 218
Babu, Silesh....................................................................................... 158
Bacci, Márcio........................................................................................ 27
Baehre, Dirk.......................................................................................... 81
Baek, Hyung...................................................................................... 141
Bai, Yuanli............................................................................................ 133
Bajpai, Vivek.......................................................................................... 94
Barnett, Andrew........................................................................ 69, 70
Barton, Kira............................................................................................ 50
Bastwros, Mina................................................................................ 185
Bataineh, Omar.................................................................................. 61
Bauza, Marcin.............................................................................. 17, 18
Bayesteh, Abdolreza....................................................................... 68
Becker, Christoph........................................................................... 159
Bedekar, Vikram............................................................................... 195
Bediz, Bekir............................................................................................ 49
Beeranur, Ravikumar.................................................................... 200
Behroozfar, Ali.................................................................................. 115
Bordatchev, Evgueni V................................................................... 92
Bower, Deon..................................................................................... 226
Bragg, Adam..................................................................................... 172
Brandal, Grant B.......................................................................31, 163
Bruennet, Horst.................................................................................. 81
Brundage, Michael........................................................................ 126
Bruschi, Stefania............................................................................. 136
Buell, Sezen........................................................................................... 96
Buffa, Gianluca.................................................................................... 30
Buis, Jennifer........................................................................................ 98
Bunget, Cristina.........................................................129, 152, 211
Bushlya, Volodymyr......................................................................... 19
Caiazzo, Fabrizia................................................................................. 54
Calvo-Amodio, Javier...................................................................... 41
Camelio, Jaime..............................................................85, 184, 225
Campana, Giampaolo.................................................................... 74
Cao, Huajun....................................................................................... 125
Cao, Jian................................................................................11, 25, 116
Cao, Xiaobo....................................................................................... 145
Cardaropoli, Francesco.................................................................. 54
Carmignato, Simone....................................................................... 73
Carrella, Marina.................................................................................. 88
Castle, James.................................................................................... 203
Cawley, Brendan............................................................................. 113
Celler, George K................................................................................. 91
Chai, Xudong....................................................................................... 77
Chandra, Abhijit.............................................................................. 172
Chandrasekar, Chandy......................................................................5
Chandrasekar, Srinivasan...................................................20, 223
Chang, Cindy.................................................................................... 126
Chaudhari, Rahul............................................................................ 195
Che, Demeng...................................................................................... 86
Chen, Bao........................................................................................... 192
Chen, Dongmei.............................................................................. 126
Chen, Hongqiang............................................................................. 90
Chen, Howard..................................................................................... 12
Chen, Roland K................................................................................... 71
Chen, Xueyang................................................................................ 189
Chen, Yan............................................................................................ 177
Chen, Yong........................................................................................... 59
Chen, Yujie...............................................................................152, 211
Cheng, Gary...................................................................................... 239
Cheng, Haiqin.................................................................................. 125
Cheng, Jie........................................................................................... 192
Cheng, Xiaomin.............................................................................. 158
Chou, Y. Kevin..............................................................135, 165, 187
Chu, Bryan.......................................................................................... 204
Cilip, Christopher.............................................................................. 18
Cohen, Paul.......................................................................................... 66
Colombo, Daniele............................................................................ 36
Compton, W. Dale..................................................................20, 223
Corman, Gero J................................................................................... 40
JUNE 10-14, 2013 // Madison, Wisconsin
ix

INDEX OF AUTHORS, cont.
Corney, Jonathan R....................................................................... 146
Corrado, Gaetano............................................................................. 54
Cuccolini, Gabriele........................................................................... 53
Cucinotta, Annamaria.................................................................... 73
Dabir-Moghaddam, Navid....................................................... 240
Darvekar, Sanjay............................................................................. 209
Davidson, Joseph............................................................................. 38
Davies, Richard W.................................................................................3
Davis, Tyler.......................................................................................... 202
Dawood, Bishoy.............................................................................. 112
Deibel, Karl-Robert........................................................................... 48
Deng, Jinan........................................................................................ 217
Deng, Nengxiu................................................................................... 64
Dhande, Sanjay............................................................................... 111
Dhokia, Vimal.................................................................................... 222
Dillon, O.W., Jr................................................................................... 131
Ding, Liqiang....................................................................................... 43
Dong, Jingyan............................................................................. 51, 66
Dongre, Ganesh....................................................................................7
Dornfeld, David.......................................................................... 40, 42
Du, Changqing................................................................................... 63
Duc, Emmanuel.............................................................................. 229
Ducato, Antonino............................................................................. 30
Duffie, Neil...............................................................................161, 232
Efimov, Igor........................................................................................... 16
Ehmann, Kornel....................................................11, 86, 116, 208
ElMokadem, Alaa........................................................................... 112
El-Mounayri, Hazim...................................................................... 235
Emblom, William J......................................................................... 225
Ess, Markus......................................................................................... 105
Fan, Z..................................................................................................... 189
Fanrong, Kong................................................................................. 162
Fehrenbacher, Axel....................................................................... 232
Feng, Sule.................................................................................................2
Ferguson, B. Lynn........................................................................... 190
Fernando, Heshan......................................................................... 233
Ferreira, Placid..................................................................................... 52
Ferrier, Nicola.................................................................................... 232
Fetecau, Catalin.......................................................................... 87, 95
Fortunato, Alessandro.................................................................... 53
Fratini, Livan......................................................................................... 30
Fu, C.H...................................................................................................... 45
Funk, Kilian......................................................................................... 194
Funtik, Brian....................................................................................... 178
Fussell, Barry............................................................................127, 231
Gadalla, Mohamed....................................................................... 193
Gan, Yuan............................................................................................... 62
Ganguly, Vasishta........................................................................... 104
Gao, Liang.......................................................................................... 121
Gao, Rober X........................................................................................ 84
Gao, Yibo...................................................................................181, 240
Ge, Xianchen....................................................................................... 14
Gebhardt, Michael........................................................................ 105
Ghiotti, Andrea................................................................................ 136
Ghosh, Amitava.............................................................................. 215
Giacomin, Alan................................................................................ 141
Gilmore, John................................................................................... 217
Gonçalves, Ricardo A...................................................................... 27
Gong, Xibing..................................................................................... 165
Gordon, Adam.................................................................................... 69
Gorton, Patrick.................................................................................... 96
Gozen, Bulent A................................................................................. 49
Graham, Eldon.......................................................................................4
Greenspan, Michael..................................................................... 233
Greer, Matthew J............................................................................ 143
Griffin, James.................................................................................... 212
Gross, Todd........................................................................................... 23
Grzesik, Wit............................................................................................ 26
Guo, Lei................................................................................................ 150
Guo, Yang................................................................................5, 20, 223
Guo, Yuebin.....................................................................45, 153, 214
Haapala, Karl........................................................................................ 41
Haase, Matthias............................................................................... 159
Hafiz, Abdullah M. K........................................................................ 92
Han, Jiang........................................................................................... 192
Han, Peidong....................................................................................... 11
Hänisch, Stephan........................................................................... 159
Hansen, Casper............................................................................... 138
Hansen, Hans N............................................................................... 138
Hasser, Peter......................................................................................... 44
Helo, Petri........................................................................................... 124
Henderson, Andrew..................................................................... 129
Hendriko............................................................................................. 229
Ho, Tung.............................................................................................. 236
Holm, Magnus............................................................................ 58, 75
Hoyne, Alexander C......................................................................... 57
Hsieh, Sheng-Jen.............................................................................. 83
Hu, Anrui............................................................................................. 122
Hu, Chunsheng............................................................................... 145
Hu, Jack..............................................................................60, 183, 234
Hu, Xiaohang.................................................................................... 122
Hughes, Greg................................................................................... 233
Hutchins, Margot.............................................................................. 42
Ilie, Marcel.......................................................................................... 217
Ismail, Mohamed........................................................................... 174
Iverson, Jon....................................................................................... 171
x MSEC 2013 NAMRC 41

Jagadeesan, Ananda P................................................................ 146
Jäger, Andreas.................................................................................. 159
Jahan, Muhammad P.........................................................................8
Jawahir, I.S.......................................................................................... 131
Jawalkar, Chandrashekhar........................................................ 207
Jeswiet, Jack...................................................................................... 113
Jin, Jionghua........................................................................................ 60
Jin, Wenjing....................................................................................... 177
Jin, Xiaoliang........................................................................................ 22
Jing, Xin.........................................................................................32, 119
Jones, Elizabeth.............................................................................. 180
Jones, Joshua..............................................................179, 180, 199
Joshi, Suhas.............................................................................................7
Jubery, Talukder Z............................................................................. 80
Jui, Sumit...................................................................................................9
Jun, Martin............................................................................................ 68
K, Ramji................................................................................................. 209
Kamaraj, Abishek..................................................................................9
Kapoor, Shiv G...................................................................57, 80, 171
Karandikar, Jaydeep M......................................................128, 213
Karingula, Varun K......................................................................... 235
Karra, Pavan K................................................................................... 172
Kennedy, Elizabeth....................................................................... 147
Khalifa, Noomane B...................................................................... 159
Khanna, Navneet............................................................................... 28
Kim, Byung H.................................................................................... 142
Kim, Dae H.................................................................................... 56, 79
Kim, Dave............................................................................................ 102
Kim, Gap-Yong.......................................................................172, 185
Kim, T.H.................................................................................................... 60
King, Galen......................................................................................... 219
Kinsey, Brad........................................................................23, 65, 137
Kirsch, Benjamin................................................................................ 88
Kishawy, H.A...................................................................................... 169
Kiswanto, Gandjar......................................................................... 229
Kiszka, P................................................................................................... 26
Knapp, Wolfgang........................................................................... 105
København, Maskinmester S.................................................. 138
Koh, Min H......................................................................................... 231
Kolbe, Jörg......................................................................................... 159
Kong, Adams W.K........................................................................... 117
Konobrytskyi, Dmytro................................................................. 210
Koratkar, Nikhil................................................................................. 204
Korkmaz, Emrullah........................................................................... 49
Korkolis, Yannis.........................................................................64, 137
Kovacevic, Radovan..................................................................... 162
Kowalczyk, D........................................................................................ 26
Krugh, Matthew................................................................................. 24
Kumar, Pradeep............................................................................... 207
Kumar, Sanjeev................................................................................ 206
Kunz, Jacob........................................................................................ 149
Kuppuswamy, Ramesh............................................................... 226
Kurfess, Thomas....................................129, 152, 186, 210, 211
Kurz, Mary E....................................................................................... 194
Kushwaha, Ajay.................................................................................. 94
Kuwabara, Toshihiko....................................................................... 64
Kwon, Patrick...............................................................102, 140, 166
Ladani, Leila J.................................................................................... 164
Lan, Shuhuai...........................................................................115, 160
Langer, Kristina................................................................................... 44
Lantrip, Jeff........................................................................................ 102
Lasecki, John........................................................................................ 62
Laughner, Jacob................................................................................ 16
Lee, Jay................................................................................................. 177
Lee, Jihyun............................................................................................ 39
Lee, Pil-Ho.............................................................................................. 56
Lee, Sangwon.............................................................................. 56, 79
Lee, Seungchul................................................................................ 175
Lee, Yuan-Shin.................................................................................... 69
Lei, Shuting.................................................................................14, 196
Lettenbauer, Hubert....................................................................... 17
Li, Feng................................................................................................. 173
Li, Fugen.............................................................................................. 192
Li, Hongcheng................................................................................. 125
Li, Jingjing.......................................................................................... 182
Li, Jingshan........................................................................................ 168
Li, Lin............................................................................................167, 176
Li, Lu.......................................................................................................... 62
Li, Qi.......................................................................................................... 62
Li, Sha.................................................................................................... 234
Li, Tonghui.......................................................................................... 148
Li, Wei.................................................................................................... 153
Li, Xiaochun....................................................................................... 161
Li, Xuekun.................................................................................110, 173
Li, Zhichao................................................................................156, 190
Liao, Yiliang........................................................................................ 239
Libardi, Amy...................................................................................... 114
Lin, Dong............................................................................................ 239
Lin, Qun............................................................................................... 121
Linke, Barbara...................................................................................... 40
Liou, Fuewen F................................................................................. 189
Liu, C. Richard................................................................................... 239
Liu, Gang..............................................................................................1, 2
Liu, Jian................................................................................................. 133
Liu, Richard........................................................................................... 43
Liu, Wei................................................................................................. 162
JUNE 10-14, 2013 // Madison, Wisconsin
xi

INDEX OF AUTHORS, cont.
Liu, Xun................................................................................................ 160
Liu, Yong-Kui........................................................................................ 76
Liu, Ze.................................................................................................... 181
Liverani, Erica....................................................................................... 53
Lu, Jiping............................................................................................. 182
Lu, Ping................................................................................................. 135
Lu, Tao................................................................................................... 131
Luo, Yi.................................................................................................... 125
Lutey, Adrian................................................................................ 35, 73
Lyons, Kevin W.................................................................................... 78
Ma, Chao............................................................................................. 161
Ma, Jianfeng...............................................................................14, 196
Ma, Lei................................................................................................... 203
Machado, Álisson R...................................................................... 227
Madan, Jatinder................................................................................. 78
Magargee, James.............................................................................. 25
Mahajan, Pushkar........................................................................... 108
Mahato, Anirban............................................................................... 20
Mahshid, Rasoul............................................................................. 138
Malhotra, Rajiv................................................................................. 116
Malik, Arif.....................................................................................44, 109
Malshe, Ajay P.........................................................................................8
Mani, Kanthababu............................................................................ 93
Mani, Mahesh...................................................................................... 78
Mann, James......................................................................5, 154, 223
March, Poloko.................................................................................. 226
Marinescu, Ioan D................................................................150, 170
Marwala, Tshilidzi.............................................................................. 55
Masotti, Giovanni.............................................................................. 36
Mathew, Nithin T............................................................................... 93
Matsumura, Takashi............................................................................6
Mayor, J................................................................................................ 149
Mayorga, Maria E............................................................................ 194
McLeay, Tom..................................................................................... 213
Mears, Laine............129, 152, 179, 180, 194, 199, 211, 230
Mehta, Parikshit............................................................................... 230
Melaibari, Ammar...................................................................19, 103
Melkote, Shreyes............................................................................ 203
Meng, Long....................................................................................... 228
Mi, Hao-Yang.............................................................................32, 119
Micari, Fabrizio.................................................................................... 30
Milner, Justin...........................................................................186, 211
Molari, Pier G........................................................................................ 73
Molian, Pal...................................................................................19, 103
Moore, Jason Z........................................................................... 69, 70
Morestin, Fabrice............................................................................... 25
Mori, Masahiko................................................................................... 47
Moura, Ricardo................................................................................ 227
Muqaddam, Mishaal....................................................................... 10
Nahata, Sudhanshu...................................................................... 106
Nam, Jung S......................................................................................... 79
Narasimhan, K.................................................................................. 108
Nath, Chandra...........................................................................57, 171
Naveed, Syed.............................................................................31, 163
Nazzal, Mohammad..................................................................... 107
Nelson, Andrew.............................................................................. 109
Newkirk, J.W...................................................................................... 189
Newman, Stephen........................................................................ 222
Ng, Kenny........................................................................................... 225
Ngaile, Gracious................................................................................. 46
Nguyen, Trung................................................................................. 140
Ni, Jun..............................................................................115, 160, 175
Nie, Zhenguo................................................................................... 191
Nigam, Pankaj..................................................................................... 96
Nikhare, Chetan................................................................................. 24
Niknam, Seyed A............................................................................ 155
Nottingham, Alex............................................................................. 99
Nouri, Mehdi...........................................................................127, 231
Novella, Michele............................................................................. 136
Ogawa, Tomohiro................................................................................6
Okwudire, Chinedum..................................................................... 39
Orazi, Leonardo.................................................................................. 53
Ozbolat, Ibrahim................................................................12, 33, 34
Ozdoganlar, Burak..................................................................49, 106
Ozel, Tugrul......................................................................91, 130, 132
Padwal, Parth..........................................................................................7
Palanisamy, Barath........................................................................ 205
Pan, Yayue.............................................................................................. 59
Panhalkar, Neeraj............................................................................ 221
Park, Chaneel..........................................................................................4
Park, Kyung-Hee............................................................................. 140
Park, Simon..............................................................................................4
Paskaramoorthy, Ratnam.......................................................... 120
Patten, John...............................................................................72, 151
Paul, Brian........................................................................................... 205
Paul, Ratnadeep.........................................................188, 220, 221
Pavel, Radu............................................................................................ 89
Paynabar, Kamran............................................................................. 60
Pearce, Brian...................................................................................... 194
Pei, Zhijian........................................................................99, 147, 216
Pelate, Nathan.................................................................................. 196
Pender, Kyle.......................................................................................... 46
Peng, Junyang.......................................................................................2
Peng, Xiang-Fang....................................................................32, 119
Perry, Thomas...................................................................................... 29
Petrò, Stefano...................................................................................... 67
xii MSEC 2013 NAMRC 41

Petrusha, Igor...................................................................................... 19
Pfefferkorn, Frank.................................................................161, 232
Pleta, Abram........................................................................................ 24
Ponthapalli, Surya C........................................................................ 72
Potluri, Hemanth............................................................................ 199
Prabu, S. Balasivanandha ......................................................... 120
Pradesh, Madhya..................................................................................7
Prakasam, Pradeep K................................................................... 157
Pratt, Daniel.......................................................................................... 18
Previtali, Barbara................................................................................ 36
Promyoo, Rapeepan.................................................................... 235
Pu, Zhengwen.......................................................................131, 197
Puleo, D.A............................................................................................ 131
Qin, Yi.................................................................................................... 146
Ragai, Ihab.......................................................................................... 134
Raja, Jayaraman................................................................................. 82
Rajurkar, Kamlakar P............................................................................8
Ramasamy, Suresh K....................................................................... 82
Rao, Abbaraju B.K........................................................................... 209
Rashad, Ragaie M........................................................................... 218
Rathinam, Arvinth............................................................................ 85
Rauschecker, Ursula..................................................................... 123
Ravindra, Deepak....................................................................72, 151
Razfar, Mohammad R........................................................115, 224
Rebaioli, Lara........................................................................................ 67
Rech, Joel............................................................................................... 26
Reddy, Narala S.K............................................................................ 169
Ren, Lei.................................................................................................... 77
Ren, Xiang.......................................................................................... 139
Robertson, John................................................................................ 85
Robinson, Stefanie........................................................................... 42
Rohatgi, Aashish...................................................................................3
Rong, Yiming...............................................................110, 173, 191
Rosen, David..................................................................................... 143
Roth, John............................................................................................. 24
Roy, Lalit............................................................................................... 164
Roy, Sougata..................................................................................... 215
Rozzi, Jay................................................................................................ 15
Saldana, Christopher................................................................... 154
Sambhav, Kumar............................................................................ 111
Samuel, Johnson............................................................................ 204
Sandu, Laurentiu I............................................................................. 95
Sangwan, Kuldip S........................................................................... 28
Sasaki, Masanori...................................................................................6
Satoh, Gen...................................................................................31, 163
Saxena, Ishan.................................................................................... 116
Schaefer, Dirk.................................................................................... 143
Schaefer, Dominik............................................................................ 21
Schel, Daniel..................................................................................... 123
Schmid, Steven............................................................................... 114
Schmitz, Tony..............................................................104, 128, 213
Schneider, William......................................................................... 114
Sekar, Remanath................................................................................ 83
Selleri, Stefano.................................................................................... 73
Selvaggio, Alessandro................................................................. 159
Semeraro, Quirico............................................................................. 67
Sen, Mihir............................................................................................ 114
Sequera, A.......................................................................................... 214
Sergi, Vincenzo................................................................................... 54
Serizawa, Masaki...................................................................................6
Shafae, Mohammed.................................................................... 184
Shah, Jami............................................................................................. 38
Shamsuzzoha, Ahm..................................................................... 124
Shao, Chenhui.................................................................................... 60
Shao, Hua............................................................................................ 167
Sharma, Apurbba K...................................................................... 207
Shazly, Mostafa................................................................................ 112
Shih, Albert........................................................................................... 71
Shih, Hua-Chu..................................................................................... 63
Shin, Yung.........................................................................13, 202, 219
Shinde, Hemant.............................................................................. 108
Shirazi, AliReza................................................................................. 134
Shivpuri, Rajiv.........................................................................158, 195
Shrestha, Sudhir....................................................................236, 237
Shrotriya, Pranav......................................................................19, 103
Shukla, Mukul...................................................................................... 55
Singh, Anshul................................................................................... 197
Singh, Ramesh..........................................................7, 94, 108, 200
Smith, Christopher........................................................................ 232
Smith, Mark T..........................................................................................3
Solito, Riccardo................................................................................... 67
Song, Xiaoxu..............................................................................99, 216
Songmene, Victor.......................................................................... 155
Soshi, Masakazu................................................................................. 47
Sozzi, Michele..................................................................................... 73
Spicer, J.P................................................................................................ 60
Spradlin, Thomas.............................................................................. 44
Srivastava, Anil K...........................................................89, 174, 228
Ståhl, Jan-Eric...................................................................................... 19
Stalbaum, Tyler......................................................................................5
Stan, Felicia................................................................................... 87, 95
Stephens, Elizabeth V........................................................................3
Stöhr, Matthias................................................................................. 123
Sturtevant, Caleb........................................................................... 102
Subbiah, Sathyan.................................................................117, 157
Sun, Xianjun......................................................................................... 62
JUNE 10-14, 2013 // Madison, Wisconsin
xiii

INDEX OF AUTHORS, cont.
Sun, Xiaofei........................................................................................... 96
Sun, Zeyi.............................................................................................. 176
Sundaram, Murali................................................................................9
Sundaram, Narayan K...........................................................20, 223
Surgenor, Brian................................................................................ 233
Suriano, Saumuy............................................................................ 183
Suslov, Sergey.................................................................................. 239
Sutherland, John............................................................................... 98
Szkilnyk, Greg................................................................................... 233
Tahan, S. Antoine.............................................................................. 37
Tai, Bruce........................................................................................ 10, 71
Takagi, Miki........................................................................................... 52
Tandon, Puneet............................................................................... 111
Tang, Shuiyuan................................................................................ 182
Tang, Zejun..............................................................................................1
Tao, Fei...........................................................................................76, 122
Tao, Jie..................................................................................................... 62
Tarbutton, Joshua.......................................................................... 210
Tekkaya, A. Erman.......................................................................... 159
Teng, Bugang.........................................................................................2
Tesfay, Hayelom.............................................................................. 156
Tesswin, Thomas............................................................................ 117
Thangapandian, N......................................................................... 120
Thanumoorthy, Ramasubramani K.R................................. 142
Thepsonthi, Thanongsak....................................................91, 130
Thibaudeau, Ethan................................................................... 23, 65
Tian, Xiaoqing.................................................................................. 192
Tian, Yinan.......................................................................................... 219
Toenissen, Stefan.............................................................................. 40
Tragni, Katia.......................................................................................... 73
Tse, Leo.................................................................................................... 50
Tsotsis, Thomas............................................................................... 118
Tucker, Tommy................................................................................ 210
Turner, Bradley.................................................................................... 23
Turner, Sam........................................................................................ 213
Turng, Lih-Sheng.....................................................32, 96, 97, 119
Tutunea-Fatan, Remus O.............................................................. 92
Tyler, Chris T....................................................................................... 128
Ueda, Eisaku......................................................................................... 47
Ulutan, Durul.................................................................................... 132
Umbrello, D....................................................................................... 131
Vadali, Madhu.................................................................................. 161
Varahramyan, Kody..................................................235, 236, 237
Velasquez, Tim.................................................................................... 11
Vemulapalli, Prabath....................................................................... 38
Vittoe, Robert................................................................................... 236
Vlad, Daniel........................................................................................... 87
Waghmare, Kiran............................................................................ 200
Wagner, Scott................................................................................... 225
Wang, Charlie...................................................................................... 59
Wang, Chongye.............................................................................. 167
Wang, Donghai............................................................................... 147
Wang, Gang....................................................................................... 191
Wang, Hongliang.............................................................................. 90
Wang, Hui.........................................................................60, 183, 234
Wang, Jie............................................................................................. 172
Wang, Lihui.........................................................................58, 75, 121
Wang, Long.......................................................................................... 76
Wang, Mingang.............................................................................. 166
Wang, Shiren..................................................................................... 185
Wang, Xi V........................................................................................... 144
Wang, Xiaosong....................................................................................2
Wang, Xin............................................................................................ 102
Wang, Xiqun........................................................................................ 89
Wang, Yajun.......................................................................................... 16
Wang, Yancheng....................................................................... 10, 71
Wang, Yong....................................................................................... 167
Webb, Jeff.............................................................................................. 62
Webster, David................................................................................ 217
Wegener, Konrad....................................................................48, 105
Wei, Chuang........................................................................................ 51
Wei, X.T.................................................................................................... 45
Weikert, Sascha............................................................................... 105
Wells, Lee J..................................................................................85, 184
Wendel, John.................................................................................... 109
Wentz, John E...................................................................................... 80
Wifi, Abdalla S........................................................................112, 218
Wilson, Joseph................................................................................. 137
Wolfe, Douglas E............................................................................... 70
Wu, Benxin...............................................................................181, 240
Wu, Changxu.................................................................................... 167
Wu, Dazhong.................................................................................... 143
Wu, Zhenhua....................................................................................... 83
Wu, Zhuoru.................................................................................19, 103
Xia, Kai.................................................................................................. 121
Xia, Lian................................................................................................ 192
Xie, Yuzhu........................................................................................... 156
Xu, Chengdong.............................................................................. 145
Xu, Chengying............................................................133, 201, 217
Xu, Xinwei........................................................................................... 176
Xu, Xun................................................................................................. 144
Xu, Zhigang....................................................................................... 156
Yagishita, Hukuzo.......................................................................... 101
Yan, Bing.............................................................................................. 156
Yan, Ruqiang........................................................................................ 84
Yan, Yan................................................................................................ 182
xiv MSEC 2013 NAMRC 41

Yang, Jinshan.................................................................................... 217
Yao, Bin................................................................................................. 202
Yao, Donggang............................................................................... 142
Yao, Y. Lawrence...............................................................31, 90, 163
Ye, Chang............................................................................................ 239
Yeung, Ho...................................................................................... 5, 223
Yin, Guoxu.......................................................................................... 170
Yin, Ruixue.......................................................................................... 125
Yip, Arthur L.K.................................................................................. 146
Yu, Emily................................................................................................. 97
Yu, Miao............................................................................................... 139
Yu, Victor.............................................................................................. 126
Yu, Yin............................................................................................... 33, 34
Yuan, Chris......................................................................................... 148
Yuan, Shijian............................................................................................1
Zak, Krzysztof...................................................................................... 26
Zarchi, M. Mahdi A........................................................................ 224
Zeng, Danielle..................................................................................... 62
Zeng, Qiang...................................................................................... 208
Zhang, Faping.................................................................................. 182
Zhang, Hao........................................................................................... 41
Zhang, Kaifu...................................................................................... 176
Zhang, Kun........................................................................................ 185
Zhang, Li................................................................................................. 66
Zhang, Lin...........................................................................76, 77, 122
Zhang, Meng....................................................................................... 99
Zhang, Meng.................................................................................... 216
Zhang, Pengfei................................................... 99, 145, 147, 216
Zhang, Qi............................................................................................ 147
Zhang, Qingwei.............................................................................. 139
Zhang, Song........................................................................................ 16
Zhang, Tianrun................................................................................ 238
Zhang, Wenwu......................................................................198, 238
Zhang, Xiping.................................................................................. 238
Zhang, Xueping.......................................................................43, 228
Zhang, Yahui........................................................................................ 33
Zhao, Chun........................................................................................... 77
Zhao, Cong........................................................................................ 168
Zhao, Fu........................................................................................98, 100
Zhao, Ran............................................................................................ 201
Zhao, Rui................................................................................................ 84
Zhao, Xin................................................................................................ 13
Zhao, Xuejin......................................................................................... 59
Zheng, Huawen.............................................................................. 198
Zhou, Chi............................................................................................... 59
Zhou, Dajun......................................................................................... 63
Zhou, Jack.......................................................................................... 139
Zhou, Jinming..................................................................................... 19
Zhou, Xiaohang.............................................................................. 139
Zhou, Yun............................................................................................ 181
Zhu, Can.............................................................................................. 185
Zhu, Tianxing.................................................................................... 173
Zhu, Zicheng.................................................................................... 222
Zinn, Michael.................................................................................... 232
Zipf, Mark............................................................................................ 109
Zuo, Guokun..................................................................................... 198
JUNE 10-14, 2013 // Madison, Wisconsin
xv

TIME AND LOCATION
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MSEC: TUBE AND ELECTROHYDRAULIC FORMING
Tuesday, June 11 10:30 - 12:00 Meeting Room K & O
MSEC: TUBE AND ELECTROHYDRAULIC FORMING
Tuesday, June 11 10:30 - 12:00 Meeting Room K & O
MSEC: TUBE AND ELECTROHYDRAULIC FORMING
Tuesday, June 11 10:30 - 12:00 Meeting Room K & O
NAMRC: NOVEL MACHINING PROCESSES
Tuesday, June 11 10:30 - 12:00 Meeting Room L & P
NAMRC: NOVEL MACHINING PROCESSES
Tuesday, June 11 10:30 - 12:00 Meeting Room L & P
NAMRC: NOVEL MACHINING PROCESSES
Tuesday, June 11 10:30 - 12:00 Meeting Room L & P
NAMRC: EDM/ECM PROCESSES
Tuesday, June 11 10:30 - 12:00 Hall of Ideas E
NAMRC: EDM/ECM PROCESSES
Tuesday, June 11 10:30 - 12:00 Hall of Ideas E
NAMRC: EDM/ECM PROCESSES
Tuesday, June 11 10:30 - 12:00 Hall of Ideas E
MSEC: ENABLING METHODS AND TOOLS FOR SOFT TISSUE SURGERY
Tuesday, June 11 10:30 - 12:00 Hall of Ideas F
MSEC: ENABLING METHODS AND TOOLS FOR SOFT TISSUE SURGERY
Tuesday, June 11 10:30 - 12:00 Hall of Ideas F
MSEC: ENABLING METHODS AND TOOLS FOR SOFT TISSUE SURGERY
Tuesday, June 11 10:30 - 12:00 Hall of Ideas F
MSEC: THERMALLY ASSISTED Manufacturing I
Tuesday, June 11 10:30 - 12:00 Hall of Ideas G
MSEC: THERMALLY ASSISTED Manufacturing I
Tuesday, June 11 10:30 - 12:00 Hall of Ideas G
MSEC: THERMALLY ASSISTED Manufacturing I
Tuesday, June 11 10:30 - 12:00 Hall of Ideas G
MSEC: MANUFACTURING AND METROLOGY SYSTEMS I
Tuesday, June 11 10:30 - 12:00 Hall of Ideas H
MSEC: MANUFACTURING AND METROLOGY SYSTEMS I
Tuesday, June 11 10:30 - 12:00 Hall of Ideas H
MSEC: MANUFACTURING AND METROLOGY SYSTEMS I
Tuesday, June 11 10:30 - 12:00 Hall of Ideas H
NAMRC: MATERIALS IN MANUFACTURING
Tuesday, June 11 10:30 - 12:00 Hall of Ideas I
NAMRC: MATERIALS IN MANUFACTURING
Tuesday, June 11 10:30 - 12:00 Hall of Ideas I
xvi MSEC 2013 NAMRC 41

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MSEC: MACHINING STABILITY
Tuesday, June 11 10:30 - 12:00 Hall of Ideas J
MSEC: MACHINING STABILITY
Tuesday, June 11 10:30 - 12:00 Hall of Ideas J
MSEC: ELECTRICALLY-ASSISTED FORMING
Tuesday, June 11 13:30 - 15:00 Meeting Room K & O
MSEC: ELECTRICALLY-ASSISTED FORMING
Tuesday, June 11 13:30 - 15:00 Meeting Room K & O
MSEC: ELECTRICALLY-ASSISTED FORMING
Tuesday, June 11 13:30 - 15:00 Meeting Room K & O
NAMRC: MACHINABILITY OF MATERIALS
Tuesday, June 11 13:30 - 15:00 Meeting Room L & P
NAMRC: MACHINABILITY OF MATERIALS
Tuesday, June 11 13:30 - 15:00 Meeting Room L & P
NAMRC: MACHINABILITY OF MATERIALS
Tuesday, June 11 13:30 - 15:00 Meeting Room L & P
NAMRC: WELDING
Tuesday, June 11 13:30 - 15:00 Hall of Ideas E
NAMRC: WELDING
Tuesday, June 11 13:30 - 15:00 Hall of Ideas E
NAMRC: WELDING
Tuesday, June 11 13:30 - 15:00 Hall of Ideas E
MSEC: BIOMANUFACTURING TECHNIQUES FOR TISSUE ENGINEERING SCAFFOLDS
Tuesday, June 11 13:30 - 15:00 Hall of Ideas F
MSEC: BIOMANUFACTURING TECHNIQUES FOR TISSUE ENGINEERING SCAFFOLDS
Tuesday, June 11 13:30 - 15:00 Hall of Ideas F
MSEC: BIOMANUFACTURING TECHNIQUES FOR TISSUE ENGINEERING SCAFFOLDS
Tuesday, June 11 13:30 - 15:00 Hall of Ideas F
MSEC: THERMALLY ASSISTED Manufacturing II
Tuesday, June 11 13:30 - 15:00 Hall of Ideas G
MSEC: THERMALLY ASSISTED Manufacturing II
Tuesday, June 11 13:30 - 15:00 Hall of Ideas G
MSEC: MANUFACTURING AND METROLOGY SYSTEMS II
Tuesday, June 11 13:30 - 15:00 Hall of Ideas H
MSEC: MANUFACTURING AND METROLOGY SYSTEMS II
Tuesday, June 11 13:30 - 15:00 Hall of Ideas H
MSEC: MANUFACTURING AND METROLOGY SYSTEMS II
Tuesday, June 11 13:30 - 15:00 Hall of Ideas H
NAMRC: SUSTAINABLE MANUFACTURING
Tuesday, June 11 13:30 - 15:00 Hall of Ideas I
JUNE 10-14, 2013 // Madison, Wisconsin
xvii

TIME AND LOCATION, cont.
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NAMRC: SUSTAINABLE MANUFACTURING
Tuesday, June 11 13:30 - 15:00 Hall of Ideas I
NAMRC: SUSTAINABLE MANUFACTURING
Tuesday, June 11 13:30 - 15:00 Hall of Ideas I
MSEC: MATERIAL CHARACTERIZATION
Tuesday, June 11 13:30 - 15:00 Hall of Ideas J
MSEC: MATERIAL CHARACTERIZATION
Tuesday, June 11 13:30 - 15:00 Hall of Ideas J
MSEC: NOVEL FORMING PROCESSES
Tuesday, June 11 15:30 - 17:00 Meeting Room K & O
MSEC: NOVEL FORMING PROCESSES
Tuesday, June 11 15:30 - 17:00 Meeting Room K & O
NAMRC: MANUFACTURING MACHINES: COMPONENTS AND SENSORS
Tuesday, June 11 15:30 - 17:00 Meeting Room L & P
NAMRC: MANUFACTURING MACHINES: COMPONENTS AND SENSORS
Tuesday, June 11 15:30 - 17:00 Meeting Room L & P
NAMRC: MANUFACTURING MACHINES: COMPONENTS AND SENSORS
Tuesday, June 11 15:30 - 17:00 Meeting Room L & P
NAMRC: NOVEL ADDITIVE PROCESSES
Tuesday, June 11 15:30 - 17:00 Hall of Ideas E
NAMRC: NOVEL ADDITIVE PROCESSES
Tuesday, June 11 15:30 - 17:00 Hall of Ideas E
NAMRC: NOVEL ADDITIVE PROCESSES
Tuesday, June 11 15:30 - 17:00 Hall of Ideas E
MSEC: THERMALLY ASSISTED MANUFACTURING III
Tuesday, June 11 15:30 - 17:00 Hall of Ideas G
MSEC: THERMALLY ASSISTED MANUFACTURING III
Tuesday, June 11 15:30 - 17:00 Hall of Ideas G
MSEC: THERMALLY ASSISTED MANUFACTURING III
Tuesday, June 11 15:30 - 17:00 Hall of Ideas G
MSEC: SUSTAINABLE MANUFACTURING METRICS AND METHODS
Tuesday, June 11 15:30 - 17:00 Hall of Ideas H
MSEC: SUSTAINABLE MANUFACTURING METRICS AND METHODS
Tuesday, June 11 15:30 - 17:00 Hall of Ideas H
NAMRC: MANUFACTURING SYSTEMS
Tuesday, June 11 15:30 - 17:00 Hall of Ideas I
NAMRC: MANUFACTURING SYSTEMS
Tuesday, June 11 15:30 - 17:00 Hall of Ideas I
NAMRC: MANUFACTURING SYSTEMS
Tuesday, June 11 15:30 - 17:00 Hall of Ideas I
xviii MSEC 2013 NAMRC 41

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MSEC: COMPOSITES, POLYMERS, NON-METALS I
Tuesday, June 11 15:30 - 17:00 Hall of Ideas J
MSEC: COMPOSITES, POLYMERS, NON-METALS I
Tuesday, June 11 15:30 - 17:00 Hall of Ideas J
MSEC: MATERIAL BEHAVIOR AND TOOLING DESIGN IN SHEET FORMING
Wednesday, June 12 8:30 - 10:00 Meeting Room K & O
MSEC: MATERIAL BEHAVIOR AND TOOLING DESIGN IN SHEET FORMING
Wednesday, June 12 8:30 - 10:00 Meeting Room K & O
MSEC: MATERIAL BEHAVIOR AND TOOLING DESIGN IN SHEET FORMING
Wednesday, June 12 8:30 - 10:00 Meeting Room K & O
NAMRC: MICRO-MACHINING
Wednesday, June 12 8:30 - 10:00 Meeting Room L & P
NAMRC: MICRO-MACHINING
Wednesday, June 12 8:30 - 10:00 Meeting Room L & P
NAMRC: MICRO-MACHINING
Wednesday, June 12 8:30 - 10:00 Meeting Room L & P
NAMRC: BIO-MANUFACTURING
Wednesday, June 12 8:30 - 10:00 Hall of Ideas E
NAMRC: BIO-MANUFACTURING
Wednesday, June 12 8:30 - 10:00 Hall of Ideas E
NAMRC: BIO-MANUFACTURING
Wednesday, June 12 8:30 - 10:00 Hall of Ideas E
MSEC: THERMALLY-ASSISTED MANUFACTURING IV
Wednesday, June 12 8:30 - 10:00 Hall of Ideas F
MSEC: THERMALLY-ASSISTED MANUFACTURING IV
Wednesday, June 12 8:30 - 10:00 Hall of Ideas F
MSEC: THERMALLY-ASSISTED MANUFACTURING IV
Wednesday, June 12 8:30 - 10:00 Hall of Ideas F
MSEC: ADVANCES IN CLOUD MANUFACTURING I
Wednesday, June 12 8:30 - 10:00 Hall of Ideas G
MSEC: ADVANCES IN CLOUD MANUFACTURING I
Wednesday, June 12 8:30 - 10:00 Hall of Ideas G
MSEC: ADVANCES IN CLOUD MANUFACTURING I
Wednesday, June 12 8:30 - 10:00 Hall of Ideas G
MSEC: SUSTAINABLE MANUFACTURING PROCESSES
Wednesday, June 12 8:30 - 10:00 Hall of Ideas H
MSEC: SUSTAINABLE MANUFACTURING PROCESSES
Wednesday, June 12 8:30 - 10:00 Hall of Ideas H
MSEC: SUSTAINABLE MANUFACTURING PROCESSES
Wednesday, June 12 8:30 - 10:00 Hall of Ideas H
JUNE 10-14, 2013 // Madison, Wisconsin
xix

TIME AND LOCATION
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NAMRC: METROLOGY
Wednesday, June 12 8:30 - 10:00 Hall of Ideas I
NAMRC: METROLOGY
Wednesday, June 12 8:30 - 10:00 Hall of Ideas I
NAMRC: MACHINE HEALTH MONITORING
Wednesday, June 12 8:30 - 10:00 Hall of Ideas J
NAMRC: MACHINE HEALTH MONITORING
Wednesday, June 12 8:30 - 10:00 Hall of Ideas J
NAMRC: MACHINE HEALTH MONITORING
Wednesday, June 12 8:30 - 10:00 Hall of Ideas J
MSEC: COMPOSITES, POLYMERS, NON-METALS II
Wednesday, June 12 8:30 - 10:00 Hall of Fame
MSEC: COMPOSITES, POLYMERS, NON-METALS II
Wednesday, June 12 8:30 - 10:00 Hall of Fame
MSEC: ABRASIVE PROCESSES
Wednesday, June 12 10:30 - 12:00 Meeting Room K & O
MSEC: ABRASIVE PROCESSES
Wednesday, June 12 10:30 - 12:00 Meeting Room K & O
NAMRC: LASER-BASED AND ASSISTED PROCESSES
Wednesday, June 12 10:30 - 12:00 Meeting Room L & P
NAMRC: LASER-BASED AND ASSISTED PROCESSES
Wednesday, June 12 10:30 - 12:00 Meeting Room L & P
NAMRC: LASER-BASED AND ASSISTED PROCESSES
Wednesday, June 12 10:30 - 12:00 Meeting Room L & P
MSEC: MICRO/NANO-MANUFACTURING I
Wednesday, June 12 10:30 - 12:00 Hall of Ideas E
MSEC: MICRO/NANO-MANUFACTURING I
Wednesday, June 12 10:30 - 12:00 Hall of Ideas E
MSEC: ADVANCES IN INJECTION MOLDING
Wednesday, June 12 10:30 - 12:00 Hall of Ideas F
MSEC: ADVANCES IN INJECTION MOLDING
Wednesday, June 12 10:30 - 12:00 Hall of Ideas F
MSEC: ADVANCES IN INJECTION MOLDING
Wednesday, June 12 10:30 - 12:00 Hall of Ideas F
MSEC: LIFE CYCLE INVENTORY MODELS
Wednesday, June 12 10:30 - 12:00 Hall of Ideas H
MSEC: LIFE CYCLE INVENTORY MODELS
Wednesday, June 12 10:30 - 12:00 Hall of Ideas H
MSEC: LIFE CYCLE INVENTORY MODELS
Wednesday, June 12 10:30 - 12:00 Hall of Ideas H
xx MSEC 2013 NAMRC 41

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NAMRC: MACHINING OF NOVEL MATERIALS
Wednesday, June 12 10:30 - 12:00 Hall of Ideas I
NAMRC: MACHINING OF NOVEL MATERIALS
Wednesday, June 12 10:30 - 12:00 Hall of Ideas I
NAMRC: MACHINING OF NOVEL MATERIALS
Wednesday, June 12 10:30 - 12:00 Hall of Ideas I
NAMRC: MACHINE TOOL CHARACTERIZATION
Wednesday, June 12 10:30 - 12:00 Hall of Ideas J
NAMRC: MACHINE TOOL CHARACTERIZATION
Wednesday, June 12 10:30 - 12:00 Hall of Ideas J
NAMRC: MACHINE TOOL CHARACTERIZATION
Wednesday, June 12 10:30 - 12:00 Hall of Ideas J
MSEC: FORMING
Wednesday, June 12 10:30 - 12:00 Hall of Fame
MSEC: FORMING
Wednesday, June 12 10:30 - 12:00 Hall of Fame
MSEC: FORMING
Wednesday, June 12 10:30 - 12:00 Hall of Fame
MSEC: GRINDING AND DRILLING
Wednesday, June 12 13:30 - 15:00 Meeting Room K & O
MSEC: GRINDING AND DRILLING
Wednesday, June 12 13:30 - 15:00 Meeting Room K & O
NAMRC: FORMING MACHINES AND EQUIPMENT
Wednesday, June 12 13:30 - 15:00 Meeting Room L & P
NAMRC: FORMING MACHINES AND EQUIPMENT
Wednesday, June 12 13:30 - 15:00 Meeting Room L & P
NAMRC: FORMING MACHINES AND EQUIPMENT
Wednesday, June 12 13:30 - 15:00 Meeting Room L & P
MSEC: MICRO/NANO-MANUFACTURING II
Wednesday, June 12 13:30 - 15:00 Hall of Ideas E
MSEC: MICRO/NANO-MANUFACTURING II
Wednesday, June 12 13:30 - 15:00 Hall of Ideas E
MSEC: MICRO/NANO-MANUFACTURING II
Wednesday, June 12 13:30 - 15:00 Hall of Ideas E
MSEC: ADVANCES IN POLYMER MATERIALS: LIQUID COMPOSITES, NANO-COMPOSITES AND
BLENDS
Wednesday, June 12 13:30 - 15:00 Hall of Ideas F
MSEC: ADVANCES IN POLYMER MATERIALS: LIQUID COMPOSITES, NANO-COMPOSITES AND
BLENDS
Wednesday, June 12 13:30 - 15:00 Hall of Ideas F
JUNE 10-14, 2013 // Madison, Wisconsin
xxi

TIME AND LOCATION, cont.
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MSEC: ADVANCES IN POLYMER MATERIALS: LIQUID COMPOSITES, NANO-COMPOSITES AND
BLENDS
Wednesday, June 12 13:30 - 15:00 Hall of Ideas F
MSEC: ADVANCES IN CLOUD MANUFACTURING II
Wednesday, June 12 13:30 - 15:00 Hall of Ideas G
MSEC: ADVANCES IN CLOUD MANUFACTURING II
Wednesday, June 12 13:30 - 15:00 Hall of Ideas G
MSEC: ADVANCES IN CLOUD MANUFACTURING II
Wednesday, June 12 13:30 - 15:00 Hall of Ideas G
MSEC: SUSTAINABLE MANUFACTURING SYSTEMS
Wednesday, June 12 13:30 - 15:00 Hall of Ideas H
MSEC: SUSTAINABLE MANUFACTURING SYSTEMS
Wednesday, June 12 13:30 - 15:00 Hall of Ideas H
MSEC: SUSTAINABLE MANUFACTURING SYSTEMS
Wednesday, June 12 13:30 - 15:00 Hall of Ideas H
NAMRC: CONTROL OF MACHINING PROCESSES
Wednesday, June 12 13:30 - 15:00 Hall of Ideas I
NAMRC: CONTROL OF MACHINING PROCESSES
Wednesday, June 12 13:30 - 15:00 Hall of Ideas I
NAMRC: CONTROL OF MACHINING PROCESSES
Wednesday, June 12 13:30 - 15:00 Hall of Ideas I
NAMRC: MACHINING PROCESS MODELING
Wednesday, June 12 13:30 - 15:00 Hall of Ideas J
NAMRC: MACHINING PROCESS MODELING
Wednesday, June 12 13:30 - 15:00 Hall of Ideas J
NAMRC: MACHINING PROCESS MODELING
Wednesday, June 12 13:30 - 15:00 Hall of Ideas J
MSEC: FATIGUE AND FRACTURE
Wednesday, June 12 15:30 - 17:00 Meeting Room K & O
MSEC: FATIGUE AND FRACTURE
Wednesday, June 12 15:30 - 17:00 Meeting Room K & O
MSEC: FATIGUE AND FRACTURE
Wednesday, June 12 15:30 - 17:00 Meeting Room K & O
NAMRC: FORMING MATERIALS CHARACTERIZATION
Wednesday, June 12 15:30 - 17:00 Meeting Room L & P
NAMRC: FORMING MATERIALS CHARACTERIZATION
Wednesday, June 12 15:30 - 17:00 Meeting Room L & P
MSEC: MICRO/NANO-MANUFACTURING III
Wednesday, June 12 15:30 - 17:00 Hall of Ideas E
xxii MSEC 2013 NAMRC 41

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MSEC: MICRO/NANO-MANUFACTURING III
Wednesday, June 12 15:30 - 17:00 Hall of Ideas E
MSEC: MICRO/NANO-MANUFACTURING III
Wednesday, June 12 15:30 - 17:00 Hall of Ideas E
MSEC: ADVANCES IN FORMING: THERMOFORMING AND HOT EMBOSSING
Wednesday, June 12 15:30 - 17:00 Hall of Ideas F
MSEC: ADVANCES IN FORMING: THERMOFORMING AND HOT EMBOSSING
Wednesday, June 12 15:30 - 17:00 Hall of Ideas F
MSEC: ADVANCES IN CLOUD MANUFACTURING III
Wednesday, June 12 15:30 - 17:00 Hall of Ideas G
MSEC: ADVANCES IN CLOUD MANUFACTURING III
Wednesday, June 12 15:30 - 17:00 Hall of Ideas G
MSEC: ADVANCES IN CLOUD MANUFACTURING III
Wednesday, June 12 15:30 - 17:00 Hall of Ideas G
MSEC: ADVANCES IN CLOUD MANUFACTURING III
Wednesday, June 12 15:30 - 17:00 Hall of Ideas G
MSEC: SUSTAINABLE MANUFACTURING TECHNOLOGIES
Wednesday, June 12 15:30 - 17:00 Hall of Ideas H
MSEC: SUSTAINABLE MANUFACTURING TECHNOLOGIES
Wednesday, June 12 15:30 - 17:00 Hall of Ideas H
NAMRC: GRINDING
Wednesday, June 12 15:30 - 17:00 Hall of Ideas I
NAMRC: GRINDING
Wednesday, June 12 15:30 - 17:00 Hall of Ideas I
NAMRC: GRINDING
Wednesday, June 12 15:30 - 17:00 Hall of Ideas I
NAMRC: MACHINING PROCESS SIMULATION
Wednesday, June 12 15:30 - 17:00 Hall of Ideas J
NAMRC: MACHINING PROCESS SIMULATION
Wednesday, June 12 15:30 - 17:00 Hall of Ideas J
NAMRC: MACHINING PROCESS SIMULATION
Wednesday, June 12 15:30 - 17:00 Hall of Ideas J
MSEC: EDGE FINISHING AND DEBURRING
Thursday, June 13 10:30 - 12:00 Meeting Room K & O
MSEC: EDGE FINISHING AND DEBURRING
Thursday, June 13 10:30 - 12:00 Meeting Room K & O
MSEC: EDGE FINISHING AND DEBURRING
Thursday, June 13 10:30 - 12:00 Meeting Room K & O
NAMRC: INNOVATIVE FORMING PROCESSES
Thursday, June 13 10:30 - 12:00 Meeting Room L & P
JUNE 10-14, 2013 // Madison, Wisconsin
xxiii

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NAMRC: INNOVATIVE FORMING PROCESSES
Thursday, June 13 10:30 - 12:00 Meeting Room L & P
NAMRC: INNOVATIVE FORMING PROCESSES
Thursday, June 13 10:30 - 12:00 Meeting Room L & P
MSEC: LASER BASED THERMAL MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas E
MSEC: LASER BASED THERMAL MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas E
MSEC: LASER BASED THERMAL MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas E
MSEC: ADDITIVE MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas F
MSEC: ADDITIVE MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas F
MSEC: ADDITIVE MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas F
MSEC: SUSTAINABLE VEHICLE MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas H
MSEC: SUSTAINABLE VEHICLE MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas H
NAMRC: TRIBOLOGY IN MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas I
NAMRC: TRIBOLOGY IN MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas I
NAMRC: TRIBOLOGY IN MANUFACTURING
Thursday, June 13 10:30 - 12:00 Hall of Ideas I
MSEC: MATERIALS PROCESSING AND HANLDING
Thursday, June 13 10:30 - 12:00 Hall of Ideas J
MSEC: MATERIALS PROCESSING AND HANLDING
Thursday, June 13 10:30 - 12:00 Hall of Ideas J
MSEC: MATERIALS PROCESSING AND HANLDING
Thursday, June 13 10:30 - 12:00 Hall of Ideas J
MSEC: JOINT MAINTENANCE AND PRODUCTION PLANNING
Thursday, June 13 13:30 - 15:00 Meeting Room K & O
MSEC: JOINT MAINTENANCE AND PRODUCTION PLANNING
Thursday, June 13 13:30 - 15:00 Meeting Room K & O
MSEC: ADVANCED TOPICS IN MANUFACTURING AND METROLOGY
Thursday, June 13 13:30 - 15:00 Meeting Room L & P
MSEC: ADVANCED TOPICS IN MANUFACTURING AND METROLOGY
Thursday, June 13 13:30 - 15:00 Meeting Room L & P
xxiv MSEC 2013 NAMRC 41

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MSEC: MULTI-ENERGY FIELD MANUFACTURING
Thursday, June 13 13:30 - 15:00 Hall of Ideas E
MSEC: MULTI-ENERGY FIELD MANUFACTURING
Thursday, June 13 13:30 - 15:00 Hall of Ideas E
MSEC: MULTI-ENERGY FIELD MANUFACTURING
Thursday, June 13 13:30 - 15:00 Hall of Ideas E
MSEC: SYSTEM INFORMATICS FOR QUALITY IMPROVEMENTS
Thursday, June 13 13:30 - 15:00 Hall of Ideas F
MSEC: SYSTEM INFORMATICS FOR QUALITY IMPROVEMENTS
Thursday, June 13 13:30 - 15:00 Hall of Ideas F
MSEC: SYSTEM INFORMATICS FOR QUALITY IMPROVEMENTS
Thursday, June 13 13:30 - 15:00 Hall of Ideas F
MSEC: MICRO/NANO-MATERIALS I
Thursday, June 13 13:30 - 15:00 Hall of Ideas H
MSEC: MICRO/NANO-MATERIALS I
Thursday, June 13 13:30 - 15:00 Hall of Ideas H
NAMRC: MODELING OF ADDITIVE PROCESSES
Thursday, June 13 13:30 - 15:00 Hall of Ideas I
NAMRC: MODELING OF ADDITIVE PROCESSES
Thursday, June 13 13:30 - 15:00 Hall of Ideas I
NAMRC: MODELING OF ADDITIVE PROCESSES
Thursday, June 13 13:30 - 15:00 Hall of Ideas I
MSEC: HEAT TREATMENT EFFECTS
Thursday, June 13 13:30 - 15:00 Hall of Ideas J
MSEC: HEAT TREATMENT EFFECTS
Thursday, June 13 13:30 - 15:00 Hall of Ideas J
MSEC: MANUFACTURING SYSTEMS AND TECHNOLOGIES FOR RAPID RESPONSES AND
DEPLOYMENT
Thursday, June 13 15:30 - 17:00 Meeting Room K & O
MSEC: MANUFACTURING SYSTEMS AND TECHNOLOGIES FOR RAPID RESPONSES AND
DEPLOYMENT
Thursday, June 13 15:30 - 17:00 Meeting Room K & O
MSEC: MANUFACTURING SYSTEMS AND TECHNOLOGIES FOR RAPID RESPONSES AND
DEPLOYMENT
Thursday, June 13 15:30 - 17:00 Meeting Room K & O
NAMRC: HARD MATERIAL MACHINING
Thursday, June 13 15:30 - 17:00 Meeting Room L & P
NAMRC: HARD MATERIAL MACHINING
Thursday, June 13 15:30 - 17:00 Meeting Room L & P
JUNE 10-14, 2013 // Madison, Wisconsin
xxv

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NAMRC: HARD MATERIAL MACHINING
Thursday, June 13 15:30 - 17:00 Meeting Room L & P
MSEC: PROCESS AND SYSTEM INNOVATION I
Thursday, June 13 15:30 - 17:00 Hall of Ideas E
MSEC: PROCESS AND SYSTEM INNOVATION I
Thursday, June 13 15:30 - 17:00 Hall of Ideas E
MSEC: PROCESS AND SYSTEM INNOVATION I
Thursday, June 13 15:30 - 17:00 Hall of Ideas E
MSEC: MODEL AND SENSOR-BASED CONTROL
Thursday, June 13 15:30 - 17:00 Hall of Ideas F
MSEC: MODEL AND SENSOR-BASED CONTROL
Thursday, June 13 15:30 - 17:00 Hall of Ideas F
MSEC: MODEL AND SENSOR-BASED CONTROL
Thursday, June 13 15:30 - 17:00 Hall of Ideas F
MSEC: MICRO/NANO-MATERIALS II
Thursday, June 13 15:30 - 17:00 Hall of Ideas H
MSEC: MICRO/NANO-MATERIALS II
Thursday, June 13 15:30 - 17:00 Hall of Ideas H
MSEC: ADVANCES IN NONTRADITIONAL MANUFACTURING PROCESSES I
Thursday, June 13 15:30 - 17:00 Hall of Ideas J
MSEC: ADVANCES IN NONTRADITIONAL MANUFACTURING PROCESSES I
Thursday, June 13 15:30 - 17:00 Hall of Ideas J
MSEC: EQUIPMENT DESIGN INNOVATIONS TO ENHANCE MANUFACTURING PROCESSES
Friday, June 14 8:30 - 10:00 Ballroom A
MSEC: EQUIPMENT DESIGN INNOVATIONS TO ENHANCE MANUFACTURING PROCESSES
Friday, June 14 8:30 - 10:00 Ballroom A
MSEC: MILLING I
Friday, June 14 8:30 - 10:00 Hall of Ideas E
MSEC: MILLING I
Friday, June 14 8:30 - 10:00 Hall of Ideas E
MSEC: PROGNOSTICS AND UNCERTAINTY
Friday, June 14 8:30 - 10:00 Hall of Ideas F
MSEC: PROGNOSTICS AND UNCERTAINTY
Friday, June 14 8:30 - 10:00 Hall of Ideas F
MSEC: PROGNOSTICS AND UNCERTAINTY
Friday, June 14 8:30 - 10:00 Hall of Ideas F
MSEC: EMERGING PROCESS TECHNOLOGIES
Friday, June 14 8:30 - 10:00 Hall of Ideas G
MSEC: EMERGING PROCESS TECHNOLOGIES
Friday, June 14 8:30 - 10:00 Hall of Ideas G
xxvi MSEC 2013 NAMRC 41

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MSEC: FABRICATION OF MICRO/NANO-STRUCTURES
Friday, June 14 8:30 - 10:00 Hall of Ideas H
MSEC: FABRICATION OF MICRO/NANO-STRUCTURES
Friday, June 14 8:30 - 10:00 Hall of Ideas H
MSEC: FABRICATION OF MICRO/NANO-STRUCTURES
Friday, June 14 8:30 - 10:00 Hall of Ideas H
NAMRC: PROCESS PLANNING FOR ADDITIVE MANUFACTURING
Friday, June 14 8:30 - 10:00 Hall of Ideas I
NAMRC: PROCESS PLANNING FOR ADDITIVE MANUFACTURING
Friday, June 14 8:30 - 10:00 Hall of Ideas I
NAMRC: PROCESS PLANNING FOR ADDITIVE MANUFACTURING
Friday, June 14 8:30 - 10:00 Hall of Ideas I
MSEC: ADVANCES IN NONTRADITIONAL MANUFACTURING PROCESSES II
Friday, June 14 8:30 - 10:00 Hall of Ideas J
MSEC: ADVANCES IN NONTRADITIONAL MANUFACTURING PROCESSES II
Friday, June 14 8:30 - 10:00 Hall of Ideas J
MSEC: ADVANCES IN NONTRADITIONAL MANUFACTURING PROCESSES II
Friday, June 14 8:30 - 10:00 Hall of Ideas J
MSEC: TOOLING DESIGN TO ENHANCE MANUFACTURING PROCESS
Friday, June 14 10:30 - 12:00 Ballroom A
MSEC: TOOLING DESIGN TO ENHANCE MANUFACTURING PROCESS
Friday, June 14 10:30 - 12:00 Ballroom A
MSEC: MILLING II
Friday, June 14 10:30 - 12:00 Hall of Ideas E
MSEC: MILLING II
Friday, June 14 10:30 - 12:00 Hall of Ideas E
MSEC: SENSOR-BASED MODELING AND DETECTION
Friday, June 14 10:30 - 12:00 Hall of Ideas F
MSEC: SENSOR-BASED MODELING AND DETECTION
Friday, June 14 10:30 - 12:00 Hall of Ideas F
MSEC: SENSOR-BASED MODELING AND DETECTION
Friday, June 14 10:30 - 12:00 Hall of Ideas F
NAMRC: ASSEMBLY PROCESSES
Friday, June 14 10:30 - 12:00 Hall of Ideas G
NAMRC: ASSEMBLY PROCESSES
Friday, June 14 10:30 - 12:00 Hall of Ideas G
MSEC: FABRICATION OF MICRO/NANO-DEVICES
Friday, June 14 10:30 - 12:00 Hall of Ideas H
MSEC: FABRICATION OF MICRO/NANO-DEVICES
Friday, June 14 10:30 - 12:00 Hall of Ideas H
JUNE 10-14, 2013 // Madison, Wisconsin
xxvii

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MSEC: FABRICATION OF MICRO/NANO-DEVICES
Friday, June 14 10:30 - 12:00 Hall of Ideas H
MSEC: PROCESS AND SYSTEM INNOVATION II
Friday, June 14 10:30 - 12:00 Hall of Ideas J
MSEC: PROCESS AND SYSTEM INNOVATION II
Friday, June 14 10:30 - 12:00 Hall of Ideas J
MSEC: PROCESS AND SYSTEM INNOVATION II
Friday, June 14 10:30 - 12:00 Hall of Ideas J
xxviii MSEC 2013 NAMRC 41

Abstracts
Simulation and experiment on warm hydroforming of AZ31 magnesium alloy tube
MSEC2013-1084
Shijian Yuan, Harbin Institute of Technology, Harbin, China, Zejun Tang, Nanjing University of Aeronautics and
Astronautics, Nanjing, China, Gang Liu, Harbin Institute of Technology, Harbin, China
The wrinkling behavior of an AZ31B magnesium alloy tube was investigated by simulation at different loading
paths and at different temperatures. The effects of strain rate, internal pressure and temperature on the wrinkles
were studied. Stress-strain track was analyzed in the quasi-static strain state graph of the plane stress processing to
explain the changing of the wrinkles shape, radius and wall thickness. It is shown that shape of the wrinkles wave
along the axial direction keeps the sine wave character. The radius and thinning at the top zone of the wrinkles
and the width of the wrinkles increased with the temperature, the internal pressure or the axial feeding. Moreover,
hydro-formability of wrinkled parts was investigated and the improvement was observed. Finally, as an application
of using wrinkled parts as preform prior to the final calibration, a magnesium alloy tubular part with 50% expansion
ratio was formed.
1 MSEC 2013 NAMRC 41

An approach for increasing branch height of a hydroforming t-joint with smaller branch diameter
MSEC2013-1169
Junyang Peng, Gang Liu, Bugang Teng, Xiaosong Wang, Harbin Institute of Technology, Harbin, China, Sule Feng,
NO.800 Research Institute of Shanghai Academy of Spaceflight Technology, Shanghai, China, Shanghai, China
Hydroforming of a stainless steel T-joint with ratio of tube diameter to thickness D/t=108 and ratio of branch
diameter to tube diameter d/D=0.6 was studied. The effects of counter punch loading path on branch height
and thickness were discussed. Because the branch diameter is smaller than the tube diameter, it is difficult to
obtain a higher branch height and avoid thinning at the same time. An approach for increasing branch height of a
hydroforming T-joint with smaller branch diameter was proposed. Finite element method (FEM) simulations were
carried out for analyzing the deformation during hydroforming of the T-joint. Thinning ratio distribution, stress and
strain states from different loading paths were presented. The experimental results show that the new approach
with counter punch moving backwards during calibration is effective to increase branch height and to improve
thickness distribution.
JUNE 10-14, 2013 // Madison, Wisconsin
2

Abstracts, cont.
An investigation of sheet metal deformation behavior during electro-hydraulic forming (EHF)
MSEC2013-1129
Aashish Rohatgi, Elizabeth V. Stephens, Richard W. Davies, Mark T. Smith, Pacific Northwest National Laboratory,
Richland, United States
This work describes recent advances in our understanding of sheet metal behavior during electro-hydraulic
forming (EHF) process. Two sets of experiments were performed using AA5182-O Al sheet material. In the first
set, 1 mm thick sheet samples were subjected to a single pressure-pulse or two consecutive pressure-pulses with
the deformation being carried out under free-forming or inside a conical die. In the second set of experiments
employing 2 mm sheet samples, a circular region at the center of the sheet was pre-thinned to 1 mm thickness and
the sheet was subjected to a single pressure-pulse under free-forming conditions. The sheet deformation history
for both sets of experiments was quantified using a recently developed technique that combines high-speed
imaging and the digital image correlation (DIC) techniques. The results from the first set of experiments show that
the manner in which the discharge is created can influence the strain-rates and hence, the deformation history
experienced by the sheet materials. The results of the multi-pulse experiments demonstrate the applicability of the
EHF technique for re-strike operations. The results from the second set of experiments show that the pre-thinned
region is analogous to a reduced gauge section with the resulting strain-rate (in the pre-thinned region) exceeding
that in the adjacent homogeneous sheet by more than 50%.
3 MSEC 2013 NAMRC 41

Inclined ball end milling of micro-dimpled surfaces for polymeric components
NAMRC41-1591
Eldon Graham, Chaneel Park, Simon Park, University of Calgary, Calgary, AB, Canada
Functional micro surfaces have been recognized for their vital roles in a wide range of advanced applications.
The fabrication of surface structures at the micro level can be used to influence tribological, optical and many
other surface characteristics. To take advantage of the benefits of functional surfaces, industry and researchers
have begun focusing on finding more sustainable and efficient manufacturing processes. The inclined micro ball
end milling technique has become a fast and efficient method for creating patterned surfaces. With the right
adjustments, the spindle speed and feed rate can be set so that the flutes of the cutter create periodic dimpled
patterns onto a workpiece surface. This micro machining technique is an ideal method for fabricating dimpled
surfaces, especially for metallic alloys such as dies and molds. For polymer based products, micro injection molding
is more applicable for manufacturing on a large scale, cost effectively. Developing surface pattern algorithms
for generating different dimple geometries and an appropriate force model can promote a sustainable future
for a variety of novel products and lead to accurate manufacturing of surface characteristics, which is vital to the
performance of a functional surface. The micro dimple machining technique is applied to micro injection molds
to create polymeric components with micro patterns. The results indicate that micro dimple machining combined
with micro injection molding is a viable method of producing polymeric components with functional surfaces for
advanced technological applications.
JUNE 10-14, 2013 // Madison, Wisconsin
4

Abstracts, cont.
Modulation-assisted high speed machining of compacted graphite Iron (CGI)
NAMRC41-1593
Yang Guo, Tyler Stalbaum, Ho Yeung, Purdue University, West Lafayette, IN, United States, James Mann, M4 Sciences
LLC, West Lafayette, IN, United States, Chandy Chandrasekar, Purdue University, W Lafayette, IN, United States
The application of controlled, low-frequency modulation (~ 100 Hz) superimposed onto the cutting process
modulation-assisted machining (MAM) - is shown to be quite effective in reducing the wear of cubic boron nitride
(CBN) tools when machining compacted graphite iron (CGI) at high machining speeds (>> 500 m/min). The tool
life is at least 20 times greater than in conventional machining. This significant reduction in wear is a consequence
of the multiple effects realized by MAM, including reduction in intimacy of the contact, formation of discrete
chips, enhanced fluid action and lower cutting temperatures. The propensity for thermochemical wear of CBN, the
principal wear mode at high speeds in CGI machining, is thus reduced. It is also found that higher cutting speed
leads to lower tool wear in MAM. The feed-direction MAM appears feasible for implementation at high speeds and
offers a potential solution to this challenging class of industrial machining applications.
5 MSEC 2013 NAMRC 41

Helical plate machining in whirling
NAMRC41-1601
Takashi Matsumura, Tokyo Denki University, Tokyo, Japan, Masaki Serizawa, Tomohiro Ogawa, Masanori Sasaki, Tokyo
Denki University, Tokyo, Japan
Machining of helical plates such as blades has recently been increased with manufacturing of the aircrafts and the
energy facilities. The high machining rate and the stable machining have been required for the manufacturing.
Whirling, in which worm screws and bone screws are usually machined, is applied to the helical plate machining.
The whirling cut is performed in the workpiece and the tool rotations with eccentricity of their centers. The
advantage of the whirling cut is described in terms of the surface finish, the tool life and the chip formation. A
mechanistic model is presented to control the machining shape with the cutting thickness. The cutting tests are
conducted for difficult-to-cut materials such as titanium alloy and stainless steel on a turning center, which has a
milling axis on the turret, to verify the helical plate machining with the presented model.
JUNE 10-14, 2013 // Madison, Wisconsin
6

Abstracts, cont.
Effect of silver coating on silicon ingot slicing by wire-EDM process
NAMRC41-1554
Ganesh Dongre, Indian Institute of Technology Bombay, Mumbai, Maharashtra, India, Parth Padwal, Indian Institute
of Technology Indore, Indore, Madhya Pradesh, India, Ramesh Singh, Indian Institute of Technology Bombay,
Mumbai, Maharashtra, India, Suhas Joshi, Indian Institute Of Tech, Bombay, Mumbai 400076, Maharashtra, India
The wire-EDM process for silicon ingot slicing is helpful in minimizing wafer thickness and kerf loss. However, the
cutting rate of the process must be improved to make it as a potential alternative to abrasive wire saw process.
This paper describes the effect of silver coating on silicon in increasing the cutting rate by reducing the contact
resistance between the electrodes. It also addresses the effect of silver coating on kerf width and surface roughness
which are important for silicon ingot slicing process. While the silver coating of silicon improves cutting rate by
40%, thermal modeling of the cutting process corroborates the improvement in the cutting rate.
7 MSEC 2013 NAMRC 41

Understanding the material removal process and heat-affected zone in nano-metric electro-machining of
graphene
NAMRC41-1567
Muhammad P. Jahan, Western Kentucky University, Bowling Green, United States, Ajay P. Malshe, University of
Arkansas, Fayetteville, AR, United States, Kamlakar P. Rajurkar, University of Nebraska, Lincoln, NE, United States
The fabrication of nano features in different functional materials such as gold, graphene, carbon nano-tubes, and
quantum dotscan open up the possibility of using them more comprehensively in micro/nano electromechanical
systems (MEMS/NEMS) applications. This paper presents a feasibility investigation of fabricating nano-holes in
graphene with a focus on machining at an atomic scale. The nano-metric material removal mechanism and
the formation of a heat-affected zone (HAZ) due to the electro-machining (EM) process are discussed. It is
demonstrated that nano-EM in a liquid dielectric medium (n-decane) is capable of fabricating features as small as
3 to 4 nm with a visible atomic arrangement of carbon in graphene. Nano-features of 5 to 6 nm can be machined
consistently with excellent repeatability using the nano-EM process. As an electro-thermal machining process,
nano-EM generates HAZ and results in the deposition of materials at the edge of the machined nano-holes. The
dimensions of both the nano-features and HAZ increase with the increase of bias voltage and pulse duration.
Gradual reconstruction of carbon lattices at the edge of the nano-holes, and thus a change in the profile of the
nano-holes, are subsequently observed. Finally, it is established that batch mode nano-holes can be machined on a
graphene surface using the nano-EM process, thus making the process suitable for scale-up applications.
JUNE 10-14, 2013 // Madison, Wisconsin
8

Abstracts, cont.
Fabrication of high aspect ratio micro holes in glass by micro electrochemical discharge machining
NAMRC41-1577
Sumit Jui, Abishek Kamaraj, Murali Sundaram, University of Cincinnati, Cincinnati, OH, United States
Micromachining of glass is essential for several microfluidic components, micro-pumps, micro-accelerometers,
micro-reactors, micro-fuel cells and several biomedical devices. Unique properties such as high chemical resistance,
thermal stability and transparency give glass scope for additional applications. However, poor machinability of
glass is a major constraint, especially in high aspect ratio applications of glass in microsystem technology. Micro
electrochemical discharge machining (micro ECDM) is an emerging nontraditional fabrication method capable
of micromachining ceramic materials like glass. While surface features less than 100 µm have been successfully
machined on glass, machining high aspect features is a challenge. Machining accuracy at high depths is severely
affected due to overcut and tool wear. In this paper, high aspect ratio microtools fabricated in-house have been
used for deep micro hole drilling on glass using low electrolyte concentration. An aspect ratio of 11 has been
achieved. The results show that lower electrolyte concentration reduced overcut by 22%, thus increasing the
aspect ratio of the micro holes. Lowering the electrolyte concentration also reduced the tool wear and hole taper
by 39% and 18% respectively.
9 MSEC 2013 NAMRC 41

Cutting force of hollow needle insertion in soft tissue
MSEC2013-1124
Bruce Tai, Yancheng Wang, Mishaal Muqaddam, University of Michigan, Ann Arbor, MI, United States
This paper presents a 3-D finite element model (FEM) using cohesive zone (CZ) concept to simulate the hollow
needle insertion and identify the change in cutting force. CZ is a FEM technique that integrates the fracture
mechanics based on surface energy and has often used in analysis of crack propagation. Experiments of needle
insertion into the soft polyvinyl chloride (PVC) phantom tissue were conducted using two types of needle (bias
bevel and lancet) under a constant speed to identify friction and cutting forces. Using the CZ concept, a thin layer
of FEM is built to observe the tissue flow and cutting force along the needle cutting edge during insertion. Both
experimental observation and modeling results show higher cutting force for the lancet tip due to smaller rake
angle along the cutting edge. This FEM approach has demonstrated the potential as being an analysis tool for
hollow needle insertion.
JUNE 10-14, 2013 // Madison, Wisconsin
10

Abstracts, cont.
Feasibility of laser surface texturing for friction reduction in surgical blades
MSEC2013-1193
Tim Velasquez, Peidong Han, Northwestern University, Evanston, United States, Jian Cao, Kornel Ehmann,
Northwestern University, Evanston, IL, United States
Trauma resulting from surgical blade friction can cause several complications and delay the recovery time of a
patient. In order to attain optimal tribological properties, an 8 ps pulsed 532 nm Nd:YVO4 laser was used to ablate
the cutting edge surface of surgical blades to create micro dimples of ~110 µm in diameter and ~30 µm in depth.
Additionally, certain arrays of dimples endured an extra laser ablation operation to add a fillet to the dimple rims
with the hope of reducing stress concentrations during tissue cutting and reducing friction even further. These
surface textures were experimentally investigated through cutting experiments on phantom tissue material.
Ultimately, the blades with the cutting surface texture that employed blended dimple rims showed a substantial
reduction in friction forces when cutting phantom tissue samples.
11 MSEC 2013 NAMRC 41

Development of a multi-arm bioprinter for hybrid tissue engineering
MSEC2013-1025
Howard Chen, Ibrahim Ozbolat, The University of Iowa, Iowa City, IA, United States
This paper highlights the development of a multi-arm bioprinter (MABP) capable of concurrent deposition of
multiple materials with independent dispensing parameters including deposition speed, material dispensing
rate and frequency for functional zonal-stratified articular cartilage tissue fabrication. The MABP consists of two
Cartesian robots mounted in parallel on the same mechanical frame. This platform is used for concurrent filament
fabrication and cell spheroid deposition. A single-layer structure is fabricated and concurrently deposited with
spheroids to validate this system. Preliminary results showed that the MABP was able to produce filaments
and spheroids with well-defined geometry and high cell viability. This fabrication system is aimed to be further
refined for printing structures with varying porosities to mimic the natural cartilage structure in order to produce
functional tissue-engineered articular cartilage using cell spheroids containing cartilage progenitor cells (CPCs).
JUNE 10-14, 2013 // Madison, Wisconsin
12

Abstracts, cont.
Ablation dynamics of silicon by femtosecond laser and the role of early plasma
MSEC2013-1107
Xin Zhao, Yung Shin, Purdue University, West Lafayette, IN, United States
In this paper, the femtosecond laser ablation of silicon is investigated by a two-dimensional hydrodynamic
model. The ablation depth of the silicon wafer ablated in air at different laser intensities is calculated, and the
corresponding experimental measurements are carried out for validation. Two different ablation regimes have
been identified by varying the laser fluence. While two-photon absorption dominates in the low fluence regime (<
2 J/cm2), electron heat diffusion is a major energy transport mechanism at higher laser fluences (>> 2 J/cm2). The
ablation efficiency first increases with the laser fluence, and reaches the peak value at the laser fluence around 8 J/
cm2. It starts to drop when the laser fluence further increases, because of the early plasma absorption of the laser
beam energy.
13 MSEC 2013 NAMRC 41

Energy efficiency in thermally assisted machining of titanium alloy: a numerical study
MSEC2013-1207
Jianfeng Ma, Saint Louis University, St. Louis, MO, United States, Xianchen Ge, Saint Louis University, Saint Louis, MO,
United States, Shuting Lei, Kansas State University, Manhattan, KS, United States
This study investigates the energy utilization and efficiency in thermally assisted machining (TEM) of a titanium
alloy using numerical simulation. AdvantEdge FEM is used to conduct the simulation of orthogonal machining
of the workpiece. Thermal boundary conditions are specified to approximate laser preheating of the workpiece
material. The effects of operating conditions (preheat temperature, cutting speed, depth of cut, and rake angle)
on mechanical cutting energy, preheat energy, and energy efficiency are investigated. The results show that
preheating the workpiece reduces the cutting energy but increases the total energy in TEM. There is significant
potential to maximize total energy efficiency in TEM by optimal design of heating strategies and machining
conditions.
JUNE 10-14, 2013 // Madison, Wisconsin
14

Abstracts, cont.
A new application of cryogenic machining for advanced manufacturing
MSEC2013-1294
Jay Rozzi, Creare Incorporated, Hanover, United States
Using liquid nitrogen to cool the backside of cutting inserts with very low flow rates in order to achieve longer tool
life and/or higher material removal rates.
15 MSEC 2013 NAMRC 41

Measuring dynamic 3D micro-structures using a superfast digital binary phase-shifting technique
MSEC2013-1088
Song Zhang, Yajun Wang, Iowa State University, Ames, United States, Igor Efimov, Washington University, St Louis,
MO, United States, Jacob Laughner, Washington University, St. Louis, MO, United States
Binary phase-shifting in digital fringe projection has demonstrated significant merit over conventional sinusoidal
phases-shifting methods in terms of measurement speed and simplicity. This paper will show that compared to
conventional sinusoidal methods, binary defocusing 1) can better resolve 3D micro-structures; and 2) can achieve
kilo-Hz 3D shape measurement rates. These features are critical for measuring dynamically deformable objects,
such as the beating heart.
JUNE 10-14, 2013 // Madison, Wisconsin
16

Abstracts, cont.
Computed tomography in metrology
MSEC2013-1149
Marcin Bauza, Carl Zeiss IMT, Maple Grove, MN, United States, Hubert Lettenbauer, Carl Zeiss IMT, Oberkochen,
Germany
While the first slice of CT image took nine days to be produced (1972), today it takes only seconds to collect
the data and reconstruct a 3D image. Over the past 10 years CT started migrating from medical (qualitative)
applications to industrial (quantitative) metrology applications. However, metrological instruments require quite
a different design and data analysis approach to produce measurements which are repeatable and provide
uncertainty budget as well.
With the combination of metrology and computed tomography, parts with difficult-to-reach structures can
be quickly measured nondestructively. In addition, a CT CMM performs measurements without exerting a
measurement force that might deform soft materials. The complete 3D capture of a workpiece makes it possible to
compare CAD models and measurement data. A color-coded, easy to interpret display of a geometry comparison
provides meaningful information about the dimensional stability of the entire workpiece.
Today, Computed Tomography has revolutionized the industry by providing unique information regarding the
metrological aspects of complex structures and inaccessible features. Applications span from consumer products
to electronics, automotive, aircraft and medical. With the aid of modern CT, the reduction of R&D time is significant,
resulting in faster first part inspection or shorter reaction times on failure analyses. As a result, CT plays an important
role in many serious decisions in the daily industrial manufacturing. For example, the plastics industry has changed
their testing and manufacturing processes due to the possibilities of this promising technology.
However, the question of trusting in measurement results is still very open and requires a very careful approach and
understanding of boundaries between imaging computed tomography and metrological computed tomography.
SCOPE OF THE PRESENTATION
The presentation will focus on differences between the qualitative and the quantitative CT system, advantages as
well as issues, challenges, and limitations of CT technology.
17 MSEC 2013 NAMRC 41

Visual inspection of free form glossy surfaces using phase shifted deflectometry
MSEC2013-1190
Christopher Cilip, Daniel Pratt, Carl Zeiss, IMT, Maple Grove, United States, Marcin Bauza, Carl Zeiss IMT, Maple Grove,
MN, United States
The difficulty seen by many industries in objectively viewing specular freeform surfaces to find defects is being
able to determine changes in gloss levels. With no real quantifiable method of gloss detection available, visual
inspectors must be used to accomplish this task. This can lead to a wide range of quality in throughput even when
stringent standard requirements are put in place. This effect can compound when production is done on a global
scale, in multiple locations, and with visual inspectors receiving different training and understanding as to what
level of defect quality is acceptable. With the advancement of phase shifted deflectometry methods, automated
visual inspection can now be done to reduce these variances and increase the overall efficiency of material flow
and standard of quality during production. Furthermore, this technique is not limited to parts that are already in
production. Phase deflectometry provides a means to validate prototype parts and fully optimize their processes
before final implementation into manufacturing.
JUNE 10-14, 2013 // Madison, Wisconsin
18

Abstracts, cont.
Extreme hardness achievements in binderless cubic boron nitride tools
NAMRC41-1547
Ammar Melaibari, Pal Molian, Pranav Shrotriya, Zhuoru Wu, Iowa State University, Ames, IA, United States, Volodymyr
Bushlya, Jinming Zhou, Jan-Eric Ståhl, Lund University, Lund, Select State/Province, Sweden, Igor Petrusha, V. Bakul
Institute for Superhard Materials of The National Academy of Science of Ukraine, Kiev, Ukraine
Binderless cubic boron nitride tools are available in two forms: single phase cBN and dual phase wBN/cBN (w is
wurtzite phase). In this work, a novel heat treatment process involving surface heating using a continuous wave
CO2 laser followed by tandem waterjet quenching of the laser beam path was applied to increase the hardness of
both forms of boron nitride. Stress-induced phase transitions and nanometric grain sizes accompanying the rapid
quench heat treatment enabled a hardness increase of 20% in single phase cBN (nominal 60 GPa) and 100% in dual
phase wBN/cBN (nominal 75 GPa) that attest the ability of cBN to reach the hardness of polycrystalline diamond
(65-80 GPa). The effects of laser heat treatment are identified by an examination of the changes in phase and
microstructure by Raman spectroscopy, high resolution scanning electron microscopy and X-ray diffraction.
19 MSEC 2013 NAMRC 41

Folding and transitions in plastic deformation in metal sliding and machining
NAMRC41-1590
Yang Guo, Narayan Sundaram, Purdue University, West Lafayette, IN, United States, Anirban Mahato, W. Dale
Compton, Purdue University, W. Lafayette, IN, United States, Srinivasan Chandrasekar, Purdue University, West
Lafayette, IN, United States
High-resolution, high-speed imaging is used to perform an in-situ study of plastic flow when a hard, wedge-shaped
tool slides against a metal surface. By varying the tool rake angle from one experiment to the other, one observes
transitions in the flow pattern from one regime of plastic deformation to the other. Starting from highly negative
rake-angles when a bulge forms ahead of the tool, to continuous chip formation at positive rake-angles, there are
several such regimes, each with its own characteristics. For instance, the workpiece surface can develop bumps
and folds which develop into cracks and diminish the quality of the finished surface. In-situ observation of these
processes reveals details of the flow that are otherwise difficult to assess from post-mortem studies. Finite Element
Analysis is used to supplement these observations and help deduce the factors controlling these deformation
mechanisms. It is expected that the improved understanding of the mechanics of flow and material behavior as a
result of this study will provide insights to improve metal-cutting processes.
JUNE 10-14, 2013 // Madison, Wisconsin
20

Abstracts, cont.
A new approach for a simulation-based prediction of torsional chatter in deep hole drilling with extra-long twist
drills
MSEC2013-1184
Eberhard Abele, Dominik Schaefer, PTW, Technische Univerität Darmstadt, Darmstadt, Germany
Numerous investigations work on torsional chatter vibrations in drilling. Particularly in terms of productivity,
torsional chatter is detrimental because of a reduction of tool life and an undesirably high level of noise emissions
due to the increased process dynam-ics. To achieve a deeper understanding of the process dynamics, a new
numerical simulation model was developed to predict torsional chatter for extra-long twist drills. It is used to
determine the influence of numerous factors such as cutting parameters, drill torsional stiffness, rotary moment
of inertia and torsional-axial coupling. In this paper, the general structure of the model and the tool model is
presented.
21 MSEC 2013 NAMRC 41

Chatter stability model of micro-milling with process damping
MSEC2013-1027
Xiaoliang Jin, University of British Columbia, Vancouver, BC, Canada, Yusuf Altintas, The University of British
Columbia, Vancouver, BC, Canada
This paper presents the prediction of cutting forces and chatter stability of micro-milling operations from the
materials constitutive flow stress and structural dynamics of the micro-end mill. The cutting force coefficients are
identified either using previously presented slip-line field or Finite Element methods by considering the effects
of chip size, cutting edge radius, rake angle and cutting speed. The process damping caused by the ploughing
of round edge is modeled by Finite Element method. The frequency response function of the fragile micro-mill
is measured through specially devised piezo actuator mechanism. Dynamic milling model with the velocity
dependent process damping mechanism is modeled, and the chatter stability is predicted in frequency domain.
The proposed models have been experimentally verified in micro-milling of AISI 1045 steel.
JUNE 10-14, 2013 // Madison, Wisconsin
22

Abstracts, cont.
Analysis of fiber optic sensor to measure velocity during electromagnetic forming and welding
MSEC2013-1242
Ethan Thibaudeau, Bradley Turner, University of New Hampshire, Durham, NH, United States, Todd Gross, Univ Of
New Hampshire, Durham, NH, United States, Brad Kinsey, University of New Hampshire, Durham, NH, United States
Previous methods of measuring high velocity deformation in electromagnetic forming and magnetic pulse
welding include Photon Doppler Velocimetry (PDV), laser micrometers, and high speed photography. In this paper
an alternative method is presented, implementing a fiber optic, reflectance dependent displacement sensor. The
sensor is shown to be an attractive low cost solution to measurement of high velocities in high voltage, magnetic
environments. Data is shown with respect to sensor characterization including various surface reflectivity values,
curvatures, and misalignments; implementation in two forming and welding processes; and verification with
high velocity measurement in parallel with PDV. The sensor system is one twentieth the cost of a PDV system,
and yet measures velocities accurately to at least 140 m/s. Sensor performance is also enhanced by the use of
retroreflective tape, which is shown to increase the displacement range by 9x, decrease sensitivity to misalignment,
and increase repeatability and ease of implementation.
23 MSEC 2013 NAMRC 41

An investigation of anisotropic behavior on 5083 aluminum alloy using electric current
MSEC2013-1244
Abram Pleta, Penn State Erie - The Behrend College, Washington, PA, United States, Matthew Krugh, Penn State Erie
- The Behrend College, Pittsburgh, PA, United States, Chetan Nikhare, Penn State Erie - The Behrend College, Erie, PA,
United States, John Roth, Penn State Erie, The Behrend College, Erie, PA, United States
Due to more stringent environmental regulations, the demand for strong, lightweight metal alloys, such as AA
5083, has increased. In sheet metal forming, aluminum is preferred over higher density steels to manufacture such
parts; however the in-plane anisotropic behavior of AA 5083 alloy greatly affects its formability. Previous researchers
have found that mechanical properties of metallic materials can be influenced by DC electrical current, a research
area known as Electrically- Assisted Manufacturing (EAM). The research herein is focused on characterizing the
in-plane anisotropic behavior of AA 5083 alloy with and without DC current application, while it is loaded in the
uniaxial direction. Furthermore, the effects of EAM on Lueders banding will also be investigated.
JUNE 10-14, 2013 // Madison, Wisconsin
24

Abstracts, cont.
Characterization of flow stress for commercially pure titanium subjected to electrically-assisted deformation
MSEC2013-1069
James Magargee, Northwestern University, Evanston, United States, Fabrice Morestin, INSA-Lyon, Villeurbanne,
France, Jian Cao, Northwestern University, Evanston, IL, United States
Uniaxial tension tests were conducted on thin commercially pure titanium sheets subjected to electricallyassisted
deformation using a new experimental setup to decouple thermal-mechanical and possible electroplastic
behavior. The observed absence of stress reductions for specimens air-cooled to near room temperature motivated
the need to reevaluate the role of temperature on modeling the plastic behavior of metals subjected to electricallyassisted
deformation, an item that is often overlooked when invoking electroplasticity theory. As a result, two
empirical constitutive models, a modified-Hollomon and the Johnson-Cook models of plastic flow stress, were used
to predict the magnitude of stress reductions caused by the application of constant DC current and the associated
Joule heating temperature increase during electrically-assisted tension experiments. Results show that the thermalmechanical
coupled models can effectively predict the mechanical behavior of commercially pure titanium in
electrically-assisted tension and compression experiments.
25 MSEC 2013 NAMRC 41

Applicability of various cutting tool materials to the machining of spheroidal cast iron
NAMRC41-1506
Wit Grzesik, Opole University of Technology, Opole, Poland, Joel Rech, Université de Lyon, ENISE, LTDS UMR 5513,
Saint-Etienne, France, Krzysztof Zak, P. Kiszka, D. Kowalczyk, Opole University of Technology, Opole, Poland
This paper characterizes the overall performance of the turning process of the spheroidal cast iron (EN-GJS-500-7
grade equivalent to ASTM A-536 grade) in terms of cutting tool materials including multilayer TiC/Ti(C,N)/Al2O3/
TiN coated carbide, uncoated and Al2O3/TiN coated silicon nitride ceramic tools as well as TiN coated low-content
CBN (L-CBN) tools. This comparative studies include the cutting forces, the specific cutting pressure/specific cutting
energy, the tool-chip interface temperature, Peclet number, tool wear and surface roughness produced (both
2D and 3D parameters). Based on the measurements carried out the set of cutting conditions which guarantee
effective SCI machining is provided. It is concluded based on many process characteristics that coated Si3N4
ceramic and CBN tools can substantially improve the performance of spheroidal iron machining.
JUNE 10-14, 2013 // Madison, Wisconsin
26

Abstracts, cont.
Investigation of the machinability of aluminum alloys of the 6xxx series
NAMRC41-1535
Ricardo Augusto Gonçalves, Federal University of Uberlândia, Uberlândia, Brazil, Márcio Bacci, Federal University of
Uberlândia, Uberlândia, Brazil
The main purpose of this work is the investigation of the machinability of five aluminum-magnesium-silicon alloys
of the 6XXX series (6082, 6351, 6005A, 6063 and 6061) in dry cutting. The machinability will be investigated in terms
of cutting and feed forces, surface roughness and chip thickness ratio. A methodology to study the elastic recovery
of these alloys during machining was also proposed in this work. The feed rate and depth of cut were fixed in 0.185
mm/rot and 1.5 mm respectively. The cutting speed was variable from 10 m/min to 900 m/min. The results showed
that cutting and feed forces were higher when machining the 6082 alloy. In terms of roughness, the best results
were achieved with 6063 alloy, which also had higher chip thickness ratio. The 6351 and 6063 alloys, more ductile,
are also the ones with higher levels of elastic recovery.
27 MSEC 2013 NAMRC 41

Machinability analysis of Ti10.2.3 titanium alloy using ANOVA
NAMRC41-1602
Navneet Khanna, Kuldip Singh Sangwan, BITS Pilani, Pilani, Rajasthan,India
There is growing interest in machinability of the various titanium alloys because of increasing application in
aerospace industry. In this paper a comparison of the machinability of a metastable beta titanium alloy Ti10.2.3
in three heat treated conditions (annealed, solution treated plus aged (STA) and solution treated plus over aged
(STOA)) is presented. A two way analysis of variance (ANOVA) is used to determine the effects of the feed rate and
cutting speed on cutting tool temperature and cutting forces in the orthogonal machining of Ti10.2.3 alloy. This
study shows that the effects of feed rate and cutting speed on force and cutting tool temperature are statistically
significant. The effects of two factor interactions of the feed rate and cutting speed are also found to be important
in different heat treatment conditions. Ti10.2.3 alloy in annealed heat treatment condition showed the better
machinability among all the analyzed alloys.
JUNE 10-14, 2013 // Madison, Wisconsin
28

Abstracts, cont.
Resistance mash welding for joining of copper conductors for electric motors
NAMRC41-1537
John Agapiou, Thomas Perry, General Motors, Warren, United States
The automotive industry is developing designs and manufacturing processes for a new generation of electric
motors intended for use in hybrid and electric vehicles. This paper is focused on using solid-state welding to
join rectangular wires in the fabrication of motor stators. Resistance welding has not typically been applied to
copper due to its very high electrical conductivity; however through optimization of the current and pressure
profiles, excellent quality copper-to-copper joints have been demonstrated with a technique known as resistance
mash welding. A better understanding of resistance mash welding characteristics will help advancements in its
application for stators. The limitations of this application will be discussed.
29 MSEC 2013 NAMRC 41

Advanced FEM modeling of friction stir welding of Ti6Al4V: Microstructural evolutions
NAMRC41-1575
Gianluca Buffa, Antonino Ducato, Livan Fratini, Fabrizio Micari, University of Palermo, Palermo, Italy
Friction Stir Welding (FSW) is a solid state welding process patented in 1991 by TWI; initially adopted to weld
aluminum alloys, is now being successfully used also for high resistant materials. Welding of titanium alloys by
traditional fusion welding techniques presents several difficulties due to high material reactivity resulting in
bonding with oxygen, hydrogen, and nitrogen with consequent embrittlement of the joint. In this way FSW
represents a cost effective and high quality solution. The final mechanical properties of the joints are strictly
connected to the microstructural evolutions, in terms of phase change, occurring during the process. In the paper
a 3D FEM model of the FSW welding process, based on a thermo-mechanical fully coupled analysis, is presented.
The model, tuned both for the thermo mechanical analysis and the phase transformation through experimental
data, is able to predict the phase volume fraction of each joint typical zone at the varying of the main process
parameters. The obtained results permit to assess that the tuned FEM model of the FSW process can be utilized as
an effective design tool.
JUNE 10-14, 2013 // Madison, Wisconsin
30

Abstracts, cont.
Laser autogenous brazing of biocompatible, dissimilar metals in tubular geometries
NAMRC41-1592
Gen Satoh, Grant B. Brandal, Columbia University, New York, United States, Y Lawrence Yao, Columbia University,
New York, NY, United States, Syed Naveed, Boston Scientific Corporation, Marlborough, MA, United States
The successful joining of dissimilar metal tubes would enable the selective use of the unique properties exhibited
by biocompatible materials such as stainless steel and shape memory materials such as NiTi, to locally tailor the
properties of implantable medical devices. The lack of robust joining processes for the dissimilar metal pairs found
within these devices, however, is an obstacle to their development and manufacture. Traditional joining methods
suffer from weak joints due to the formation of brittle intermetallics or use filler materials that are unsuitable for use
within the human body. This study investigates a new process, Laser Autogenous Brazing, that utilizes a thermal
accumulation mechanism to form joints between dissimilar metals without filler materials. This process has been
shown to produce robust joints between wire specimens but requires additional considerations when applied
to tubular parts. The strength, composition, and microstructure of the resultant joints between NiTi and Stainless
Steel are investigated and the effects of laser parameters on the thermal profile and joining mechanism are studied
through experiments and numerical simulations.
31 MSEC 2013 NAMRC 41

Microcellular injection molding of thermoplastic polyurethane (TPU) scaffold using carbon dioxide and water as
co-blowing agents
MSEC2013-1154
Hao-Yang Mi, Xin Jing, University of Wisconsin-Madison, Madison, WI, United States, Lih-sheng Turng, University
of Wisconsin-Madison, Madison, WI, United States, Xiang-Fang Peng, South China University of Technology,
Guangzhou, China
In this study, a novel microcellular injection foaming method employing supercritical CO2 (scCO2) and water as
co-blowing agents was developed to produce thermoplastic polyurethane (TPU) tissue engineering scaffolds with
a uniform porous structure and no solid skin layer. Various characterization techniques were applied to investigate
the cell morphology, crystallization behavior, and static and dynamic mechanical properties of solid molded
samples, foamed samples using CO2 or water as a single blowing agent, and foamed samples using both CO2 and
water as co-blowing agents. Compared with CO2 foamed scaffolds, scaffolds produced by the co-blowing method
exhibit much more uniform cell morphologies without a noticeable reduction in mechanical properties. Moreover,
these TPU scaffolds have almost no skin layer, which permits free transport of nutrients and waste throughout the
samples, which is highly desirable in tissue engineering. The effect of these blowing agents on the shear viscosity
of various samples is also reported.
JUNE 10-14, 2013 // Madison, Wisconsin
32

Abstracts, cont.
Characterization of printable vessel-like cellular micro-fluidic channels towards organ printing
MSEC2013-1024
Yahui Zhang, Yin Yu, Ibrahim Ozbolat, The University of Iowa, Iowa City, IA, United States
Organ printing is a complex and challenging process in execution due to lack of fundamental understanding
of tissue and organ formation. Many challenges impede the further development of artificial organs for tissue
engineering. These challenges include high cell seeding density; integration of blood vessels for cell viability;
seeding spatially organized multiple cell types and degradation process and associated by-products. Embedded
micro-fluidic network during organ printing provide a way to overcome abovementioned problems.
In this research, a new approach is presented in tissue engineering through development of novel printable vessellike
permeable micro-fluidic channels towards organ printing. The proposed micro-fluidic channels in this work
enable media transport through diffusion as well as support mechanical integrity for extracellular matrix in 3D.
The proposed technique can be easily integrated with additive stem cell printing process in tandem enabling cell
viability in 3D significantly. In this research, a pressure-assisted solid freeform fabrication platform is developed with
coaxial needle dispenser unit to print hollow hydrogel filaments. Hydrogel flow rheology through coaxial nozzle
system is studied. Effect of biomaterial concentration, crosslinker concentration, nozzle assembly, flow parameters
and biomaterial types are explored to understand bioprintability of micro-fluidic channels. In addition, cell viability
and gene expression studies are presented in this paper. Cell viability shows that cartilage progenitor cells (CPCs)
maintained their viability right after bioprinting and during prolonged in vitro culture. Real time PCR analysis
yielded relatively higher expression of cartilage specific genes in hydrogel microfluidic channels encapsulating
CPCs, compared with monolayer cultured CPCs, which revealed that micro-fluidic channels were ideal environment
for cell growth and function.
33 MSEC 2013 NAMRC 41

Characterization of bioprinting induced cell damage in cellular micro-fluidic channel fabrication
MSEC2013-1081
Yin Yu, Ibrahim Ozbolat, The University of Iowa, Iowa City, IA, United States
Layer by layer additive tissue fabrication is a revolutionary concept recently emerged as an interdisciplinary effort
to produce three-dimensional living organs for clinical application. Among many challenges, it was agreed that
inclusion of vascular system is critical for maintaining the viability and functionality of relatively thick 3D bioprinted
tissue constructs. Our previous research addressed the printability of novel vessel-like micro-fluidic channels made
of alginate hydrogel using a co-axial nozzle assembly. Here, we further investigated the influence of bioprinting
parameters on cartilage progenitor cells (CPCs) survival during and post printing. The results of this study revealed
that quantifiable cell death could be induced by varying dispensing pressure, co-axial nozzle geometry, biomaterial
concentration. However, damaged cells were able to recover during incubation, as well as undergo proliferation to
certain extend. These findings may serve as a guideline for optimizing our system as well as predict cell damage in
future studies.
JUNE 10-14, 2013 // Madison, Wisconsin
34

Abstracts, cont.
Modeling of thin-film single and multi-layer nanosecond pulsed laser processing
MSEC2013-1093
Adrian Lutey, Università di Bologna, Bologna, Italy, Italy
A complete model of nanosecond pulsed laser scribing of arbitrary thin multi-layer structures is presented. The
chain of events is separated according to time-scale; an initial simulation considers material response during the
pulse; another combines this result with the much slower effects of heat flow away from the laser axis. The former
considers heating, vaporization and phase explosion of metals in the course of a single pulse, accounting for
variations in thermal conductivity and optical absorption as the material becomes superheated and approaches
its critical temperature. The latter calculates the bidimensional heat flow in a complete multi-layer structure over
the course of a scribing operation, combining material properties and considering removal by both short-pulse
ablation and long-term heating of the work piece. Simulation results for the single pulse ablation of an aluminum
target align well with published experimental data both in terms of phase explosion threshold and ablation depth
as a function of fluence. Bidimensional heat flow simulations of a polypropylene-aluminum-polypropylene triplex
structure reveal the progression of events towards steady state behavior; aluminum ejected due to short-pulse
ablation and plastic removed due to conduction.
35 MSEC 2013 NAMRC 41

Remote fiber laser processing of zinc coated steels for automotive applications
MSEC2013-1256
Daniele Colombo, Politecnico di Milano, Milano, Italy, Barbara Previtali, Politecnico di Milano Mechanical
Engineering Department, Milan, Italy, Giovanni Masotti, El.En. Group S.p.A., Calenzano, Italy
In the automotive industry conventional welding processes such resistant spot and plasma welding are gradually
replaced by laser welding technology. Traditionally, laser welding was performed by robots equipped with laserfocusing
heads for close processing. However, the recent introduction of High Power Fiber Laser sources (HPFL) in
the multi-kilowatt range has facilitated the use of laser welding in remote configurations. Different materials can
be laser welded in different remote welding configurations. Among them, a common welding process is the laser
welding of zinc-coated steel in the lap-joint configuration. The high brightness that can be achieved with these
laser sources allows for the execution of keyhole welding with high penetration. However the high beam quality
can lead to a narrow width of the weld bead that could be not large enough to ensure the correct mechanical
resistance of the welded joint, generally obtained with the conventional welding processes. A classical solution
that can be adopted to enlarge the weld width in laser welding is based on the defocusing of the laser beam even
of some millimeters in respect to the surface of the workpiece to be welded. However, the consequent decrease
of irradiance related to this solution is not able to guarantee the execution of a keyhole welding, resulting in a
reduction of the weld bead penetration and also in a loss of the overall efficiency of the melting process. A recent
welding technique developed to overcome this problem is the adoption of wobbling techniques by which the
laser welding process is performed with the superimposition of a fast oscillation of the laser beam around a centre
of oscillation that is moved over the welding trajectory. In this way an apparent spot size with a width equal to the
oscillation width is produced, allowing for an increased laser spot and consequently for a larger weld bead, without
penalizing the power density incident on the workpiece and then the penetration of the weld seam. Thanks to the
adoption of remote scanning systems enabled for beam wobbling, different wobbling strategies can be performed,
allowing for an increased flexibility for process optimization. Aim of the paper is to present and characterize the
adoption of the remote wobbling technique in HPFL welding of overlapped zinc coated steels for automotive
applications. Effect of the wobbling parameters on the quality attributes of the weld bead will be presented.
Furthermore a comparison with the traditional remote HPFL welding process will be given not only in terms of
quality attributes but also in terms of efficiency of the process, by comparing the energy per unit volume of molten
material required in the welding process.
JUNE 10-14, 2013 // Madison, Wisconsin
36

Abstracts, cont.
Curvature estimation for metrology of fixtureless non-rigid parts
MSEC2013-1122
Ali Aidibe, École de Technologie Supérieure, Montréal, QC, Canada, S. Antoine Tahan, École Technologie Supérieure,
Montreal, QC, Canada
At the end of the manufacturing process, engineers need to know if a manufactured part fits its computeraided
design (CAD) model and how is the amplitude of inherent variation of manufacturing process. Non-rigid
parts, at free state condition, may have a significant different form than their CAD model due to gravity loads;
residual stresses induced distortion and/or assembly load. Today, complicated and expensive specialized fixtures
are needed to conform these parts. To tackle the above challenges, we present in this paper a new approach
for metrology of fixtureless non-rigid parts. This approach combines the curvature properties of manufactured
parts with the extreme value statistic test as identification method to distinguish profile deviation due to the
manufacturing process from parts deformation due to the flexibility of the part and to determine whether the
tolerance fits the CAD model or no. This approach is tested on simulated typical industrial sheet metal giving
satisfying results in terms of percentage of errors in defect area and in peak profile deviation estimated.
37 MSEC 2013 NAMRC 41

Reconciling the differences between tolerance specification and measurement methods
MSEC2013-1206
Prabath Vemulapalli, Arizona State University, Tempe, United States, Jami Shah, Arizona State University, Tempe, AZ,
United States, Joseph Davidson, Arizona State University, Tempe, AZ, United States
The ASME Y14.5M standard has defined different types of tolerances that can be applied to a feature to achieve
the required functionality. Each tolerance defines a zone within which the feature under inspection must lie. The
conformance of the parts to these tolerances is checked by manual measurements or a CMM. But it has been
observed that the measurements between different CMMs do not match. There are two generally accepted
reasons for this discrepancy. The first one is the measurement uncertainty in CMM software. This problem was
addressed by NIST by developing reference softwares for feature fitting algorithms. And the second one is the
popular choice of using Least Squares algorithms for fitting substitute feature to the data points measured from
CMM. The Feature fitting algorithms used in CMM are often based on mathematical convenience rather than
the interpretation of the definitions in the GD&T standard. Our research is focused on identifying that normative
algorithm to be used for each type of tolerance. Each normative algorithm is identified as the one to best represent
the interpretation of geometric control as defined by the Standard and on the manual methods used for the
measurement of a specific tolerance type.
JUNE 10-14, 2013 // Madison, Wisconsin
38

Abstracts, cont.
Optimal motor location for the reduction of residual vibrations in mode-coupled ultra-precision manufacturing
machines
MSEC2013-1228
Chinedum Okwudire, Jihyun Lee, University of Michigan, Ann Arbor, MI, United States
Ultra-precision manufacturing (UPM) machines are used to fabricate and measure complex parts having
micrometer-level features and nanometer-level tolerances/surface finishes. Therefore, low-frequency residual
vibrations that occur during the motion of the machines axes must be minimized. Recent research by the authors
has revealed that coupling the vibration modes of passively-isolated machines by properly selecting the location
of the vibration isolators could lead to a drastic reduction in residual vibrations. However, the effect of motor
location on the residual vibrations of mode-coupled UPM machines has not been rigorously analyzed. In this paper,
an objective function which minimizes residual vibration energy with respect to motor location is defined and
analyzed. It is shown to have a guaranteed global minimum irrespective of the parameters of the UPM machine.
Conditions that ensure that the global minimum is located in a practically feasible design space are explored.
Finally, the merits of optimal motor placement on residual vibration reduction are demonstrated using simulations
conducted on a 5-axis ultra-precision machine tool.
39 MSEC 2013 NAMRC 41

Sustainability indicators for discrete manufacturing processes applied to grinding technology
NAMRC41-1531
Barbara Linke, University of California Davis, Davis, CA, United States, Gero J. Corman, University of California
Berkeley, Berkeley, CA, United States, Stefan Toenissen, RWTH Aachen University, Aachen, Germany, David Dornfeld,
University Of California Berkeley, Berkeley, CA, United States
As environmental and social awareness in production engineering rises, sustainability in discrete manufacturing
processes has to be controlled better and enhanced. Sustainability indicators offer a simple and affordable
solution for quickly assessing sustainability; however, they have been employed rarely on the process level. This
study selects simple and relevant sustainability indicators and discusses different means of normalization. The
sustainability indicators can be displayed as a performance profile, which is individual to each manufacturing
process variant. In addition, the indicators can be simplified to one sustainability indicator through a utility analysis
allowing for a quick comparison between different process variants. The whole procedure is executed with a
grinding process case study. This work provides a straightforward method for evaluating sustainability of discrete
manufacturing processes.
JUNE 10-14, 2013 // Madison, Wisconsin
40

Abstracts, cont.
Assisting sustainable manufacturing enterprise through system dynamics: A conceptual model
NAMRC41-1573
Hao Zhang, Javier Calvo-Amodio, Karl Haapala, Oregon State University, Corvallis, OR, United States
Industry is confronted with the challenge of balancing economic and financial priorities against environmental and
social responsibilities. Current methods are deficient in aiding proactive engineering management decision making
and elucidating broader sustainability opportunities within manufacturing enterprises, often resulting in ad hoc,
reactive decisions to circumvent fines, resource costs, or simply poor public perception. While these challenges
are long recognized, research has focused on increasing efficiencies toward reducing costs and environmental
burdens individually and simultaneously with cursory integration of social metrics. This work seeks to facilitate
decision making by incorporating systems thinking into sustainable manufacturing assessment and to develop
an understanding of the complex interplay of factors from the operational (micro) scale through the enterprise
(macro) scale. A combined approach using principles of sustainable manufacturing and systems thinking (in the
form of systems dynamics) is explored, which leads to development of a conceptual model being explored in
ongoing research.
41 MSEC 2013 NAMRC 41

Understanding life cycle social impacts in manufacturing: A processed-based approach
NAMRC41-1617
Margot Hutchins, Stefanie Robinson, University of California - Berkeley, Berkeley, United States, David Dornfeld,
University Of California Berkeley, Berkeley, CA, United States
Developing sustainable products and processes is growing in importance due to increasing regulation, consumer
interest, access to information, and competitive forces. In order to adequately evaluate the sustainability of
products and processes, there is a need to consider the impacts from all three pillars of sustainability - society,
environment, and economics. There are substantial challenges to identifying and understanding the social impacts
associated with manufacturing activities. This paper provides a framework for characterizing the social impacts
of manufacturing throughout the life cycle of a product or process. Social impacts occur on various scales in
manufacturing, from the level of a unit process to the level of the enterprise. Additionally, manufacturing activities
impact consumers, communities, and larger political/spatial realms. This paper identifies key characteristics of social
impacts associated with manufacturing that should be considered to more effectively address the social dimension
of sustainability for products and processes. Examples involving a typical manufacturing process - welding - are
presented to illustrate the utility of the framework.
JUNE 10-14, 2013 // Madison, Wisconsin
42

Abstracts, cont.
Finite element modeling on dislocation density and grain size evolution in machined surface
MSEC2013-1130
Liqiang Ding, Xueping Zhang, Shanghai Jiao Tong University, Shanghai, China, C. Richard Liu, Purdue University, W.
Lafayette, IN, United States
Machining process usually induces Severe Plastic Deformation (SPD) in chip and machined surface, which will
further lead to rapid increase of dislocation density and alteration of grain size in micro-scale. This paper presents
a novel FE model to simulate the dislocation density and grain size evolution in machined surface and subsurface
generated from the orthogonal cutting process of Al6061-T6. A dislocation density model of microstructure
evolution is implemented in the FE model as a user-defined subroutine written in FORTRAN. The model can predict
the microstructure characteristic in machined surface. The predicted chip thicknesses, cutting forces, distributions
of dislocation density and grain size are verified by the experimental tests chip, forces, microstructure and microhardness.
The predicted results show that the dislocation density decreases along the depths of machined
surface; whereas the grain size shows an opposite tendency. Dislocation density in machined surface decreases
and grain size increases when cutting speeds increase. The higher cutting speeds are associated with the thinner
deformation layers. Dislocation density in machined surface decreases initially and then increases with feed rates.
Dislocation density increases significantly when cutting tool has negative rake angles. The bigger negative rake
angles further lead to the thicker deformation layers in machined surface.
43 MSEC 2013 NAMRC 41

Simulation of surface roughness effects on residual stress in laser shock peening
MSEC2013-1232
Peter Hasser, Arif Malik, Saint Louis University, Saint Louis, MO, United States, Kristina Langer, US Air Force, Wright-
Patterson AFB, OH, United States, Thomas Spradlin, US Air Force, Wright-Patterson AFB, OH, United States
Laser peening (LP) has shown to be a viable method by which the fatigue life of metallic components can be
extended. Although current commercial implementation of LP techniques has not developed much beyond a
trial-and-error methodology to implement the process, researchers at several institutions have examined various
parameters that affect residual stress fields induced by LP, using Finite Element Analysis (FEA) and semi-empirical
eigenstrain methods. This research is a preliminary investigation of a potentially under-considered variable in laser
peeningmaterial surface roughness. The influence of surface roughness on laser peening has not previously been
studied through finite element modeling. The main point of interest for this work is to discover the amount that
surface roughness magnitude affects the residual stresses created by LP.
The FEA models, used in the exploration of surface roughness effects, had a simulated roughness produced by
displacing surface nodes a pre-determined distance orthogonal to the original, smooth model surface. The amount
that each node was moved was based on Kernel Density Estimation (KDE), a statistical method used to quantify
uncertainties in random variables according to non-standard probability distribution functions. The KDEs were
created from surface-roughness measurements taken from three separate 6061-T6 aluminum tubes. Two separate
roughness sample sets were tested at magnifications of 1x, 10x, and 20x times the measured average roughness
(Ra). Each roughness magnitude was simulated at peening pressures of 2, 2.5 and 3 times the Hugonoit Elastic
Limit (HEL) for Al6061-T6. The 10x and 20x magnitude roughness samples produced significant changes in residual
stress components relative to a smooth model, for all pressure loadings.
JUNE 10-14, 2013 // Madison, Wisconsin
44

Abstracts, cont.
Austenite-martensite phase transformation of biomedical NI50.8TI49.2 alloy by ball burnishing
MSEC2013-1241
C.H. Fu, The University of Alabama, Tuscaloosa, AL, United States, Yuebin Guo, Ph.D., Univ. of Alabama, Tuscaloosa,
AL, United States, X.T. Wei, Shandong University of Technology, Zibo, China
Nitinol alloys have received considerable attentions in biomedical and aerospace applications. They can exhibit
both austenite and martensite phases at room temperature. Austenite can transform to martensite by applied
stress or temperature. Ball burnishing is a very promising technique to modify surface integrity via plastic
deformation on the workpiece surface. Phase transformation of Nitinol by burnishing may occur at certain load,
which results in the mechanical property change on the workpiece. A burnishing experiment has been conducted
in this research at different burnishing loads. The burnishing tracks are characterized and microstructures in the
subsurface are studied. A corresponding simulation is also performed to shed light on phase transformation
mechanism of Nitinol in burnishing.
45 MSEC 2013 NAMRC 41

A novel hybrid process for drawing operation
MSEC2013-1253
Kyle Pender, North Carolina State University, Raleigh, NC, United States, Gracious Ngaile, North Carolina State
University, Raleigh, NC, United States
A novel hybrid process for drawing operations is proposed. This process combines the conventional drawing
and hydroforming features. The hybrid drawing die assembly is designed to incorporate multiple die segments
engraved with high pressure fluid channels. Preliminary results on drawn Al 6061 specimens under two fluid
pressure levels showed that the drawing load can decrease significantly. The hybrid drawing process has also
shown that varying the fluid pressure can alter the surface asperities at the tool-workpiece interface in real-time,
promoting micro pool lubrication. This was evidenced by distinct surface topographies observed via scanning
electron micrographs and optical micrographs.
JUNE 10-14, 2013 // Madison, Wisconsin
46

Abstracts, cont.
A study on friction and wear characteristics of sliding guideways finished by cbn milling and conventional grinding
NAMRC41-1507
Masakazu Soshi, University of California Davis, Davis, CA, United States, Eisaku Ueda, Mori Seiki Co., Ltd., Iga, Mie,
Japan, Masahiko Mori, Mori Seiki Co., Ltd., Nagoya, Aichi, Japan
Demands for machining difficult-to-cut materials, which require machine tools with high dynamic performance,
keep increasing in various industries. Thus, sliding guideways have received renewed interest in recent years as they
a have high damping effect in comparison to linear guides. While a grinding process has been widely implemented
to finish the guideway surfaces to obtain a very fine surface, an alternative machining based approach is desired to
improve manufacturing cost and time. A problem for the milling-based approach is believed to be its poor surface
finish in comparison to grinding, although no evidence is published. This paper studies the effect of the sliding
guideway machined surfaces on the performance of machine tools. Four different guides prepared by grinding
and milling were used during experimentation to compare wear, and static and dynamic friction coefficients
of the guideways. It was found that sliding guideways require an appropriate surface roughness for maximum
performance, which can be achieved by milling processes.
47 MSEC 2013 NAMRC 41

Methodology for shape optimization of ultrasonic amplifier using genetic algorithms and simplex method
NAMRC41-1511
Karl-Robert Deibel, ETH Zürich, Zurich, ZH, Switzerland, Konrad Wegener, IWF, ETH Zurich, Zurich, ZH, Switzerland
Designing devices for ultrasonic vibration applications is mostly done by intuitively adjusting the geometry to
obtain the desired mode of vibration at a specific operating frequency. Recent studies have shown that with
optimization methods, new devices with improved performance can be easily found. In this investigation, a new
methodology for designing an ultrasonic amplifier through shape optimization using Genetic Algorithms and
Simplex Method with specific fitness functions is presented. Displacements at specific functional areas, main
functionality, and mode frequency are considered to determine the properties of an individual shape to meet the
stated criteria. Length, diameter, position of mountings, and further specific geometric parameters are set up for
the algorithm search for an optimized shape. Beginning with genetic algorithms, the basic shape fitting the stated
requirements is found. After that the simplex method further improves the found shape to most appropriately
minimize the fitness function. At the end, the fittest individual is selected as the final solution. Finally, resulting
shapes are experimentally tested to show the effectiveness of the methodology.
JUNE 10-14, 2013 // Madison, Wisconsin
48

Abstracts, cont.
Force measurement characteristics of multi-axis dynamometers
NAMRC41-1622
Emrullah Korkmaz, Bekir Bediz, Carnegie Mellon University, Pittsburgh, PA, United States, Bulent A. Gozen, Carnegie
Mellon University, Pittsburgh, PA, United States, Burak Ozdoganlar, Carnegie Mellon University, Pittsburgh, United
States
This paper presents an experimental approach to determine three-dimensional force measurement characteristics
of multi-axis dynamometers, including those used for micromachining applications. An experimental
characterization method that uses a tailor-made impact excitation system and a custom-designed test artifact is
developed to extract force-to-force (i.e., applied force-to-measured force) frequency response functions (FRFs) of
the dynamometer in three dimensions within a broad frequency range. Subsequently, the characterization method
is applied to study the effect of the force application position, which can potentially alter the dynamic force
measurement characteristics. It was concluded that the presented method can be used to determine the threedimensional
force measurement characteristics of multi-axis dynamometers up to 25 kHz in a repeatable fashion.
Furthermore, it was seen that the dynamic force measurement characteristics depend on force application position
at certain frequency ranges.
49 MSEC 2013 NAMRC 41

Integrated electrohydrodynamic jet printing: A flexible deposition approach for micro/nano-manufacturing
NAMRC41-1536
Leo Tse, Kira Barton, University of Michigan, Ann Arbor, United States
High resolution electrohydrodynamic jet (e-jet) printing is a novel manufacturing technology that shows superior
resolution compared to traditional ink jet printing, while being cost competitive compared to many other high
resolution manufacturing techniques, such as micro-scale lithography. Despite clear advantages for micro-/nanomanufacturing
due to a combination of high resolution (< 10 microns) feature sizes and material diversity (organic
and inorganic materials, suspensions of solid objects, silver nanoparticles, DNA), the transition of e-jet printing to
mainstream manufacturing has been slowed by limitations such as process throughput and substrate flexibility.
This paper addresses a key limitation that stems from substrate constraints associated with conductivity and
flatness requirements. This paper presents a novel printhead designed to minimize these substrate effects on the
e-jet printing process. Challenges related to nozzle alignment and process control are discussed. The functionality
of the novel design will be demonstrated through the fabrication and implementation of a working prototype.
JUNE 10-14, 2013 // Madison, Wisconsin
50

Abstracts, cont.
Hybrid hierarchical fabrication of three-dimensional scaffolds
NAMRC41-1552
Chuang Wei, Jingyan Dong, North Carolina State University, Raleigh, NC, United States
Three-dimensional (3D) porous structures facilitating cells attachment, growth, and proliferation is critical to tissue
engineering application. Traditional Solid Freeform Fabrication (SFF) methods have limited capabilities in the
fabrication of high resolution micro-scale features for advanced biomedical functions. We present a hybrid scaffold
fabrication approach by integrating electrohydrodynamic (EHD) printing technology with extrusion deposition
together to fabricate 3D scaffolds with well controlled structures at in both macro scale and micro scale. In this
study, we developed a hybrid fabrication platform and a robust fabrication process to achieve 3D hierarchical
structures. The melting extrusion by pneumatic pressure was used to fabricate 3D scaffolds using thermoplastic
biopolymer polycaprolactone (PCL) with filaments dimension of hundreds of microns. An electrohydrodynamic
(EHD) hot jet plotting process was developed to fabricate micro-scale features on the scaffolds with sub-10µm
resolution, which has great potential in advanced biomedical applications, such as cell alignment and guidance.
51 MSEC 2013 NAMRC 41

Multi-nozzle array electrohydrodynamic jet (Ejet) printing
NAMRC41-1607
Miki Takagi, Placid Ferreira, University of Illinois at Urbana-Champaign, Urbana, United States
Electrohydrodynamic jet printing offers advantages such as high resolution over more traditional manufacturing
printing techniques, but lacks in the high throughput that is demanded by industry. Here we propose a multinozzle
array (MNA) print head which has the capability of addressing each nozzle individually or simultaneously
print with the whole array. For proof of concept, a four nozzle print head is discussed and has the potential to
be increased for batch pattern/image printing. By using a pulse width DC voltage printing setup, printed image
quality can be controlled depending on the desired application and is also studied. Achieved droplet size standard
deviation across the print head is approximately 0.5-0.6µm. A simple cost analysis was performed to determine
feasibility of a one-time use nozzle print head.
JUNE 10-14, 2013 // Madison, Wisconsin
52

Abstracts, cont.
A comprehensive model for laser hardening of carbon steels
MSEC2013-1094
Alessandro Fortunato, University of Bologna, Bologna, Italy, Leonardo Orazi, University of Modena and Reggio
Emilia, Reggio Emilia, Italy, Alessandro Ascari, University of Bologna, Bologna, Italy, Gabriele Cuccolini, University of
Modena and Reggio Emilia, Reggio Emilia, Italy, Erica Liverani, University of Bologna, Bologna, Italy
This article illustrates the development of a complete and exhaustive mathematical model for the simulation of the
transformations in laser hardening of hypo-eutectoid carbon steels. The authors propose an integrated approach
aimed at taking into consideration all the phenomena involved in this manufacturing process, with particular
attention to implementing easy mathematical models in order to optimize the trade-off between the accuracy of
the predicted results and the computational times. The proposed models involve the calculation of the 3D thermal
field occurring into the workpiece and predict the microstructural evolution of the target material exploiting an
original approach based on the definition of thermodynamic thresholds which can be considered as a physical
constant of the material itself. Several parameters and phenomena are taken into consideration in order to
accurately simulate the process: laser beam characteristics, fast austenization of the steel and tempering effect due
to mutually interacting beam trajectories.
53 MSEC 2013 NAMRC 41

Investigation and optimization of laser welding of Ti-6Al-4V titanium alloy plates
MSEC2013-1134
Fabrizia Caiazzo, University of Salerno, Fisciano, Italy, Vittorio Alfieri, Gaetano Corrado, Francesco Cardaropoli,
Vincenzo Sergi, University of Salerno, Department of Industrial Engineering, Fisciano, SA, Italy
Titanium alloys are employed for several applications, ranging from aerospace to medicine. In particular, Ti-6Al-
4V is the most common, thanks to an excellent combination of low density, high specific strength and corrosion
resistance.
Laser welding has been increasingly considered as an alternative to traditional techniques to join titanium alloys.
An increase in penetration depth and a reduction of possible welding defects is achieved indeed; moreover a
smaller grain size in the fused zone is benefited in comparison to either TIG and plasma arc welding, thus providing
an increase in the tensile strength of the welded structures.
The aim of this work is to develop the regression model for a number of responses which are crucial for the feature
of the joint. The study was carried out on 3 mm thick Ti-6Al-4V plates; a square butt welding configuration was
considered employing a disk-laser source. A 3-level factorial plan was hence arranged in a face-centered cubic
scheme. The responses were analyzed referring to the governing variables. Then, an optimization was carried out
via statistical tools, in order to find the optimal welding set-up for the alloy under examination.
JUNE 10-14, 2013 // Madison, Wisconsin
54

Abstracts, cont.
Laser beam forming: Experimental investigation and statistical analysis of the effects of parameters on bending
angle.
MSEC2013-1215
STEPHEN Akinlabi, Mukul Shukla, Tshilidzi Marwala, University of Johannesburg, Johannesburg, Gauteng, South
Africa
Laser Beam Forming (LBF), a non-contact manufacturing process has become a viable manufacturing process
for shaping of metallic components. The capability of LBF and bending demands more on experimental studies
to identify optimized parameter settings and also establish the probable influence of process parameters on
the response i.e. the resulting bending angles in the present work. The experiments on laser forming process of
3 mm steel plates were conducted using a 4.4 kW Nd: YAG laser (Rofin DY 044), at the Council for Science and
Industrial Research - National Laser Centre (CSIR-NLC), Pretoria, South Africa. This paper investigates the effects
of five important process parameters namely laser power, beam diameter, number of scan tracks, scan velocity
and the effect of cooling on the resulting formed sample curvature. Statistical tools combined with the Taguchi
robust Design of Experiment, based on the L-27 Taguchi Orthogonal array (TOA) have been used. The samples
were successfully formed to different curvatures following the experimental design. Both the Taguchi analysis
and Analysis of Variance (ANOVA) established that the number of scan irradiation had the maximum effect while
the cooling effect coolant flow had the least contribution on the bending angle of the formed components.
Regression analysis was also conducted on the experimental data and a linear model relating all the influencing
parameters was developed with an R-square value of around 98% showing the goodness of fit of the model. The
regression model confirms that the experimentally measured bending angles were in good agreement with the
model predicted values.
55 MSEC 2013 NAMRC 41

Experimental study on micro-scale milling process using electro-hydro-dynamic (EHD) spray lubrication with chilly
air
MSEC2013-1157
Pil-Ho Lee, Dae Hoon Kim, Sungkyunkwan University, Suwon, Korea (Republic), Sangwon Lee, Sungkyunkwan
University, Suwon, Korea (Republic)
This paper investigates the characteristics of a micro-scale end-milling process using the electro-hydro-dynamic
(EHD) spray lubrication with chilly air. A new hybrid cooling and lubrication system was developed by integrating
EHD spray and chilly air supply modules. In the experiments, the milling forces and burr formation are observed
according to varying cooling and lubrication conditions. It is demonstrated that the developed new hybrid cooling
and lubrication system can reduce milling forces and burrs significantly.
JUNE 10-14, 2013 // Madison, Wisconsin
56

Abstracts, cont.
Characterization of fluid film produced by an atomization-based cutting fluid (ACF) spray system during machining
MSEC2013-1187
Alexander C. Hoyne, Chandra Nath, S. G. Kapoor, University of Illinois at Urbana-Champaign, Urbana, IL, United
States
The atomization-based cutting fluid (ACF) spray system has recently been proposed as a cooling and lubrication
solution for machining hard to machine materials (e.g. titanium alloys). On the tool rake face, the ACF spray system
forms a thin film from cutting fluid that penetrates into the toolchip interface to improve tool life. The objective of
this work is to characterize this thin fluid film in terms of thickness and velocity for sets of ACF spray parameters.
ACF spray experiments are performed by varying impingement angle in order to observe the nature of the
spreading film, and to determine the film thickness at different locations after impingement of the droplets. It is
observed that the film spreads radially outward producing three fluid film development zones (i.e. impingement,
steady, unsteady). The steady zone is found to be between 3 and 7 mm from the focus (impingement point) of the
ACF spray for the set of parameters investigated. An analytical 3D thin fluid film model for the ACF spray system has
also been developed based on the equations for continuity of mass and momentum. The model requires a unique
treatment of the crossfilm velocity profile, droplet impingement and pressure distributions, as well as a strong
gasliquid shear interaction. The thickness profiles predicted by the analytical film model have been validated.
Moreover, the model predictions of film velocity and chip flow characteristics during a titanium turning experiment
reveal that the fluid film can easily penetrate into the entire toolchip interface with the use of the ACF spray system.
57 MSEC 2013 NAMRC 41

Enhancing adaptive production using IEC 61499 event-driven function blocks
NAMRC41-1561
Magnus Holm, Göran Adamson, University of Skövde, Skövde, Sweden, Lihui Wang, KTH Royal Institute of
Technology, Stockholm, Sweden
Reduction of production costs and the ability to continuously improve is a must for every manufacturer. High
availability in a dynamic and complex production environment demands adaptability to recurring changes. Each
device within the production systems holds more and more intelligence and computing power which supports
an approach implementing the standard of IEC 61499 to enhance adaptive production by enabling a distributed
automation system with improved productivity. Research approaching IEC 61499 is investigated and reported in
this paper, covering both control of manufacturing equipment and adaptive process planning. The objective is
to develop methodologies for process planning as well as machine control and monitoring for machining and
assembly operations in a dynamic, adaptive and distributed environment using event-driven function blocks.
JUNE 10-14, 2013 // Madison, Wisconsin
58

Abstracts, cont.
An integrated CNC accumulation system for automatic building-around-inserts
NAMRC41-1574
Xuejin Zhao, Yayue Pan, Chi Zhou, Yong Chen, University of Southern California, Los Angeles, CA, United States,
Charlie Wang, Chinese University of Hong Kong, Hong Kong, China
In this paper a non-layer-based additive manufacturing (AM) process named computer numerically controlled
(CNC) accumulation process is presented for applications such as plastic part repairing and modification. To
facilitate the CNC accumulation process, a novel three-dimensional (3D) laser scanning system based on a
micro-electo-mechanical system (MEMS) device is developed for in situ scanning of inserted components. The
integration of the scanning system in the CNC accumulation process enables the building-around-inserts with little
human efforts. A point processing method based on the Algebraic Point Set Surface (APSS) fitting and Layered
Depth-normal Image (LDNI) representation is developed for converting the scanning points into triangular meshes.
The newly developed 3D scanning system is compact and has sufficient accuracy for the CNC accumulation
process. Based on the constructed surface model, data processing operations including multi-axis tool path
planning and motion control are also investigated. Multiple test cases are performed to illustrate the capability of
the integrated CNC accumulation process on addressing the requirements of building-around-inserts.
59 MSEC 2013 NAMRC 41

Feature selection for manufacturing process monitoring using cross-validation
NAMRC41-1584
Chenhui Shao, University of Michigan, Ann Arbor, Ann Arbor, MI, United States, Kamran Paynabar, Georgia Institute
of Technology, Atlanta, GA, United States, T. H. Kim, Jionghua Jin, University of Michigan, Ann Arbor, Ann Arbor,
MI, United States, Jack Hu, University Of Michigan, Ann Arbor, MI, United States, J. P. Spicer, Hui Wang, J. A. Abell,
General Motors, Warren, MI, United States
A novel algorithm is developed for feature selection and parameter tuning in quality monitoring of manufacturing
processes using cross-validation. Due to the recent development in sensing technology, many on-line signals are
collected for manufacturing process monitoring and feature extraction is then performed to extract critical features
related to product/process quality. However, lack of precise process knowledge may result in many irrelevant or
redundant features. Therefore, a systematic procedure is needed to select a parsimonious set of features which
provide sufficient information for process monitoring. In this study, a new method for selecting features and tuning
SPC limits is proposed by applying k-fold cross-validation to simultaneously select important features and set the
monitoring limits using Type I and Type II errors obtained from cross-validation. The monitoring performance for
production data collected from ultrasonic metal welding of batteries demonstrates that the proposed algorithm
is able to select the most efficient features and control limits and thus leading to satisfactory monitoring
performance.
JUNE 10-14, 2013 // Madison, Wisconsin
60

Abstracts, cont.
An empirical model for the coefficient of friction in injection molding of thermoplastics
MSEC2013-1018
Omar Bataineh, Jordan University of Science and Technology, Irbid, Jordan
Mold design in injection molding of thermoplastics, especially the ejector system, depends largely on the intensity
and distribution of friction forces between the molded part and mold surfaces. The calculation of these forces, in
one part, requires predicting the coefficient of friction at these surfaces, which is usually a complex task. In this
study, an empirical model is developed in an attempt to estimate the coefficient of friction as applicable for the
injection molding of thermoplastics. It is assumed in this model that the coefficient of friction is a sum of two
correlated effects: adhesion effect and surface roughness effect. Both effects are treated as functions of mold
surfaces average asperity slope. A statistical model is developed for the surface roughness effect. To model the
adhesion effect, ring moldings of same size and different thermoplastic materials were injection molded, then
ejected. Measurement of the maximum ejection force made it possible to estimate the coefficient of friction,
which is then fitted through regression methods. Generated regression functions were then utilized to model the
adhesion effect.
61 MSEC 2013 NAMRC 41

Evaluation of fiber orientation prediction of moldflow using an injection molded IP panel
MSEC2013-1255
Xianjun Sun, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu, China, Yuan Gan, John Lasecki,
Danielle Zeng, Qi Li, Lu Li, Jeff Webb, Ford Motor Company, Dearborn, MI, United States, Jie Tao, Nanjing University
of Aeronautics and Astronautics, Nanjing, Jiangsu, China
The fiber orientation distribution is one of the important microstructural variables for thermoplastic composites
reinforced with discontinuous fibers. In this article, Moldflow is used to predict the fiber orientation distribution
in an automotive component. Image analysis by MATLAB is adopted to validate the simulated results after taking
pictures of fibers by X-ray CT. It is shown that the Moldflow predicts the average distribution in direction of the
thickness accurately, with predicted eigenvalue of the orientation tensor within 5% of that measured. However, it
failed to capture the change of principal eigenvalue in thickness direction.
JUNE 10-14, 2013 // Madison, Wisconsin
62

Abstracts, cont.
Die wear and galling in stamping DP980 steel
MSEC2013-1142
Hua-Chu Shih, United States Steel Corporation, Rochester Hills, MI, United States, Changqing Du, Dajun Zhou,
Chrysler Group, Auburn Hills, MI, United States
Stamping of dual phase (DP) 980 steel creates higher deformation heat, contact pressure and friction force
between the tooling and sheet steel. These, in turn, cause higher die wear and galling. Although various
countermeasures have been adopted in production to prevent excessive wear associated with forming DP980
steel, the stamping die tryout process has not been revised accordingly to ensure that the die surfaces in contact
with sheet metal have been hardened and coated. The effects of die hardness and lubrication conditions on
die wear and galling in stamping DP980 steel during the die tryout process were evaluated at different contact
pressures using the bending under tension (BUT) tester. A reciprocal cyclic bend test system (CBTS) of modifying
bending under tension test was used to investigate wear and galling between a die in the tryout phase and in
a production condition. The results indicate that the hardness of the die material dominates the galling and
wear behavior in the die tryout phase. A better surface treated die material and an anti-galling strategy was also
identified to decrease galling and wear in both die tryout and production.
63 MSEC 2013 NAMRC 41

Experimental study of biaxial load-unload behavior of DP590 steel sheets
MSEC2013-1171
Yannis Korkolis, Nengxiu Deng, University of New Hampshire, Durham, NH, United States, Toshihiko Kuwabara,
Tokyo University of Agriculture and Technology, Tokyo, Japan
Biaxial load-unload tests under radial paths in the true stress space were carried out for DP590 steel sheets using
specially-designed cruciform specimens. Depending on the specific path, over 15% equivalent logarithmic plastic
strain was achieved so that the load-unload behavior was successfully probed at relatively high strain levels. It was
found that the stress-strain response at the initial load/unload follows the predicted linearly elastic response very
well and that subsequently the slope decays. Following that, a second linear response is observed, which ultimately
leads to the non-linear plastic response. The biaxial non-linear strain recovery components _x^nl and _y^nl were
measured to be on average approx. 11% of the elastic strains _x^e and _y^e, respectively. At higher strains, this
ratio is approx. 25%, indicating the inaccuracy of springback simulations when a linearly elastic unloading response
is assumed. For each load-unload cycle, the dissipated energy density tends to increase with the progression of
prestrain. The plastic work contours covering the first quadrant of the stress space were successfully constructed
and the directions of the plastic strain rates were then calculated. A good agreement with the experimental facts
was found by adopting the anisotropic yield function Yld2000-2D.
JUNE 10-14, 2013 // Madison, Wisconsin
64

Abstracts, cont.
Analytical design and implementation of a uniform pressure actuator for electromagnetic forming and welding
MSEC2013-1238
Ethan Thibaudeau, Brad Kinsey, University of New Hampshire, Durham, NH, United States
Lightweight sheet metal components and assemblies formed and welded electromagnetically can be
implemented in various industries such as automotive, aerospace, and electronics. Past applications and modeling
of Electromagnetic Forming (EMF) and Magnetic Pulse Welding (MPW) have typically focused on crimping and
expansion of tubular workpieces. While some Finite Element Analysis (FEA) packages exist that are capable of
modeling these processes, there is a lack of simplified analytical modeling efforts, especially for sheet metal
workpieces. Analytical modeling is attractive for its simplicity and cost in effectively determining e.g., an optimal
coil design. In this paper a coil design and analysis procedure developed at The Ohio State University is modified
and extended through an analytical model and FEA. The coil, named a Uniform Pressure Actuator (UPA), offers
increased forming efficiency and repeatability, as well as a robust design. Coil design parameters such as the
number of turns and conductor cross section are determined for a given workpiece. Magnetic pressure applied to
the workpiece and workpiece velocity are predicted to ensure impact velocities are sufficient for MPW. A coil was
constructed based on the analyses, and experimental results are compared to the analytical predictions for both
electrical characteristics and workpiece velocity.
65 MSEC 2013 NAMRC 41

Machining depth regulation and friction reduction in AFM-based ultrasonic vibration assisted nanomachining
NAMRC41-1532
Li Zhang, Jingyan Dong, Paul Cohen, North Carolina State University, Raleigh, NC, United States
This paper studies the capability of ultrasonic vibration in regulating feature depth and reducing machining force in
ultrasonic vibration assisted nanomachining using an AFM. Ultrasonic tip-sample vibration is introduced to regulate
machining depth, while an in-plane circular vibration is used to control the feature width. Features with different
depth and width are fabricated on PMMA and aluminum. With a small set-point force (as small as 200 nN) and
the same vibration amplitude for machining PMMA and aluminum, nearly the same trench depth is achieved. It is
demonstrated that the fabricated feature depth is mainly controlled by the amplitude of the tip-sample z-vibration,
and is insensitive to sample materials. From the acquired frictional force data, ultrasonic vibration significantly
reduces friction during machining comparing to pure nanomachining without ultrasonic assistance. The proposed
ultrasonic force regulated nanomachining provides a high-speed and tunable approach for fabricating nano
structures with high controllability and less frictional force.
JUNE 10-14, 2013 // Madison, Wisconsin
66

Abstracts, cont.
Process parameters effect on cutting forces and geometrical quality in thin wall micromilling
NAMRC41-1549
Massimiliano Annoni, Stefano Petrò, Lara Rebaioli, Quirico Semeraro, Riccardo Solito, Politecnico di Milano, Milano,
Italy
Micromilling is one of the most versatile tooling processes, three-dimensional features can be effectively
manufactured on molds and dies achieving a good accuracy performance. Typical and challenging features for
these microcomponents are high aspect ratio thin walls. The present study evaluates the effect of wall thickness,
milling strategy and tool path on cutting forces in C40 thin walls micromilling. An experimental campaign
was designed in order to statistically analyse the cutting force responses and a proper technique (ANalysis
of COVAriance) was applied to remove the tool wear effect. Considerations drawn in the present paper on
micromilling cutting forces were coupled with previous knowledge to start considering the feasibility of a more
general approach based on a force-quality direct link. Final target of the presented research is to improve the
current thin walls micromilling accuracy by suggesting the correct parameters combination for producing the
desired cutting forces.
67 MSEC 2013 NAMRC 41

Feed rate optimization issues in micro-milling
NAMRC41-1586
Abdolreza Bayesteh, University of Victoria, Victoria, BC, Canada, Martin Jun, University Of Victoria, Department Of
Mechanical Engineering, Victoria, BC, Canada
Miniaturization of products in a wide range of sectors including biomedical, electronic, and aerospace applications
have dramatically increased the need to fabricate complex features as small as a few microns to achieve a high
accuracy in a diverse set of materials like stainless steel, titanium, brass, aluminum, platinum, ceramics, polymers,
etc. The micro end milling process can efficiently produce these features, but due to the limited stiffness of the
micro end mill and the specific nature of the cutting mechanism at the microscale, selection of the optimum
feed rate for micro milling operations is quite difficult and requires much experience. This paper presents a simple
optimization method to determine the optimum feed rate for micro-milling process using solid model based
calculation of chip volume for a given tool path. Issues with feed rate optimization due to segment lengths of the
tool path in micro-milling are also discussed.
JUNE 10-14, 2013 // Madison, Wisconsin
68

Abstracts, cont.
Vibration tissue cutting for blunt hollow needles
NAMRC41-1566
Andrew Barnett, Arif M. Abdullah, Adam Gordon, Pennsylvania State University, University Park, PA, United States,
Yuan-Shin Lee, North Carolina State University, Raleigh, NC, United States, Jason Z. Moore, Pennsylvania State
University, University Park, PA, United States
This research investigates vibrational tissue cutting for blunt hollow needles. Accidental needlestick injuries
account for millions of dollars of health care costs each year. Blunting the tip of a needle, imposing a rake and
inclination angle of 0° at the tip, can significantly reduce the likelihood of accidental needlestick injuries. However,
a blunt needle tip is not functional at cutting during regular insertion, but with the application of vibration, a blunt
needle can become an effective cutting tool. The geometry of a blunt hollow needle is mathematically defined and
tissue cutting experiments are conducted by vibrating blunt needles at varying frequencies through porcine skin.
Experiments showed that vibrational cutting can decrease the insertion force while an increase in blunt tip area
increases the force.
69 MSEC 2013 NAMRC 41

Investigation of friction in needle to soft tissue interaction
NAMRC41-1568
Arif M. Abdullah, Andrew Barnett, Pennsylvania State University, University Park, PA, United States, Douglas E.
Wolfe, Penn State University, University Park, PA, United States, Jason Z. Moore, The Pennsylvania State University,
University Park, PA, United States
Similar to metal cutting, frictional forces occur during medical tissue cutting procedures. In needle insertion high
friction causes tissue deflection which hinders the needle positioning accuracy inside the tissue. Poor needle
positioning accuracy can be detrimental to the efficacy of the medical procedure. This work investigates how
needle surface roughness, the application of TiN coating, and insertion speed affect the frictional force between
a needle and tissue. Experiments with four 11 gauge needles of varying surface roughness and one TiN coated
needle were carried out to investigate only the frictional forces at the needle tissue interface. It was found that
increasing speed increases frictional force, texturing a needle can lower the frictional force, and applying a TiN
coating reduced the needles friction by 38%.
JUNE 10-14, 2013 // Madison, Wisconsin
70

Abstracts, cont.
A haptic position measurement system for compliant objects and an application in guidewire stitching of soft
tissue
NAMRC41-1569
Yancheng Wang, Roland K. Chen, Bruce L. Tai, University of Michigan, Ann Arbor, United States, Albert Shih,
University of Michigan, Ann Arbor, MI, United States
A haptic position measurement system (HPMS), which utilizes the haptic feedback of a hand-held magnetic sensor
to touch and measure the position and shape of soft material and compliant objects, is developed and applied to
measure the NiTi pre-curved guidewire suturing of stomach. A miniature (0.90 mm diameter) magnetic sensor is
the touch probe to contact and measure the 0.69 mm thin pre-curved guidewire during insertion to the soft tissue,
which is an endoscope-based obesity treatment procedure. The system, which has an accuracy of about 0.3 mm,
was applied to measure the geometry of four types of pre-curved guidewire in the ex-vivo stomach wall suturing.
Experimental results show that the pre-curved guidewire with a small bevel angle and a small radius of curvature
has less change in shape and better suturing accuracy. The HPMS is capable of tracking the guidewire during
suturing and measuring the shape for computer-aided surgical path planning.
71 MSEC 2013 NAMRC 41

Micro-laser assisted feasibility test on soda-lime-glass
SEC2013-1200
Deepak Ravindra, Micro-lLaser Assisted Machining Technologies, LLC, Battle Creek, MI, United States, Surya
Chaitanya Ponthapalli, John Patten, Western Michigan University, Kalamazoo, MI, United States
Soda lime glass is the most prevalent type of glass, used for glass containers and windowpanes. It is difficult to
machine in traditional manufacturing processes due to its extreme hardness and brittleness. Good optical quality
surfaces can be achieved by removing the material in a ductile manner. The strength, hardness and fracture
toughness of the workpiece material are the governing factors that control the extent of brittleness. The main
goal of the subject research is to determine the effect of laser heating (using the µ-LAM process) on the material
removal of soda lime glass using a single point diamond tool. The results show that the micro-laser assisted scratch
tests were successful in demonstrating the enhanced laser heating and thermal softening in glass resulting in
greater depths of cuts when compared to similar applied loads for cuts with no laser.
JUNE 10-14, 2013 // Madison, Wisconsin
72

Abstracts, cont.
Picosecond and nanosecond pulsed laser ablation of aluminium foil
MSEC2013-1189
Michele Sozzi, University of Parma, Parma, Parma, Italy, Adrian Lutey, Università di Bologna, Bologna, Italy, Italy,
Simone Carmignato, University of Padua, Vicenza, Italy, Katia Tragni, Stefano Selleri, Annamaria Cucinotta, University
of Parma, Parma, Parma, Italy, Pier Gabriele Molari, Università di Bologna, Bologna, Bologna, Italy
The pulsed laser ablation of 20 micron thick aluminum foil is investigated by exposing moving samples to
picosecond pulses of wavelength 1064nm and nanosecond pulses of wavelength 515nm and 1030nm. Ablation
thresholds and depths are determined for a range of conditions using an optical microscope and 3D optical
profiler. Complete three-dimensional crater profiles for single and multiple pulses are presented. The results reveal
a variation in ablation threshold with wavelength, pulse duration and the number of pulses; a large reduction is
observed for picosecond pulses. Ablation rates per pulse are expressed by general equations and found to vary
strongly with both laser type and the number of pulses. The green nanosecond laser is found to ablate most
efficiently for fluences above 10J/cm2, whilst the picosecond source is instead advantageous for low fluences. A
large reduction in ablation depth per pulse is observed with an increasing number of pulses. The present work
affords prediction of scribe and cut parameters for the processing of thin aluminum layers and, more generally,
characterizes the driving parameters of pulsed picosecond and nanosecond laser ablation of metals.
73 MSEC 2013 NAMRC 41

Application of laser in joining aluminum foam hybrid materials
MSEC2013-1057
Alessandro Ascari, Giampaolo Campana, University of Bologna, Bologna, Italy
This article illustrates an experimental campaign aimed at assessing preliminary guidelines for the application
of the laser in joining cellular-structured hybrid materials. In particular the target specimens exploited were all
characterized by the presence of an aluminum foam core and by an external skin, made in aluminum or in stainless
steel. The goal of the present paper is to underline a global feasibility of laser joining of these materials pointing
out the role of the main process parameters and to suggest some original techniques which could be adopted
in order to improve the overall quality of the joint. The experience described pointed out that, when dealing with
this kind of materials, the role of the laser can be dual: in case of high energy density applications it can be used
for local fusion of the workpiece, as in traditional welding, while in low energy density ones the radiation can be
exploited as a controlled heating source for promoting local thermal actions particularly on the cellular portion of
the material.
JUNE 10-14, 2013 // Madison, Wisconsin
74

Abstracts, cont.
The state of the art of cloud manufacturing and future trends
MSEC2013-1123
Göran Adamson, University of Skövde, Skövde, Sweden, Lihui Wang, Royal Institute of Technology, Stockholm,
Sweden, Magnus Holm, University of Skövde, Skövde, Sweden
Cloud manufacturing has emerged as a new manufacturing paradigm, which combines technologies (such
as Internet of Things, Cloud computing, semantic Web, virtualization and service-oriented technologies) with
advanced manufacturing models, information and communication technologies. It aims to be networked,
intelligent, service-oriented, knowledge-based and energy efficient, and promises a variety of benefits and
advantages by providing fast, reliable and secure on-demand services for users. It is envisioned that companies
in all sectors of manufacturing will be able to package their resources and know-hows in the Cloud, making
them conveniently available for others through pay-as-you-go, which is also timely and economically attractive.
Resources, e.g. manufacturing software tools, applications, knowledge and fabrication capabilities, will then
be made accessible to presumptive consumers on a worldwide basis. After surveying a vast array of available
publications, this paper presents an up-to-date literature review together with future trends and research directions
in Cloud manufacturing.
75 MSEC 2013 NAMRC 41

Development and implementation of cloud manufacturing: An evolutionary perspective
MSEC2013-1172
Yong-Kui Liu, Lin Zhang, Fei Tao, Beihang University, Beijing, China, Long Wang, Peking University, Beijing, China
Cloud manufacturing (CMfg) is a new service-oriented networked manufacturing paradigm. In a CMfg system, the
operator of CMfg platform provides services for resource providers to publish their idle manufacturing resources
and for resource demanders to access the resource pool on-demand. To uncover the underlying mechanism
supporting the development and implementation of CMfg, a model of CMfg system is proposed by abstracting
the CMfg operator as a third party and modeling the relationships of CMfg users using the scale-free network. We
investigate the effect of saturation degree of manufacturing task and find that there exists an intermediate value
of the parameter optimally favoring the participation of enterprises in CMfg. We also study the charging issue. The
obtained result shows that the CMfg system is robust with respect to resource charge. Finally, we discuss the future
work and conclude the paper.
JUNE 10-14, 2013 // Madison, Wisconsin
76

Abstracts, cont.
Cloud manufacturing platform: Operating paradigm, functional requirements, and architecture design
MSEC2013-1185
Lei Ren, Lin Zhang, Beihang University, Beijing, Beijing, China, Xudong Chai, Beijing Simulation Center, Beijing,
China, Chun Zhao, Beihang University, Beijing, Select State/Province, China
Cloud manufacturing is emerging as a new promising business paradigm as well as an integrated technical
approach, contributing to the shaping of a highly-collaborative, knowledge-intensive, service-oriented and ecoefficient
manufacturing industry. The following research issues concerning cloud manufacturing platform, what
users can achieve with the platform, what the platform can do, and how to design it, play crucial roles in this new
area. This paper proposes a cloud manufacturing paradigm that depicts a typical scenario which can provide
an explanation for the concept of cloud manufacturing and makes the mysterious “cloud” transparent. Then the
functional requirements of cloud manufacturing platform are investigated to specify design objectives. Based
on these, the paper presents the design of MfgCloud, a cloud manufacturing platform prototype. In discussion
of the main components of MfgCloud, the specific concepts different from those corresponding terms in IT area
are also defined and given their implementation mechanisms. Consequently, this paper proposes a new point of
view for the concept of cloud manufacturing, and accordingly presents a reference design of cloud manufacturing
platform.
77 MSEC 2013 NAMRC 41

Characterizing energy consumption of the injection molding process
MSEC2013-1222
Jatinder Madan, National Institute of Standards & Technology, Gaithersburg, United States, Mahesh Mani, Kevin W.
Lyons, National Institute of Standards and Technology, Gaitherburg, MD, United States
Presently available systems for sustainability assessment do not fully account for aspects related to a products
manufacturing. In an effort to make more sustainable decisions, today’s industry seeks reliable methods to assess
and compare sustainability for manufacturing. As part of the Sustainable Manufacturing program at the National
Institute of Standards and Technology (NIST), one of our objectives is to help develop the needed measurement
science, standards and methodologies to evaluate and improve sustainability of manufacturing processes. As a first
step towards developing standard reference sustainability characterization methodologies for unit manufacturing
processes, in this paper we focus on injection molding with energy as the sustainability indicator. We present a
science-based guideline to characterize energy consumption for a part manufactured using the injection molding
process. Based on the study, we discuss the selection of process parameters and manufacturing resources,
determination of cycle time, theoretical minimum energy computations, and estimated energy computations for
characterizing the injection molding process.
JUNE 10-14, 2013 // Madison, Wisconsin
78

Abstracts, cont.
A parametric study on micro-drilling process with nanofluid minimum quantity lubrication using nanodiamond
particles
MSEC2013-1223
Jung Soo Nam, Dae Hoon Kim, Sungkyunkwan University, Suwon, Korea (Republic), Sangwon Lee, Sungkyunkwan
University, Suwon, Korea (Republic)
This paper presents a parametric analysis on micro-drilling process using nanofluid minimum quantity lubrication
(MQL). In this paper, the effects of several machining parameters such as a feed rate, rotational speed and drill
diameter on micro drilling performances are investigated under various lubrication conditions compressed air
lubrication, pure MQL and nanofluid MQL. For nanofluid MQL, nanodiamond particles are used with the volumetric
concentration of 4 %. A series of micro-drilling experiments are carried out in the miniaturized machine tool
system. The experimental results show the nanofluid MQL can be effective for reducing average drilling torques
and thrust forces, in particular, at relatively low feed rate (10 mm/min) and low spindle speed (30,000 RPM) in the
case using the drill with small diameter (0.1 mm). Meanwhile, in the case using the drill with large diameter (0.5
mm), the nanofluid MQL may not be effective for reducing average torques and thrust forces.
79 MSEC 2013 NAMRC 41

Effect of inter-particle interaction on particle deposition in a cross-flow microfilter
MSEC2013-1211
Talukder Z Jubery, S. G. Kapoor, University Of Illinois At Urbana-Champaign, Urbana, IL, United States, John E Wentz,
University of St. Thomas, St. Paul, MN, United States
Recent studies show that inter-particle interaction can affect particle trajectories and particle deposition causing
fouling in the microfilters used for metal working fluids (MWFs). Inter-particle interaction depends on various
factors: particle geometry and surface properties, membrane pore geometry and surface properties, MWFs
properties and system operating conditions, etc. A mathematical model with a Langevin equation for particle
trajectory and a hard sphere model for particle deposition has been used to study the effect of particles size,
particles surface zeta potential, inter-particle distance, and shape of membrane pore wall surface on particle
trajectory and its deposition on membrane pore wall. The study reveals that bigger particles have a lesser tendency
to be deposited on membrane pore walls than smaller particles. The shape of the membrane pore wall surface can
also affect the particle deposition behavior.
JUNE 10-14, 2013 // Madison, Wisconsin
80

Abstracts, cont.
Modeling of the influence of sample preparation sequences when measuring selectively induced residual stress
depth profiles
NAMRC41-1508
Horst Bruennet, Dirk Baehre, Saarland University, Institute of Production Engineering, Saarbruecken, Germany
The selective introduction of compressive residual stresses is gaining increasing importance as design tool in
today’s manufacturing process chains. Manufacturing processes such as shot peening or hydraulic Autofrettage
are used to improve the surface integrity, and hence the fatigue life of the components. However, measuring
the corresponding residual stress depth profiles is a challenging task as the results will always include the
manufacturing and preparation history of the components. In this paper, results of residual stress measurements
with x-ray diffraction and optical hole-drilling after Autofrettage and sample preparation are presented and
compared to a finite element analysis for two representative geometries. The presented approach can be used to
predict the influence of the mandatory sample preparation procedure. As a consequence, the effectiveness of the
manufacturing process to improve the surface integritycan be predicted more precisely and wrong interpretations
of the measured residual stress depth profiles can be avoided.
81 MSEC 2013 NAMRC 41

Performance evaluation of multi-scale data fusion methods for surface metrology domain
NAMRC41-1542
Suresh Kumar Ramasamy, Hutchinson Technology Inc., Carver, MN, United States, Jayaraman Raja, University Of
North Carolina, Charlotte, NC, United States
With the rapid evolution of new engineered surfaces for Micro Electro Mechanical Systems (MEMS), micro-fluidics
etc, there is a strong need for developing tools to measure and characterize these surfaces at different scales.
Multi-scale data fusion is a cost effective way of characterizing multi-scale structured surfaces. Generally, standard
images like Lena or Lenna are used to conduct the performance study. But typical engineered surface datasets are
obtained with infinite focus. Hence there is a need to evaluate the performance of the fusion metrics and methods
for the surface metrology domain. This paper discusses the performance evaluation results of three data fusion
methods on measurements obtained on structured surfaces.
In order to evaluate the performance of multi-scale data fusion methods, twelve sets of data - four sets each of
directional structured surface, non-directional structured surface and systematic non-engineered surface, were
used. Coarse registration was performed using Normalized Cross Correlation (NCC), and Watershed edge detection
on single scale was used to obtain control points. For fine registration, Iterative Closest Point (ICP) finite difference
method was used. A six-level Discrete Wavelet Frame (DWF) transformation was used to generate six sub-datasets
which were then fused using kernel based weighted averaging techniques - Regional Energy (RE), Regional Edge
Intensity (REI) and Wavelet Gradient Combination (WGC).
Mutual Information (MI), Universal Quality Index (UQI), Structural Similarity Index (SSIM), and Multi-Scale Structural
Similarity Index (MS-SSIM) were chosen as preferred data fusion metrics, based on a separate performance study
for selection of suitable data fusion metrics. The low magnification data (Rl) and high magnification data (Rh) were
compared with fused data (F). Based on this study, it was demonstrated that:
-Comparison of the values between > and > demonstrated that the fused data (F) has better
similarity to the high magnification data (Rh) than to the low magnification data (Rl).
-Regional Edge Intensity (REI) fusion method performed better.
JUNE 10-14, 2013 // Madison, Wisconsin
82

Abstracts, cont.
Study of factors impacting remote fault diagnosis performance on a PLC based automated system
NAMRC41-1600
Zhenhua Wu, Virginia State University, Petersburg, United States, Remanath Sekar, Sheng-jen Hsieh, Texas A&M
University, College Station, TX, United States
In this paper, we present systematically experimental and analytical evaluations on design of remote fault
diagnosis systems for a PLC based automated system. In order to investigate the factors of remote architecture,
operators skill level, and fault natures effect on diagnosis performance, comprehensive experiment evaluation
and statistical analysis were conducted. The experiment compared three levels of remote architecture, two levels
of operators diagnosis performance on four typical faults in automated system. After 24 runs of experiment,
performance evaluation including detection time, amount of information search, number of diagnostic tests
tried, and performance score, were extracted from the experiment record. Two-stage statistical analysis including
1) analysis of variance (ANOVA) and 2) least significant difference (LSD) paired comparison was conducted on
the performance evaluation data. From the statistical analysis results, we concluded that: 1) the architecture
eased the diagnosis on the faults that are related to the measurement signals, and 2) the diagnosis performance
also increased with the sophistication of the architecture, but 3) operators skill level did not significantly affect
the diagnosis performance. The proposed evaluation approach is systematic; it can be applied on design and
evaluation of diagnostics systems on other automated systems.
83 MSEC 2013 NAMRC 41

Dual-scale cascaded adaptive stochastic resonance for rotary machine health monitoring
NAMRC41-1606
Rui Zhao, University of Connecticut, Storrs, CT, United States, Ruqiang Yan, Southeast University, Nanjing, China,
Rober X. Gao, University of Connecticut, Storrs, United States
A major challenge in fault diagnosis for rotary machines is the effective extraction of features from weak signals
that are indicative of faulty components, submerged in strong noise. Unlike traditional techniques that focused on
noise filtering and reduction, stochastic resonance (SR) takes a noise-assisted approach to detecting and analyzing
weak signals. This paper presents a new method for weak signal detection, termed Dual-scale Cascaded Adaptive
Stochastic Resonance (DuSCASR), in which the new adaptive strategy can quantify the frequency content of a weak
signal without prior knowledge. Simulations and experiments have confirmed the effectiveness of the method in
early stage bearing fault diagnosis under strong noise, with high precision and robustness.
JUNE 10-14, 2013 // Madison, Wisconsin
84

Abstracts, cont.
Statistical monitoring for broaching processes using energy features extracted from cutting force signatures
NAMRC41-1611
John Robertson, Arvinth Rathinam, Lee J. Wells, Jaime Camelio, Virginia Tech, Blacksburg, VA, United States
The implementation of statistical process control (SPC) strategies over the past several decades has been
fundamental in improving product quality in manufacturing. This is especially true for machining processes, where
maintaining tight tolerances is critical to overall product quality and end-user performance. However, more often
than not SPC strategies for machining processes focus on monitoring product data rather than process data, which
tends to hinder the ability of the system to detect process shifts. This is due to the fact that a shift in a machining
process may not immediately affect the quality of the part being machined. Therefore, in order to increase the
pool of machining process monitoring tools available to practitioners, this paper introduces a new SPC approach
for monitoring broaching process data. This approach is based upon using current profile monitoring techniques
to detect shifts in broaching energy curves, which are obtained via real-time cutting forces measured during the
broaching process. In the proposed approach, these energy curves are segmented into piecewise linear functions.
This segmentation allows for specific sections of the broach to be monitored independently and increases the
sensitivity of the system to detect localized shifts in the broach, such as a broken or wore tooth. A laboratory-based
case study of a hexagonal broaching process is used to validate the proposed quality control approach.
85 MSEC 2013 NAMRC 41

Polycrystalline diamond turning of rock
MSEC2013-1127
Demeng Che, Northwestern University, Evanston, United States, Kornel Ehmann, Northwestern University, Evanston,
IL, United States
Polycrystalline Diamond Compact (PDC) cutters, as the most commonly used inserts for rock cutting/drilling
processes, are drawing increased attentions in manufacturing and petroleum engineering driven by the necessity
to elevate cutter and process performance. The knowledge of the force response of single PDC cutters under
various cutting conditions is an essential prerequisite for achieving this goal. In this paper, an analytical model
is derived by extending Nishimatsus two-dimensional orthogonal cutting theory for rock cutting to the threedimensional
quasi-orthogonal case. A rock turning testbed that uses single PDC cutters is developed on a CNC
turning center for measuring both thermal and mechanical responses at the rock-cutter interface in real-time. The
developed testbed is used to perform the experimental validation of a newly proposed force prediction model.
JUNE 10-14, 2013 // Madison, Wisconsin
86

Abstracts, cont.
Statistical cutting force model for orthogonal cutting of polytetrafluoroethylene (PTFE) composites
MSEC2013-1033
Felicia Stan, Daniel Vlad, Catalin Fetecau, Dunarea de Jos University of Galati, Galati, Select State/Province, Romania
This paper presents an experimental investigation of the cutting forces response during the orthogonal cutting of
polytetrafluoroethylene (PTFE) and PTFE-based composites using the Taguchi method. Cutting experiments were
conducted using the L27 orthogonal array and the effects of the cutting parameters (feed rate, cutting speed and
rake angle) on the cutting force were analyzed using the S/N ratio response and the analysis of variance (ANOVA).
Statistical models that correlate the cutting force with process variables were developed using ANOVA and
polynomial regression. The variation of the apparent friction coefficient was analyzed with respect to tool geometry
and the cutting process. The results indicated that cutting and thrust forces increase with increasing feed rate, and
decrease with increasing rake angles from negative to positive values and increasing cutting speed. A power law
relationship between the apparent friction coefficient and the normal force exerted by the chip on the tool-rake
face was identified, the former decreasing with an increasing normal force.
87 MSEC 2013 NAMRC 41

Product-oriented sustainability aspects of abrasive processes
MSEC2013-1186
Jan C. Aurich, TU Kaiserslautern, Kaiserslutern, Germany, Marina Carrella, TU Kaiserslautern, Kaiserslautern, Germany,
Benjamin Kirsch, University of Kaiserslautern, Kaiserslautern, Rheinland-Pfalz, Germany
Sustainability in manufacturing became more and more important in the last years, and, because of scarcity of
resources, will become even more important in the future. In a process-oriented view, abrasive processes appear
to be the worst manufacturing processes concerning sustainability, due to their high required specific energies. In
this paper a Product-oriented view is proposed, taking the whole Life Cycle of the machined Products into account.
In doing so, it becomes evident that abrasive processes can enhance sustainability, even when investing additional
energy during machining.
JUNE 10-14, 2013 // Madison, Wisconsin
88

Abstracts, cont.
Multi-constraint optimization for grinding nickel-based alloys
MSEC2013-1205
Radu Pavel, Ph.D., TechSolve, Inc., Cincinnati, United States, Xiqun Wang, Ph.D., Techsolve Inc, Cincinnati, OH, United
States, Anil Srivastava, Ph.D., Techsolve Inc., Cincinnati, OH, United States
Nickel-based alloys (Ni-based alloys) are used on a large scale in military, aerospace, missile and defense
applications with the aim of improving performance, life, and fuel efficiency. Grinding is extensively used for final
finishing of these components. Due to their specific material properties, such as work-hardening and low thermal
conductivity, the workpieces made of Ni-based alloys are difficult to grind. The difficulty consist in finding the
combination of dressing and grinding parameters that generate the prescribed dimensions, finish, and surface
integrity of the finished part with high productivity. Increasing productivity is generally associated with increasing
the material removal rate. This, in turn, can create detrimental effects on the ground parts such as micro-cracks,
high residual stresses, white layers, and thermal damage. This paper presents a novel methodology for determining
an optimal combination of dressing and grinding parameters with respect to maximizing the material removal rate,
while taking into account a number of process constraints including: grinding force, power, surface roughness,
wheel wear, and surface integrity. According to this methodology, predictive models for grinding behavior are
determined using a reduced number of experiments based on an in-process, fast sensor data acquisition system.
The models are used as inputs for the multiple criterion optimization program based on a genetic algorithm
approach. A CNC surface grinding machine was instrumented to allow process monitoring and data collection.
The model building and the optimization methodology have been validated using specimens made of Nibased
alloys. The workpiece materials and the range of the grinding parameters were selected according to
applications from aerospace industry. The results support the use of adopted methodology for finding the optimal
combination of dressing and grinding parameters.
89 MSEC 2013 NAMRC 41

Removal mechanism and defect characterization for glass-side laser scribing of CdTe/CdS multilayer in solar cells
NAMRC41-1563
Hongliang Wang, Columbia University, New York, United States, Y Lawrence Yao, Columbia University, New York, NY,
United States, Hongqiang Chen, GE Global Research, Niskayuna, NY, United States
Laser scribing is an important manufacturing process used to reduce photocurrent and resistance losses and
increase solar cell efficiency through the formation of serial interconnections in large-area solar cells. High-quality
scribing is crucial since the main impediment to large-scale adoption of solar power is its high production cost
(price-per-watt) compared to competing energy sources such as wind and fossil fuels. In recent years, the use of
glass-side laser scribing processes has led to increased scribe quality and solar cell efficiencies, however, defects
introduced during the process such as thermal effect, micro cracks, film delamination, and removal uncleanness
keep the modules from reaching their theoretical efficiencies. Moreover, limited numerical work has been
performed in predicting thin film laser removal processes. In this study, a nanosecond (ns) laser with a wavelength
at 532nm is employed for pattern 2 (P2) scribing on CdTe (Cadmium telluride) based thin-film solar cells. The film
removal mechanism and defects caused by laser-induced micro-explosion process are studied. The relationship
between those defects, removal geometry, laser fluences and scribing speeds are also investigated. Thermal and
mechanical numerical models are developed to analyze the laser-induced spatio-temporal temperature and
pressure responsible for film removal. The simulation can well-predict the film removal geometries, generation of
micro cracks, film delamination and remaining materials. The characterization of removal qualities will enable the
process optimization and design required to enhance solar module efficiency.
JUNE 10-14, 2013 // Madison, Wisconsin
90

Abstracts, cont.
Pulsed laser assisted exfoliation of hydrogen ion implanted single crystalline SiC thin layers
NAMRC41-1582
Tugrul Ozel, Thanongsak Thepsonthi, Voshadhi Amarasinghe, George K. Celler, Rutgers University, Piscataway, NJ,
United States
This paper reports about the investigation on pulsed laser assisted exfoliation of thin layers from hydrogen ion
implanted single crystalline SiC. Single crystalline SiC offers various high power and high temperature device
applications including hybrid and electric vehicles. Its high cost can be lowered by precision cutting of thin layers
and transferring them on to lower cost substrates such as Si and polycrystalline SiC. Nanosecond high energy laser
pulses have been utilized for thin film exfoliation and removal just under the hydrogen implanted and damaged
subsurface. Exfoliated and transferred SiC surfaces have been evaluated with Scanning Electron Microscopy.
Furthermore, thermal modelling of pulse laser irradiation of implanted multi-layer SiC material has been conducted
and temperature profiles vs. depth and time are obtained at different peak pulse intensity settings to optimize
exfoliation process parameters.
91 MSEC 2013 NAMRC 41

Application of picosecond laser for polishing of AISI H13 tool steel sample prepared by micro-milling
NAMRC41-1618
Abdullah M. Khalid Hafiz, Western University, London, ON, Canada, Evgueni V. Bordatchev, National Research
Council of Canada, London ,Canada, Remus O. Tutunea-Fatan, Western University, London, ON ,Canada
This paper explores the potentiality of high frequency short pulsed picosecond laser for laser micro-polishing (LµP)
of AISI H13 tool steel by remelting method. The melting regime was determined experimentally by varying the
focus offset to attain the required fluence level. The parameters associated with this regime were considered for
its probable application in LµP. The initial surface profile for LµP was prepared by µ-milling with a periodicity of 50
µm and amplitude height of 2 µm. The LµP trails were performed at 5 different fluence levels in melting regime
by setting the focus offset at 5 different heights. The polishing performance was evaluated by the distribution of
line profiling average surface roughness (Ra) at various spatial wavelength intervals. Additional statistical analyses
in terms of material ratio function and power spectral density function were also carried out to determine the
parameters associated with best possible surface finish. Finally, as a demonstration a flat µ-milled area was
polished using the optimum set of parameters resulting surface quality improvement by 68 % through a reduction
of a areal topography surface roughness Sa from 0.53 µm to 0.17 µm.
JUNE 10-14, 2013 // Madison, Wisconsin
92

Abstracts, cont.
Multi-objective optimization of microturning process parameters using particle swarm technique
MSEC2013-1011
Nithin Tom Mathew, Kanthababu Mani, College of Engineering Guindy, Anna University, Chennai, Chennai, India
In this work, for the first time an attempt has been made to carry out multi-objective optimization for tool based
micro-turning process parameters using particle swarm optimization (PSO) technique. The input microturning
process parameters considered are speed, feed and depth of cut. The output parameters considered are
material removal rate (MRR), surface roughness (Ra) and tool wear (TW). The significant parameters are identified
individually using ANOVA and main effect plots. However, it is observed that the main goal of the manufacturers is
to produce high quality products in shorter interval of time. In order to meet the above objective, multi-objective
optimization is carried out to achieve simultaneously higher MRR, low Ra and low TW using PSO. From the PSO
analysis, it is observed that the combination of microturning parameters such as speed (18.25 m/min), feed (9.31
µm/rev) and depth of cut (14.61 µm) results in high MRR, low Ra and low tool wear. The PSO analysis indicates that
it is a promising optimization algorithm due to its simplicity, low computational cost and good performance. A
confirmation test was carried out to validate the predicted results.
93 MSEC 2013 NAMRC 41

Burr formation and surface quality in high speed micromilling of titanium alloy (TI6AI4V)
MSEC2013-1216
Vivek Bajpai, Ajay Kushwaha, Ramesh Kumar Singh, Indian Institute of Technology Bombay, Mumbai, Maharashtra,
India
Titanium and Ti alloys are popular materials used in aviation and biomedical field due to their excellent strengthto-weight
ratio and corrosion resistance properties. Micromilling is a common mechanical machining process
used in the production of microscale features. The microtool has very low stiffness and even small forces can lead
to catastrophic tool failure. High speed micromachining can be used to address the issue because of lower chip
loads at higher rotational speeds. Consequently, high speed micromilling can be used for micromachining of
hard metals/alloys which are difficult to accomplish at lower speeds. Now days high speed micromilling is gaining
popularity due to its high material removal rate and good surface finish. In many cases, the machined product does
not need an additional finishing process. However, the burr formation in the mechanical machining process is the
most important problem which becomes more critical for a microscale feature. Removal of micro-size burr is much
more difficult than its macro counterpart. The current work is focused on the characterization of the burr formation
in high speed micromilling. Influence of various process parameters, viz., spindle speed, feed rate, depth of cut, tool
diameter and number of flutes of the micromilling tool has been analyzed on the burr size and on the quality of
the machined surface via measuring the surface roughness.
JUNE 10-14, 2013 // Madison, Wisconsin
94

Abstracts, cont.
Correlation between mechanical properties in standard test specimens and injection molded thin-wall parts
MSEC2013-1032
Laurentiu I. Sandu, Felicia Stan, Catalin Fetecau, Dunarea de Jos University of Galati, Galati, Romania
In this paper, we investigated the effect of injection molding parameters on the mechanical properties of thin-wall
injection molded parts. A four-factor (melt temperature, mold temperature, injection speed and packing pressure)
and three-level fractional experimental design was performed to investigate the influence of each factor on the
mechanical properties and determine the optimal process conditions that maximize the mechanical properties
of the part using the signal-to-noise (S/N) ratio response. The mechanical properties (e.g., elastic modulus, yield
strength and strain at break) were measured by tensile tests at room temperature, at a crosshead speed of 5 mm/
min, and compared with those of the injection-molded specimens.
The experimental results showed that the tensile properties were highly dependent on the injection molding
parameters, regardless of the type of the specimens. The values of Young modulus and yield strength of the
injection-molded specimens were lower than those of the injection-molded parts, while the elongation at break
was considerably lower for the injection-molded parts. The optimal process conditions were strongly dependent
on the measured performance quantities (elastic modulus, yield strength and strain at break).
95 MSEC 2013 NAMRC 41

Microcellular injection molding of gas-laden pellets using nitrogen and carbon dioxide as co-blowing agents
MSEC2013-1158
Xiaofei Sun, University of Wisconsin-Madison, Madison, United States, Lih-sheng Turng, University of Wisconsin-
Madison, Madison, WI, United States, Patrick Gorton, Sezen Buell, Pankaj Nigam, Energizer Personal Care, Dover, DE,
United States
A novel combination approach to producing quality foamed injection molded parts has been investigated. By
combining extruded, gas-laden pellets with microcellular injection molding, the processing benefits and material
characteristics of using both N2 and CO2 blowing agents can be realized, thus yielding features superior to that
of using either N2 or CO2 alone. Using an optimal content ratio for the blowing agents, as well as the proper
sequence of introducing the gases, foamed parts with a much better morphology can be produced. In particular,
extruding N2 gas-laden pellets, followed by microcellular injection molding with higher amounts of CO2,
produces a cellular structure that is very fine and dense. In this paper, the theoretical background is discussed
and experimental results show that this combined approach leads to significant improvements in foam cell
morphology for low density polyethylene (LDPE), polypropylene (PP), and high impact polystyrene (HIPS) using
two different mold geometries.
JUNE 10-14, 2013 // Madison, Wisconsin
96

Abstracts, cont.
Prediction of mechanical properties of microcellular plastics using the variational asymptotic method for unit cell
homogenization (VAMUCH) method
MSEC2013-1254
Emily Yu, University of Wisconsin - Madison, Madison, United States, Lih-sheng Turng, University of Wisconsin-
Madison, Madison, WI, United States
This work presents the application of the micromechanical variational asymptotic method for unit cell
homogenization (VAMUCH) with a three-dimensional unit cell (UC) structure and a coupled, macroscaled finite
element analysis for analyzing and predicting the effective elastic properties of microcellular injection molded
plastics. A series of injection molded plastic samples, which include polylactic acid (PLA), polypropylene (PP),
polystyrene (PS), and thermoplastic polyurethane (TPU), with microcellular foamed structures were produced and
their mechanical properties were compared with predicted values. The results show that for most material samples,
the numerical prediction is in fairly good agreement with experimental results, which suggests the applicability
and reliability of VAMUCH in analyzing the mechanical properties of porous materials. Other findings are that
the material characteristics (e.g., brittleness and ductility) can influence the predicted results and that VAMUCH
prediction can effectively be improved when the UC structure is more representative of the real composition.
97 MSEC 2013 NAMRC 41

Unit process life cycle inventory models of hot forming processes
MSEC2013-1054
Jennifer Buis, Fu Zhao, Purdue University, West Lafayette, IN, United States, John Sutherland, Purdue University, West
Lafayette, IN, United States
Life cycle assessment (LCA) is a widely used tool to evaluate the environmental profile of a product or process,
and can serve as a starting point for product and process improvement. Using LCA to support sustainable product
design and sustainable manufacturing has recently attracted increasing interest. Unfortunately, the available life
cycle inventory databases have very limited coverage of manufacturing processes. To make matters worse, the
available datasets are either highly aggregated or consider only selected processes and process conditions. In
addition, in the case of the latter, the data provided may be based on limited measurements or even just estimates.
This raises questions on applicability of these databases to manufacturing process improvement where different
operating parameters and conditions are adopted. Recently a novel methodology called unit process life cycle
inventory or uplci has been proposed to address these issues, and models for several machining processes (e.g.,
turning, milling, and drilling) and joining (e.g, submerged arc welding) have been developed. This paper follows the
uplci approach and develops models for a series of hot forming processes, including billet heating, performing, and
indirect extrusion. It is shown that the model predictions on energy consumption are in good agreement with data
measured on a production line. For hot forming processes, the results suggest that billet heating dominates the
overall energy consumption and the carbon footprint relative to the deformation steps.
JUNE 10-14, 2013 // Madison, Wisconsin
98

Abstracts, cont.
Dilute acid pretreatment of wheat straw: A predictive model for energy consumption using response surface
methodology
MSEC2013-1043
Xiaoxu Song, Meng Zhang, Kansas State University, Manhattan, KS, United States, Zhijian Pei, Kansas State
University, Manhattan, KS, United States, Alex Nottingham, Pengfei Zhang, Kansas State University, Manhattan, KS,
United States
Response surface methodology was used to study the effects of parameters namely, time, temperature, and solid
content and to optimize the process conditions for the minimum energy consumption in dilute acid pretreatment.
Box-Behnken design using response surface methodology was employed. Effects of time and temperature are
significant at the significant level of =0.05. Longer time and higher temperature result in higher power energy
consumption. The best optimal values of the process conditions are time 14-21 min and temperature 129-139 °C.
99 MSEC 2013 NAMRC 41

Unit process life cycle inventory models of hot forming processes
MSEC2013-1264
Fu Zhao, Purdue University, West Lafayette, IN, United States
Life cycle assessment (LCA) is a widely used tool to evaluate the environmental profile of a product or process,
and can serve as a starting point for product and process improvement. Using LCA to support sustainable product
design and sustainable manufacturing has recently attracted increasing interest. Unfortunately, the available life
cycle inventory databases have very limited coverage of manufacturing processes. To make matters worse, the
available datasets are either highly aggregated or consider only selected processes and process conditions. In
addition, in the case of the latter, the data provided may be based on limited measurements or even just estimates.
This raises questions on applicability of these databases to manufacturing process improvement where different
operating parameters and conditions are adopted. Recently a novel methodology called unit process life cycle
inventory or uplci has been proposed to address these issues, and models for several machining processes (e.g.,
turning, milling, and drilling) and joining (e.g, submerged arc welding) have been developed. This paper follows the
uplci approach and develops models for a series of hot forming processes, including billet heating, performing, and
indirect extrusion. It is shown that the model predictions on energy consumption are in good agreement with data
measured on a production line. For hot forming processes, the results suggest that billet heating dominates the
overall energy consumption and the carbon footprint relative to the deformation steps.
JUNE 10-14, 2013 // Madison, Wisconsin
100

Abstracts, cont.
Hole making technology of honeycomb sandwich materials
NAMRC41-1521
Hukuzo Yagishita, Numzu National College of Technology, Numazu-city, Shizuoka-pref.,Japan
Honeycomb sandwich materials, which are constructed by sandwiching aramid honeycomb between two CFRP
(carbon fiber reinforced plastic) plates or AFRP (aramid fiber reinforced plastic) plates, are used to make a cabin floor
and wall of aircraft in order to lighten a fuselage. Honeycomb sandwich materials are also used to manufacture a
high speed train vehicle and so on. To manufacture these bodies hole making operations are needed to fasten by
bolting each constituent part. Honeycomb sandwich materials have following characteristics; stiffness is extremely
different in the direction due to honeycomb porous structure. Three different hole making methods, which are
drilling a normal shape of cutting edge, drilling by a special shape of cutting edge and circular milling by a square
endmill having four cutting edges, were executed and hole accuracy, edge quality at inlet and outlet of hole and so
on are compared and evaluated.
101 MSEC 2013 NAMRC 41

Effect of tool wear on hole quality when drilling CFRP with coated tools
NAMRC41-1589
Caleb Sturtevant, Dave Kim, Washington State University, Vancouver, WA, United States, Xin Wang, Michigan State
University, East Lansing, MI, United States, Patrick Kwon, Michigan State University, East Lansing, MI, United States,
Jeff Lantrip, Boeing Co., Renton, WA, United States
The hole quality parameters of diamond, nanocomposite and AlTiN coated drills were compared with those of
the uncoated carbide drills when drilling CFRP. The change in the hole quality was also studied with tool wear
with these coatings. The hole quality parameters chosen for the study include hole size, hole roundness, surface
roughness, and entry delamination. The diamond coated drill showed the most consistent hole size and lowest
roundness because of its superior wear resistance. The other coated tools showed a two hole-size trends of coating
removal and subsequent carbide wear. It was found that surface roughness and delamination damage slightly
increased with tool wear for all three coated carbides and uncoated carbides. Of the various coatings tested, the
diamond coated drill showed the slightly better performance overall. The nanocomposite and AlTiN coated tools
showed better hole quality initially than the uncoated. However, the wear of coatings led to a decrease in hole
quality.
JUNE 10-14, 2013 // Madison, Wisconsin
102

Abstracts, cont.
Mechanism governing cutting of polycrystalline cubic boron nitride (pCBN) with transformation induced fracture
NAMRC41-1614
Zhuoru Wu, Ammar Melaibari, Pal Molian, Pranav Shrotriya, Iowa State University, Ames, IA, United States
A combined experimental and analytical approach is undertaken to identify the relationship between process
parameters and fracture behavior in the cutting of polycrystalline Cubic Boron Nitride (pCBN) sample by a hybrid
CO2 laser/waterjet (CO2-LWJ) manufacturing process. In CO2-LWJ machining, a high power laser was used for local
heating followed by waterjet quenching of the sample surface leading to fracture propagation along the sample
surface. Cutting results indicate two fracture behaviors: scribing and through fracture. Raman spectroscopy analysis
of the cut surface indicates that laser heated PCBN undergoes chemical phase transformation from sp3-bonded
cubic Boron Nitride (c-BN) into hexagonal Boron Nitride (h-BN) and other sp2-bonded phases. Surface profile
was experimentally measured using profilometer and compared with analytical predictions in order to estimate
the expansion strain and dimensions of transformation region associated with CO2-LWJ induced transformation.
FEM calculation was used to determine stress elds generated in the workpiece based on the strain and volume
measured experimentally in order to determine the feasibility of crack propagation.
103 MSEC 2013 NAMRC 41

Spindle dynamics identification using particle swarm optimization
NAMRC41-1541
Vasishta Ganguly, Tony Schmitz, University of North Carolina at Charlotte, Charlotte, NC, United States
Optimal parameters to eliminate machining chatter may be identified using analytical stability models which
require the dynamics of the tool-holder-spindle-machine assembly. Receptance coupling substructure analysis
(RCSA) provides a useful analytical tool to couple measured spindle-machine dynamics with tool-holder models
to predict the tool point frequency response function for the assembly. Previous research has demonstrated
a procedure to determine all required spindle receptances from a single measurement, where each mode
within the measurement bandwidth was modeled as a fixed-free Euler Bernoulli beam and fit using a manual,
iterative procedure. Here, a particle swarm optimization technique is described for fitting the spindle-machine
measurement using a fixed-free Euler-Bernoulli beam model for each mode. The performance of the optimization
process and RCSA in predicting the tool tip frequency response is evaluated and the results are presented.
JUNE 10-14, 2013 // Madison, Wisconsin
104

Abstracts, cont.
Compensation of thermally caused position and orientation errors of rotary axes
NAMRC41-1555
Michael Gebhardt, Markus Ess, Sascha Weikert, Wolfgang Knapp, IWF / ETH Zurich, Zurich, Switzerland, Konrad
Wegener, IWF, ETH Zurich, Zurich, ZH, Switzerland
Thermal errors of machine tools are one of the major sources of inaccuracy. Therefore, the reduction of temperature
induced deviations or the compensation of the resulting tool center point (TCP) errors have been of strong
interest to the manufacturing industry for a couple of years. Up to now, the observation of the environment, the
main spindle, the linear axes and the machine bed were in the focus of research, but with the rising demand
for 5axis machine tools, and the increasing requirements regarding their accuracy, the analysis of the thermal
behavior of rotary axes becomes more and more important. This paper gives an overview of corresponding
thermal measurements of machine tools. The thermal behavior of rotary and swiveling axes is analyzed in detail.
A simulation model and an approach for a phenomenological compensation of the TCP error are introduced and
verified by measurements.
105 MSEC 2013 NAMRC 41

LDV-based spindle metrology for ultra-high-speed micromachining spindles
NAMRC41-1621
Sudhanshu Nahata, K. Prashanth Anandan, Burak Ozdoganlar, Carnegie Mellon University, Pittsburgh, PA, United
States
This paper presents a laser Doppler vibrometer (LDV)-based technique to measure accurately the radial error
motions of a miniature ultra-high-speed spindle. The measurements are made from the surface of a custom
fabricated sphere-on-stem artifact. The form error of the artifact is separated and removed from the measurements
by adapting the multi-orientation error separation technique. Measurements are made for two different spindle
speeds, viz., 50 krpm and 80 krpm. The validity of the multi-orientation implementation is concluded from the
fact that the artifact form error obtained at the two spindle speeds were nearly same, with the radial spindle error
motions being considerably different.
JUNE 10-14, 2013 // Madison, Wisconsin
106

Abstracts, cont.
Stability analysis and finite element simulations of superplastic forming in the presence of hydrostatic pressure
MSEC2013-1179
Mohammad Nazzal, German Jordanian University, Amman, Jordan
It is established that some superplastic materials undergo significant cavitation during deformation. In this work,
stability analysis based on Harts definition on stable plastic deformation and finite element simulations are carried
out to study the effects of hydrostatic pressure on damage evolution during superplastic forming. The analysis is
conducted for the superplastic copper based alloy Coronze-638 at 550 °C. The results show the effectiveness of
imposing hydrostatic pressure in eliminating cavitation growth and increasing ductility for the balanced biaxial
loading case.
107 MSEC 2013 NAMRC 41

Three dimensional finite element analysis of staggered backward flow forming process
MSEC2013-1219
Hemant Shinde, Pushkar Mahajan, Ramesh Singh, K Narasimhan, Indian Institute of Technology Bombay, Mumbai,
Maharashtra, India
Flow forming is one of the cold forming processes which is mainly used to produce thin-walled high-precision
tubular components. A three dimensional coupled-field thermo-mechanical finite element model for staggered
three-roller backward flow forming of a cylindrical workpiece of MDN-250 maraging steel has been developed
using Abaqus/Explicit. In this model, the effect of tip radius of the rollers and friction between the rollers and
the workpiece has been considered. The bottom of the workpiece is fixed in the axial direction so that diametral
reduction and the axial elongation can be studied. Simulations have been carried out at different process
conditions to study the state variables, such as stresses and strains obtained during the deformation. The model has
been benchmarked with the experimental results for thickness reduction and the error in the thickness prediction
is limited to 4%. The roll forceshave been benchmarked against analytical formulation and a difference of 13-20%
has been observed. The effect of flow forming process variables, such as feed rate and reduction ratio on the stress/
strain distribution and roll forces have been studied. The results show that the roll forces increase at higher feed
rates and higher reduction ratios whereas the equivalent strains increase at lower feed rates and higher reduction
ratios. In addition, a parametric study has been conducted to study ovality, diametral growth, roll forces, stresses
and strains as a function of process parameters.
JUNE 10-14, 2013 // Madison, Wisconsin
108

Abstracts, cont.
Bayesian-based probabilistic force modeling in cold rolling
MSEC2013-1226
John Wendel, Parks College of Engineering, Richmond Heights, MO, United States, Andrew Nelson, Parks College
of Engineering, Saint Louis, MO, United States, Arif Malik, Saint Louis University, Saint Louis, MO, United States, Mark
Zipf, Tenova I2S, LLC, Yalesville, CT, United States
A primary factor in manufacturing high-quality cold-rolled sheet is the ability to accurately predict the required
rolling force. The rolling force directly influences roll-stack deflections, which correlate to the resulting flatness
quality of the rolled sheet. Increasingly high demand for thin and ultra-thin gauge for cold-rolled sheet metals,
along with the correspondingly larger sensitivity of flatness defects when rolling thin gauges, makes it more
important to accurately and rapidly predict the rolling force before the rolling operation begins. Accurate rolling
force predictions enable assignment of appropriate pass schedules and flatness mechanism set-points early in the
rolling process, thereby reducing rolling time, improving quality, and reducing scrap. Traditionally, force predictions
in cold rolling have employed two-dimensional analytical models such as those proposed by Roberts and by Bland
& Ford. These simplified methods are prone to inaccuracy, however, because of several uncertain, yet influential,
model parameters that are difficult to establish deterministically for wide-ranging products. These parameters
include, for example, the average compressive yield strength of the rolled strip, frictional characteristics relating
to low and high mill speeds, and the strain rate dependency of yield strength. Conventionally, these unknown
parameters have been evaluated deterministically by comparing force predictions with actual rolling force data
and using a best-fit regression approach. In this work, Bayesian updating using a probability mass function (PMF)
is applied to identify joint posterior probability distributions of the uncertain parameters in rolling force models. It
is shown that the non-deterministic Bayesian updating approach is particularly useful as new evidence becomes
available in the form of additional rolling force data. The aim of the work is to incorporate Bayesian inference
into rolling force prediction for cold rolling mills to create a probabilistic modeling approach which can also
learn as new production data is added. The goal is a model that can better predict necessary mill parameters
based on accurate probability estimates of the actual rolling force. The rolling force data used in this work for
applying Bayesian updating is actual production data of grades 301 and 304L (low carbon) stainless steels, rolled
on a 10-inch wide 4-high cold rolling mill. This force data was collected by observing and averaging load cell
measurements at steady rolling speeds.
109 MSEC 2013 NAMRC 41

The correlation of abrasive grain dimensional derivation with grinding performances from simulation perspective
MSEC2013-1071
Xuekun Li, Tsinghua University, Beijing, Beijing, China, Yiming(Kevin) Rong, Worcester Polytechnic Institute,
Worcester, MA, United States
For single layer superabrasive wheels, they are made by joining all abrasive grains onto the wheel hub by
electroplating or brazing. Recently, the attention has risen to acquire better grinding quality through more
stringent grain control. For the grain control process, the abrasive grains are re-meshed for smaller dimensional
derivation after outsourced from external grain manufacturers. Therefore, the understanding to correlate the grain
dimensional derivation with the wheel performances will be critical for the wheel design and optimization. In this
paper, the physics based grinding process simulation for single layer CBN wheels is carried out with a virtual wheel
model. The correlation of resultant ground surface quality with grain sized distribution is established through the
simulation, which provides the quantitative basis for grinding wheel quality control and process design.
JUNE 10-14, 2013 // Madison, Wisconsin
110

Abstracts, cont.
Force modeling for generic profile of drills
MSEC2013-1262
Kumar Sambhav, Indian Institute of Technology, Kanpur, Kalyanpur, India, Puneet Tandon, PDPM Indian Institute
of Information Technology, Design & Manufacturing, Khamaria, Jabalpur, India, Sanjay Dhande, IIT Kanpur, Kanpur
208016, Uttar Pradesh, India
The paper presents a methodology to model the cutting forces by twist drills with generic point geometry. A
generic definition of point geometry implies that the cutting lips and the relief surfaces can have arbitrary shapes.
Such geometry is easily modeled using NURBS surface patches which give sufficient freedom to the tool designer
to alter the tool geometry. The drill point has three cutting zones: primary cutting lips, secondary cutting lips and
the indentation zone at the center of chisel edge. At the indentation zone, the drill extrudes the workpiece, while at
the cutting lips, shearing takes place. At primary cutting lip, the cutting is oblique while at secondary cutting lip, it
is predominantly orthogonal. Starting from a computer-aided geometric design of a fluted twist drill with arbitrary
point profile, the cutting forces have been modeled separately for all the three cutting zones. The mechanistic
method has been employed wherever applicable to have a good correlation between the analytical and the
experimental results. The force model has been calibrated and validated for conical drills. Then the model has been
evaluated for a drill ground with curved relief surfaces. The theoretical and experimental results are found out to be
in good conformity.
111 MSEC 2013 NAMRC 41

Effect of blank holder force schemes on weld-line movements in u-draw bending of tailor welded blanks
NAMRC41-1530
Mostafa Shazly, The British University in Egypt, Elshorouk City, Not USA or Canada, Egypt, Bishoy Dawood, Modern
Academy, Cairo, Egypt, Abdalla Wifi, Alaa ElMokadem, Cairo University, Giza, Not USA or Canada, Egypt
In the present paper, a simplified finite element-based procedure is developed, to determine a proper blank holder
(binder) force (BHF) scheme for the draw bending process of tailor welded blanks (TWBs). Under constant BHF,
significant weld-line movement is observed. Tearing of TWB is encountered at high values of BHF. Careful analysis
of weld-line movements and various numerical experiments show that a constant maximum-then decreasing BHF
scheme on the weaker blank side would eliminate weld-line movement without the need for a counter punch.
The developed finite element model, integrated with the rational of carefully correlating the weld-line movement
to the applied BHF, presents a simplified procedure for suggesting proper BHF schemes, rendering itself for use in
various industrial applications.
JUNE 10-14, 2013 // Madison, Wisconsin
112

Abstracts, cont.
Examining tool shapes in single point incremental forming
NAMRC41-1581
Brendan Cawley, David Adams, Queen’s University, Kingston, ON, Canada, Jack Jeswiet, Queens University, Kingston,
ON, Canada
To improve the forming limits and expand the range of potential applications of SPIF, testing was performed on
a variety of tool heads, with emphasis on non-standard tool profiles. Two head types have been investigated
using a custom 2.5 degree step curve frustum. The results have been compared to standard hemispherical and
flat-bottomed tools. Hemispherical and flat-end profile results were correlated with previous work on the subject.
Parabolic heads of various shapes were tested, resulting in a decreasing formability and increasing surface quality
with increased coefficient. Angle-radius heads of 60, 70, and 80 degrees from the vertical were tested, resulting in
forming limits approaching that of the 90 degree flat-end tool, indicating that the reduced stress resulting from
increased contact area limits the plastic deformation required for adequate material redistribution.
113 MSEC 2013 NAMRC 41

Evaluation of ionic fluids as lubricants in manufacturing
NAMRC41-1619
Amy Libardi, University of Notre Dame, Notre Dame, IN, United States, Steven Schmid, Mihir Sen, William Schneider,
University of Notre Dame, Notre Dame, IN, United States
Ionic fluids are liquid salts that have been investigated for a number of applications, including catalysis, their use as
solvents and electrically conducting fluids. Chemically, they consist of ionically bonded species, and depending on
the cation and anion, can be extremely valuable in the chemical processing industry. Another characteristic that
makes them useful is a high viscosity and good lubrication properties. This paper examines a number of ionic fluids,
and determines their suitability as lubricants. This involves determining rheological properties, including viscosity
and high-pressure viscosity, generally using a Barus law. In addition, their traction behavior is measured to evaluate
their lubricating properties. Since metalworking fluids (and lubricants in general) are used in non-isothermal
situations, the thermal conductivity of these fluids have also been measured.
JUNE 10-14, 2013 // Madison, Wisconsin
114

Abstracts, cont.
An investigation on electrochmical discharge micro-drilling of glass
MSEC2013-1135
Mohammad Reza Razfar, Amirkabir University of Technology(Polytechnic of Tehran), Tehran, Tehran, Iran, Jun Ni,
University of Michigan, Ann Arbor, MI, United States, Ali Behroozfar, Amirkabir University of Technology, Tehran,
Tehran, Iran, Shuhuai Lan, University of Michigan, Ann Arbor, MI, United States
Electrochemical Discharge Machining (ECDM) as an innovative spark-based micromachining method has been
successfully applied for fabricating micro-holes in non-conductive brittle materials such as glass. However, the
effects of influencing parameters for attaining accurate structures and dimensions remain to be explored. This
paper attempts to analyze the effects of process parameters including applied voltage, tool immersion depth and
electrolyte concentration on process outputs such as radial overcut(ROC), material removal rate(MRR), heat affected
zone(HAZ) thickness and roundness error(RE) of the holes. In this regard, a set of experiments based on response
surface experiment design method were conducted on soda lime glass. The relevant experimental data were used
to establish mathematical models for process outputs using the response surface methodology (RSM). In order
to optimize the proposed mathematical models, a genetic algorithm (GA) applied and the optimum selection
of parameters for minimum roundness error, ROC, HAZ and maximum MRR were reported. The adequacy of the
developed mathematical models was also evaluated by an analysis of variance (ANOVA) test. The obtained results
show the efficiency and capability of the proposed approach for analysis and optimization of the electrochemical
discharge machining of glass.
115 MSEC 2013 NAMRC 41

Line-based laser induced plasma micro-machining (L-LIPMM)
MSEC2013-1153
Rajiv Malhotra, Ishan Saxena, Northwestern University, Evanston, IL, United States, Kornel Ehmann, Jian Cao,
Northwestern University, Evanston, IL, United States
Recently, the technique of Spot-based Laser Induced Plasma Micro-Machining (Spot-LIPMM) has been developed
to address the limitations of conventional ultra-short pulse laser micro-machining. Its main advantages are
adaptability to a wide range of materials and superior wall geometries. We propose a variation of the Spot-LIPMM
process by creating line plasma instead of spot plasma, with the use of suitable optics. This paper describes the
experimental setup used to create line plasma and the process used for micro-machining with L-LIPMM. Optics
simulations are developed as a means of guiding the choice of optics to be used for line plasma generation and
estimating the energy and shape of the plasma created. It is shown that this Line-based LIPMM (L-LIPMM) process
is capable of micromachining channels at a much higher speed than conventional Spot-based laser ablation or
spot-based LIPMM. Additionally, the effects of process parameters on machined geometry using L-LIPMM are
discussed.
JUNE 10-14, 2013 // Madison, Wisconsin
116

Abstracts, cont.
Embedding information on metal surfaces by micro-milling
MSEC2013-1173
Thomas Tesswin, Sathyan Subbiah, Adams Wai Kin Kong, Nanyang Technological University, Singapore, Singapore
A new method of storing or embedding information on the surface of metals is presented here. The feed marks
left behind by the passing tool in micro-milling are used as a way to embed the information. By simply varying the
feed rates during milling in predetermined way information can be stored similar to how an optical storage disc
embeds digital information in a binary fashion. Such storage is demonstrated by creating the surface topography
using micro-milling and performing information retrieval by extracting and analyzing the surface profiles. Expected
applications of this are in steganography and water marking of products for authenticity checks.
117 MSEC 2013 NAMRC 41

Requirements for moving towards liquid molding of large composite structures for aerospace
MSEC2013-1023
Thomas Tsotsis, The Boeing Co, Huntington Beach, CA, United States
Requirements for moving beyond the current state of the art in polymer-matrix composites for large commercial
and military transport aircraft via the use of liquid molding will be presented. These requirements will be rooted
in understandings of regulatory safety requirements and in recent developments in materials and modeling. Key
parameters such as the interrelationships between modeling, quality control, and scale-up will be discussed in
some detail with a focus on how these need to be matured or adapted for aerospace usage and how they address
the persistent need for improved performance at reduced weight. Ongoing work in several technologies will be
presented relative to how they fit into the maturation of next-generation composites and tools for developing new
composite materials. Scale-up will be illustrated by examples in modeling moving up from material-property-level
requirements to system-level performance and moving down to micro and submicron level. These illustrations will
be used to show an approach for effectively moving between scales in modeling, testing, fabrication, and design.
JUNE 10-14, 2013 // Madison, Wisconsin
118

Abstracts, cont.
Study of biobased shape memory polylactic acid/thermoplastic polyurethane (PLA/TPU) blends
MSEC2013-1237
Xin Jing, Hao-Yang Mi, University of Wisconsin-Madison, Madison, WI, United States, Lih-sheng Turng, University
of Wisconsin-Madison, Madison, WI, United States, Xiang-Fang Peng, South China University of Technology,
Guangzhou, China
This paper presents the development of shape-memory polymers (SMPs) based on polylactic acid (PLA) and
thermoplastic polyurethane (TPU) blends. PLA was melt blended with TPU at weight ratios of 20, 30, and 40%, and
then injection molded and hot compressed into permanent shapes. Unlike most of the existing SMPs, all three PLA/
TPU blends could be formed (via bending, folding, compression, stretching, etc.) into temporary shapes at room
temperature without an extra heating step. Upon heating to above the glass transition temperature of PLA (at 70
ºC), the deformed parts regained their original shapes quickly. Differential scanning calorimetry (DSC) and scanning
electron microscopy (SEM) tests showed that PLA and TPU were immiscible. The dynamic mechanical analyzer
(DMA) data and the mechanical tests, including tensile, compression, and flexural tests, showed that the PLA/TPU
with the 80/20 weight ratio had the best shape-memory properties, even if it was somewhat brittle. The 70/30 PLA/
TPU blend had the best combination of shape recovery and mechanical properties.
119 MSEC 2013 NAMRC 41

Synthesis and characterization of high performance polymer nanocomposite using carbon nanotubes as fillers
MSEC2013-1251
N. Thangapandian, S. Balasivanandha Prabu, Anna University, Chennai, India, Ratnam Paskaramoorthy, University of
the Witwatersrand, Johannesburg, South Africa
In this work, the chemical vapor deposition (CVD) method is used for the production of carbon nanotubes (CNTs).
The catalyst, Fe/MgO, was prepared through sonication technique. It was heated to 600 ºC for 6 hours and this
was used as the template for growing the CNTs using acetylene as carbon precursor. The deposited CNTs were
separated by acid treatment followed by air oxidation. The purified CNTs were examined by scanning electron
microscopy (SEM) and high resolution transmission electron microscopy (HRTEM). The CNTs were observed to have
a multi-wall structure with the diameter in the range of 10-20 nm. These multiwalled carbon nanotubes were used
as filler material in an epoxy matrix. Sonication technique was used to achieve uniform dispersion of CNTs within
the matrix. The CNT/epoxy nanocomposite was cured at a temperature of 100 °C for 3 hours. Tensile strength,
flexural strength, fire retardant properties and surface conductivity were studied. The results reveal that addition of
MWCNTs to the epoxy promotes improvement to the above mentioned properties.
JUNE 10-14, 2013 // Madison, Wisconsin
120

Abstracts, cont.
Research progress of cloud manufacturing in China: A literature survey
MSEC2013-1168
Qun Lin, Kai Xia, Huazhong University of Science and Technology, Wuhan, Hubei, China, Lihui Wang, Royal Institute
of Technology, Stockholm, Sweden, Liang Gao, Huazhong University of Science and Technology, Wuhan, Hubei,
China
Cloud manufacturing has been of considerable interest to Chinese academic researchers over the last decade.
This paper presents a broad perspective of the research on cloud manufacturing in China. The topics studied
mainly include design of cloud manufacturing architecture, resource and capability virtualization, combinatorial
optimization of virtual resource and capability, design and collaboration of cloud manufacturing services,
intelligent searching and matching method and trust evaluation. The present literature survey also includes
two successful cases applying cloud manufacturing in China to verify the feasibility of the cloud manufacturing
architecture and services. Potentially interesting directions for future research in this area are also identified.
121 MSEC 2013 NAMRC 41

Lifecycle management of knowledge in a cloud manufacturing system
MSEC2013-1133
Anrui Hu, Lin Zhang, Fei Tao, Xiaohang Hu, BeiHang University, Beijing, Beijing, China
Cloud manufacturing is a new service-oriented intelligent manufacturing paradigm. Knowledge is a core part
and the foundation to realize its intelligence. In this paper, the importance and functions of knowledge to cloud
manufacturing was first investigated from the lifecycle of cloud service. Then a knowledge management system
was designed, and the layered architecture and key technologies were analyzed. A case study was conducted to
demonstrate the feasibility of the proposed knowledge management system.
JUNE 10-14, 2013 // Madison, Wisconsin
122

Abstracts, cont.
Requirements and concept for a manufacturing service management and execution platform for customizable
products
MSEC2013-1021
Ursula Rauschecker, Matthias Stöhr, Daniel Schel, Fraunhofer IPA, Stuttgart, Germany
Cloud manufacturing provides solutions for a number of tasks concerning the integration of manufacturing
resources and production networks. Through it, new possibilities also arise for increasing product individualization.
The paper describes how cloud manufacturing concepts allow an Internet marketplace to be established for
flexible manufacturing services, which can be used to provide customized products. To do this, first of all use cases
related to an appropriate IT infrastructure are analyzed with special regard to the management of manufacturing
services which are used to represent manufacturing resources from a technical, financial, logistical, and
contractual perspective. Furthermore, requirements on the platform which have to be fulfilled during execution of
manufacturing services in a manufacturing cloud are explained and concepts and an architecture for realization of
both are described.
123 MSEC 2013 NAMRC 41

Virtual enterprise architectural framework: Collaboration towards small and medium enterprises
MSEC2013-1004
AHM Shamsuzzoha, Petri Helo, University of Vaasa, Vaasa, Finland
This paper presents a methodological approach to support the running of a temporary collaborative network
through the formation and operation of a virtual enterprise (VE), where the participating enterprises, especially
small and medium size enterprises (SMEs), collaborate with each other for mutual benefit. Overall VE architectural
framework which is considered as the baseline to execute VE manufacturing processes is highlighted in this
research. Different components within this architecture such as visualization and configuration, message exchange,
process designer, forecasting and simulation, optimization, cloud-based data storage, etc., are briefly explained
with respect to their corresponding interfaces with each other. Among all the components of VE architecture, the
user interface component termed Dashboard is explicitly highlighted with a case example of a VE network. This
Dashboard component is implemented to visualize the VE operational activities that directly contribute to monitor
and manage the associated collaborative processes successfully. Further research potential along with the general
research outcomes are also highlighted in the conclusion section of this paper.
JUNE 10-14, 2013 // Madison, Wisconsin
124

Abstracts, cont.
A framework model for characterizing the carbon emissions dynamics of manufacturing system
MSEC2013-1151
Huajun Cao, Hongcheng Li, Chongqing University, Chongqing, China, Ruixue Yin, Chongqing University, Chonqing,
China, Haiqin Cheng, Chongqing University, Chongqing, China, Yi Luo, Chongqing University, Chognqing, China
There is increasing evidences that more and more companies throughout the world are seeking measures to
reduce their production carbon emissions or product carbon footprint. This paper proposes a framework model
for characterizing the carbon emission dynamics of manufacturing system which is a hybrid system in terms of
emission mechanism. The dynamics are expressed by the general state equations of hybrid system, which consists
of the state evolution and output equations. Furthermore, two emission characterization indicators, carbon
emission rate deriving from the sate evolution equation and carbon efficiency from the output equation, are
defined for dynamics analysis. Production disturbances are considered in the model to investigate their impacts
on the carbon emission dynamics. Finally, an experimental study on carbon emission characteristics of gear
manufacturing system illustrates how the framework model should be utilized.
125 MSEC 2013 NAMRC 41

Energy savings opportunities of an integrated facility and production line
MSEC2013-1191
Michael Brundage, Stony Brook University, Massapequa, NY, United States, Cindy Chang, Stony Brook University,
Stony Brook, NY, United States, Dongmei Chen, Victor Yu, University of Texas, Austin, TX, United States
In modern manufacturing facilities there are many energy saving opportunities (ESO) that are wasted by the lack
of integration between the facility and the production system. This paper deals with an integrated production
line and the heating, ventilation, and air conditioning (HVAC) system and explores the different energy saving
opportunities of the two largest energy consumers in the manufacturing plant. The energy opportunity window
of each machine is utilized to allow for energy savings for the production line without throughput loss on the
floor. This opportunity window is synced with the peak periods of energy demand for the energy demand of the
HVAC system. The integration of these two systems allows for the maximum energy cost savings. These systems are
modeled and tested using simulation case studies.
JUNE 10-14, 2013 // Madison, Wisconsin
126

Abstracts, cont.
Real-time milling force control and tool wear monitoring using constraint-based feedrates
NAMRC41-1522
Mehdi Nouri, Barry Fussell, University of New Hampshire, Durham, United States
This research is focused on improving the efficiency, quality and safety of Computer Numerical Control (CNC)
machining by enabling automatic feedrate selection, and real-time peak force and tool wear control. Different
elements of this smart machining system are described in detail. Preprocessing consists of automatic constraintbased
feedrate selection and producing a table of estimated peak forces for every tool move. The real time force
control section of the system is designed to maintain the measured peak force within the estimated threshold by
adjusting the cutting conditions in real-time. This prevents potential quality problems from increased forces due to
tool wear. The real-time monitoring section tracks the tool wear and stops the process before catastrophic events
like tool breakage occur. The effectiveness of the smart machining system is investigated on a simple cutting
process.
127 MSEC 2013 NAMRC 41

Process damping coefficient identification using bayesian inference
NAMRC41-1525
Jaydeep M. Karandikar, Chris T. Tyler, Tony Schmitz, University of North Carolina at Charlotte, Charlotte, NC, United
States
This paper describes the application of the random walk method for Bayesian inference to the identification of
the process damping coefficient in milling. An analytical process damping algorithm is used to model the prior
distribution of the stability boundary and it is updated using experimental results via Bayesian inference. The
updated distribution of the stability boundary is used to determine the posterior process damping coefficient
value. The method is validated by comparing the process damping posterior values to residual sum of squares
results. A value of information approach for experimental test point selection is demonstrated which minimizes the
number of experiments required for process damping coefficient identification.
JUNE 10-14, 2013 // Madison, Wisconsin
128

Abstracts, cont.
Adaptive tool wear estimation using on-machine touch probes
NAMRC41-1597
Andrew Henderson, Clemson University - International Center for Automotive Research, Simpsonville, SC, United
States, Cristina Bunget, Clemson University - ICAR, Greenville, SC, United States, Thomas Kurfess, Georgia Institute of
Technology, Atlanta, GA, United States, Laine Mears, Clemson University ICAR, Greenville, SC, United States
Cast gamma-prime-strengthened nickel-based superalloys are extremely difficult to machine and, therefore, induce
rapid wear on cutting tools under all machining conditions. The objective of this paper is to show the development
of an in-process, adaptive, wear estimation for milling nickel-based superalloys.
In this paper, data from tool wear experiments are used to determine parameters for a linear tool wear model
and estimate tool wear based on measurements from a tool setting touch probe. Equations for implementing
the Kalman filter are developed and tool wear model parameters are used in conjunction with estimates from
probe measurements to determine an improved estimate of tool wear. The mean absolute error from the probe
estimation was 17 micrometer and 8 micrometer from the Kalman filter estimation. The Kalman filter reduces the
estimation error by 53%.
129 MSEC 2013 NAMRC 41

Finite element simulation of micro-end milling titanium alloy: Comparison of viscoplastic and elasto-viscoplastic
models
NAMRC41-1557
Thanongsak Thepsonthi, Tugrul Ozel, Rutgers University, Piscataway, NJ,United States
Computational methods such as finite element simulation have been utilized in analyses of machining process
for several decades. With the advance of the computing power, its applications can be further extended. In
micro-machining, finite element simulation has been used for predicting cutting forces, minimal chip thickness,
temperatures, and tool wear. The accuracy of results and time consumed are highly dependent upon the
assumptions which govern that problem. This study shows a comparison of employing two different material
assumptions in finite element simulation of micro-end milling titanium alloy Ti-6Al-4V. The same simulation was
conducted by using the elasto-viscoplastic and the viscoplastic material assumptions. The results have shown that
the material assumption has a major effect on the mechanism of chip formation and heat generation but it only
has a minor effect on the cutting force and tool wear prediction. In terms of computational time, it was found that
the viscoplastic model can reduce simulation time up to 8 times that of required for elasto-viscoplastic model.
JUNE 10-14, 2013 // Madison, Wisconsin
130

Abstracts, cont.
Finite element modeling of microstructural changes in dry and cryogenic machining AZ31B magnesium alloy for
enhanced corrosion resistance
NAMRC41-1564
Zhengwen Pu, University of Kentucky, Lexington, KY, United States, D. Umbrello, University of Calabria, Rende,
Province of Cosenza, Italy, D.A. Puleo, O.W. Dillon, Jr., I.S. Jawahir, Tao Lu, University of Kentucky, Lexington, KY, United
States
Unsatisfactory corrosion resistance is one of the major disadvantages of magnesium alloys that impede their wide
application. Microstructural changes, especially grain sizes, of Mg alloys have significant influence on their corrosion
resistance. Cryogenic machining was reported to effectively induce grain refinement on Mg alloys and has a
potential to improve their corrosion resistance. It is important to model these changes so that proper machining
conditions can be found to enhance the corrosion rate of Mg alloys. In this paper, a preliminary study was
conducted to model the microstructural changes of AZ31B Mg alloy during dry and cryogenic machining using
the finite element (FE) method and a user subroutine based on the dynamic recystallization (DRX) mechanism of
Mg alloys. Good agreement in terms of grain size and affected layer thickness was found between experimental
and predicted results. A numerical study was conducted using this model to investigate the influence of rake angle
on microstructural changes after cryogenic machining.
131 MSEC 2013 NAMRC 41

Determination of constitutive material model parameters in FE-based machining simulations of Ti-6Al-4V and IN-
100 alloys: An inverse methodology
NAMRC41-1580
Durul Ulutan, Rutgers University, Piscataway, United States, Tugrul Ozel, Rutgers University, Piscataway, NJ, United
States
Finite Element-based simulations provide good capability to predict the outcomes of machining processes, and
their value soar when utilized to simulate machining of hard-to-machine materials such as titanium alloys (e.g.
Ti-6Al-4V) and nickel-based alloys (e.g. IN-100). This study presents a new FE simulation-based methodology to
determine the modified constitutive model parameters utilizing the force results from face turning experiments
conducted for both Ti-6Al-4V and IN-100. In these simulations, material constitutive models have a great influence
on the results and must be selected carefully to represent the correct material flow stress characteristics.
Conventional modified constitutive material models with flow softening behavior are utilized and further modified
to represent the thermal softening effect on the flow softening behavior, where the temperatures can be much
higher than normal for machining these materials. Parameters of the temperature-dependent flow softening
based material constitutive model for both materials have been determined by using an inverse methodology.
Comparison of measured and simulated forces with the modified material models has shown close agreements.
JUNE 10-14, 2013 // Madison, Wisconsin
132

Abstracts, cont.
Evaluation of ductile fracture models on finite element simulation of metal cutting process
MSEC2013-1061
Chengying Xu, Jian Liu, Yuanli Bai, University of Central Florida, Orlando, United States
In this paper, a systematic evaluation of six ductile fracture models is conducted to identify the most suitable
fracture criterion for metal cutting processes. Six fracture models are evaluated in this study, including constant
fracture strain, Johnson-Cook, Johnson-Cook coupling criterion, Wilkins, modified Cockcroft-Latham, and Bao-
Wierzbicki fracture criterion. By means of Abaqus built-in commands and a user material subroutine (VUMAT), these
fracture models are implemented into a Finite Element (FE) model of orthogonal cutting processes in ABAQUS/
Explicit platform. The local parameters (stress, strain, fracture factor, velocity fields) and global variables (chip
morphology, cutting forces, temperature, shear angle, and machined surface integrity) are evaluated. The numerical
simulation results are examined by comparing to experimental results of 2024-T3 aluminum alloy published in
open literatures. Based on the results, it is found that damage evolution should be considered in cutting process
FE simulation. Moreover, the B-W fracture model with consideration of rate dependency, temperature effect and
damage evolution gives the best prediction of chip removal behavior of ductile metals.
133 MSEC 2013 NAMRC 41

Fatigue properties and life prediction of 8630 cast steel in the presence of weld repair and porosities
MSEC2013-1119
AliReza Shirazi, Hitachi, Guelph, ON, Canada, Ihab Ragai, Hitachi Construction Truck Manufacturing Ltd., Guelph, ON,
Canada
The objective of the this work is to study the effect of weld repair and macro-porosities on fatigue properties and
fatigue life of AISI 8630 cast steel subjected to bending cyclic loads. Test specimens were cut from a cast steel
component that contains macro-porosities. To regain the structural integrity, the component is typically excavated
and weld repaired.
In this study, weld repairs are simulated by machining a cylindrical groove across the width of the specimen then
the groove is welded using different weld rods and various pre and post weld heat treatment conditions. All
specimens were examined by radiography (X-Ray) in accordance with ASTM E446 before depositing the weld in
order to verify the quality of the samples. After welding, the quality of the welded grooves was examined using
ultrasonic testing (UT) and magnetic particle inspection (MPI) in accordance with ASTM A609 and ASTM E709
standards, respectively.
Qualified samples were then machines to the final dimensions. The fatigue test was performed under pure bending
conditions using four-point bend set up. This set up allows localizing stresses at the sites where weld repairs were
applied.
Experimental results show that specimens with stronger weld material tested under no heat treatment conditions
have comparable fatigue performance to those heat treated specimens with lower strength weld material.
Furthermore, it was found that the fatigue test results are highly affected by the presence of micro-porosities within
the cast steel material. Therefore, an analytical approach to predict the fatigue life is also presented in this work. A
good agreement is achieved between the predicted fatigue lives and the experimental results.
Generally, the results show that for porosities with width to depth ratios between 0.25 to 1 and width size smaller
than or equal to 1 mm the life is reduced by up to 1.5 orders of magnitude while the endurance limit was reduced
by a factor of 1.57. Similarly for porosities with ratios between 1.5 and 2.5 and width greater than 1.5 mm the life
was reduced by 2.5 orders of magnitude and the endurance limit was reduced by a factor of 2.2
JUNE 10-14, 2013 // Madison, Wisconsin
134

Abstracts, cont.
Interface delamination of diamond-coated carbide tools considering coating fractures by XFEM
MSEC2013-1132
Ping Lu, University of Alabama, Tuscaloosa, AL, United States, Y. Kevin Chou, Ph.D., The University of Alabama,
Tuscaloosa, AL, United States
Interface delamination is the major failure mode of diamond-coated carbide tools in machining. On the other
hand, coating cracking is possibly accompanied during a tribological process that induces the delamination
phenomenon. However, such an influence between the two failure behaviors has not been investigated in a
quantitative way to better understand and design diamond coating tools.
In this study, a three-dimensional (3D) indentation model combining cohesive interactions and extended finite
element method (XFEM) was developed to investigate the diamond-coating, carbide-substrate interface behavior
with the incorporation of coating cracking. The interface interaction was based on a cohesive zone model (CZM)
with a bilinear traction-separation law. XFEM was applied to the coating domain to model cracking in the diamond
coating with a damage criterion of the maximum principal stress. Deposition stresses were also included to
investigate their effect on the coating delamination and fractures. The model was implemented in finite element
(FE) codes to analyze the cone crack in brittle coatings, as well as the interface delamination of diamond coated
carbide tools. The XFEM model was validated by the indentation testing data from literature in crack initiations and
propagations in brittle materials. FE results from the indentation on diamond-coated tools show that the interface
delamination size and the loading force become smaller when coating fractures are incorporated in the model, and
the deposition stresses will increase the initial crack radius as well as the critical load for delamination in diamond
coatings.
135 MSEC 2013 NAMRC 41

Ductile fracture limits of the CuZn40Pb2 brass alloy deformed at elevated temperature
NAMRC41-1539
Stefania Bruschi, Andrea Ghiotti, Michele Novella, Dept. of Industrial Engineering, University of Padova, Padova, Italy
The effectiveness of predicting the fracture occurrence in forging process chains strongly depends on the correct
choice and calibration of damage and fracture laws under specific stress and strain conditions. The objective of
the paper is to evaluate the fracture limits of a brass alloy deformed at elevated temperature under a wide range
of stress states typical of hot forging process chains. A combined use of experimental and numerical techniques
allowed determining the material fracture limits. Tensile and torsion tests at elevated temperature were conducted
to investigate the influence that the stress triaxiality and the deviatoric parameters may have on the material
formability. Numerical simulations of the above cited tests were carried out to calculate the values of the stress
triaxiality factor of the tests and to correlate them with the experimentally determined strain at fracture. The
CuZn40Pb2 brass alloy was taken as the reference material, being characterized by a restrict forgeability window
in current hot forging processes. The obtained results state that the material deformation at fracture is greatly
influenced not only by the forging temperature (allowing the determination of the lower temperature limit of the
forgeability window), but also by the stress triaxiality and deviatoric parameters, meaning that a general fracture
law should be dependent on these stress parameters, besides on the temperature.
JUNE 10-14, 2013 // Madison, Wisconsin
136

Abstracts, cont.
Development of a biaxial loading frame for sheet metal
NAMRC41-1605
Joseph Wilson, Brad Kinsey, Ioannis Korkolis, University of New Hampshire, Durham, NH, United States
Characterization of the evolving yield loci and forming limit diagrams for sheet materials under biaxial loading is
necessary for the development of accurate sheet metal forming process simulations. Biaxial tension testing has
been shown to have significant advantages over the current computational and experimental methods for such
material characterization, however, the few commercially available loading frames are far too large and expensive
to be practical for most metal forming research labs. In this paper, the design of a practical servohydraulic biaxial
loading frame is presented. The design, control, and operation of the loading frame are discussed in detail, and
uniaxial test data is provided to validate the effectiveness of the control system with respect to specimen center
shifting. Initial biaxial testing is expected to be completed in the next month, and the results will be included in
subsequent versions of this paper. Finally, testing methods for various applications are presented and discussed.
137 MSEC 2013 NAMRC 41

A motion study of a manipulator for transferring microparts in a multi stage former
MSEC2013-1072
Rasoul Mahshid, Hans Nørgaard Hansen, Denmark Technical University, Lyngby, Denmark, Casper Hansen,
Maskinmester Skolen København, Lyngby, Select State/Province, Denmark, Mogens Arentoft, IPU, Lyngby, Select
State/Province, Denmark
In the earlier studies, it was shown that a whole multi stage former can be divided into three major sub-sections,
the positioning unit, the gripping unit and the forming unit. The two first units were investigated and related
parameters and features of each were discussed. This research herein deals with the forming unit. For this research,
the positioning unit and the gripping unit are applied to the forming unit including a micro press equipped
with a die system. The analysis focuses on verifying the results already extracted from previous researches
by implementing all mentioned units together. A motion study of the system gives an overview of different
steps and movements inside the multi stage former. Significantly, increasing the production rate increases the
acceleration and also causes the time frame tight. The time limitations put overlaps on the moving parts in terms
of milliseconds. A high speed camera was used in the experiments with high resolution to show the details of
the motion while enabling to detect any unwanted movement within milliseconds. Importantly, increasing the
frequency of image capturing within the movement is another beneficial feature in the high speed camera in order
to give sufficient information on critical movements where they may need sensors and enough time to ensure
getting at the right position as programmed. In this research the production rate raised to 169 strokes per minute.
The results show that the concept introduced for the manipulator works very well at a real process implementation.
This significantly approves the techniques already were given to evaluate the precision in the positioning unit and
the gripping unit.
JUNE 10-14, 2013 // Madison, Wisconsin
138

Abstracts, cont.
Fabrication of chitosan porous structure and applications on artificial photosynthesis device
MSEC2013-1109
Xiang Ren, Drexel University, Philadelphia, United States, Miao Yu, Drexel University, Upper Darby, PA, United States,
Xiaohang Zhou, Drexel University, Philadelphia, PA, United States, Qingwei Zhang, Drexel University, Philadelphia,
PA, United States, Jack Zhou, Drexel University, Philadelphia, PA, United States
Research and development on artificial photosynthesis provide a new direction to obtain sustainable energy. To
increase the artificial photosynthesis reaction rates and the efficiency of collecting the energy product, a novel
artificial photosynthesis device was designed and developed to constrain the photosynthesis reactions in chitosan
porous structure. Both 3D printing and molding-casting could be used in fabrication of chitosan structure on
artificial photosynthesis devices. In molding and casting, the molds were made by acrylonitrile butadiene styrene
(ABS) and polydimethylsiloxane (PDMS). Concurrently, 3D interconnected chitosan channels were built with a
user-made heterogeneous 3D rapid prototyping machine, and the lyophilization method was used to generate the
micro or nano pores inside the chitosan scaffold. After lyophilization, the pore size and porosity was generated by
MATLAB image processing. CO2 absorption was simulated based on porous structures properties when import the
chitosan into the artificial photosynthesis devices. The results suggested that chitosan porous structure is a good
candidate to be an interface between atmosphere and micro-fluidic devices with biochemical reactions.
139 MSEC 2013 NAMRC 41

A critical factor in enhancement of MQL lubricants: Platelet thickness
MSEC2013-1145
Trung Nguyen, Michigan State University, East Lansing, MI, United States, Kyung-Hee Park, Korea Institute of
Industrial Technology, Cheonan-Si, Korea (Republic), Patrick Kwon, Michigan State University, East Lansing, MI,
United States
The lamellar-type solid lubricants are readily available in a form of platelets. The diameter and thickness of these
platelets are typically up to tens of microns and few microns, respectively, which are classified as micro-platelets.
Some of these platelets are also available as nano-platelets whose thickness is well below a micron (even to few
nanometers). In the previous work, the vegetable oil mixed with nano-platelets was enormously effective for
Minimum Quantity Lubrication (MQL) machining. Clearly, the micro-platelets are not as inexpensive. In addition,
the mixtures with the micro-platelets are not as stable as those with the nano-platelets. This paper intends to
find the effect of the thickness differential on these platelets in MQL machining. The tribometer test shows that
the nano-platelets are much more effective than the micro-platelets in reducing wear without changing the
friction. With the MQL ball mill experiment, the micro-platelets present in MQL oil increased the tool wear, even
compared to the traditional MQL with pure oil only. Thus, the thickness of the nano-platelets holds an important
characteristic to enhance MQL-based machining.
JUNE 10-14, 2013 // Madison, Wisconsin
140

Abstracts, cont.
Corotating or codeforming models for thermoforming: Free forming
MSEC2013-1114
Hyung Baek, Alan Giacomin, University of Wisconsin-Madison, Madison, WI, United States
Our previous work [J Pol Eng, 32, 245 (2012)] explores the role of viscoelasticity for the simplest relevant problem
in thermoforming, the manufacture of cones. In this previous work, we use a differential model employing the
corotational derivative [the corotational Maxwell model (CM)] for which we find an analytical solution for the sheet
deformation as a function of time. This previous work also identifies the ordinary nonlinear differential equation
corresponding to the upper convected Maxwell model (UCM), for which she finds no analytical solution. In this
paper, we explore the role of convected derivative by solving this UCM equation numerically by finite difference.
We extend the previous work to include sag by incorporating a finite initial sheet curvature. We treat free forming
step in thermoforming and find that the convected derivative makes the free forming time unreasonably sensitive
to the initial curvature. Whereas, for the CM model, we get a free forming time that is independent of initial
sheet curvature, so long as the sheet is nearly flat to begin with. We cast our results into dimensionless plots of
thermoforming times versus disk radius of curvature.
141 MSEC 2013 NAMRC 41

Constant temperature embossing of PEEK films
MSEC2013-1175
Ramasubramani Kuduva Raman Thanumoorthy, 3M Company, Woodbury, United States, Byung H. Kim, University
of Massachusetts Amherst, Amherst, MA, United States, Donggang Yao, Georgia Institute Of Technology, Atlanta,
GA, United States
A new variant of the hot embossing process has been conducted with amorphous PEEK films as a model material.
Constant Temperature Embossing (CTE) utilizes the crystallizing nature of amorphous polymers such as poly (ether
ether ketone) (PEEK), poly (ethylene terephthalate) (PET) and poly (ethylene naphthalate) (PEN) when heated
above their glass transition temperature to eliminate the thermal cycling. The key process parameters such as
embossing temperature and embossing time depend on the thermal behavior of the amorphous PEEK film.
Embossing studies were conducted using silicon tools with microchannel arrays of different aspect ratios and
the films were characterized using scanning electron microscopy and optical profilometry. The process enables a
simple isothermal embossing process for polymers that have a glass transition temperature well above the room
temperature, and also with a wide temperature gap between the glass transition temperature and melting point.
JUNE 10-14, 2013 // Madison, Wisconsin
142

Abstracts, cont.
Cloud manufacturing: Drivers, current status, and future trends
MSEC2013-1106
Dazhong Wu, Gatech, Atlanta, GA, United States, Matthew John Greer, Georgia Tech, Atlanta, GA, United States,
David Rosen, Georgia Institute of Technology, Marietta, GA, United States, Dirk Schaefer, Georgia Institute Of
Technology, Atlanta, GA, United States
Cloud Manufacturing (CM) refers to a customer-centric manufacturing model that exploits on-demand access
to a shared collection of diversified and distributed manufacturing resources to form temporary, reconfigurable
production lines which enhance efficiency, reduce product lifecycle costs, and allow for optimal resource loading
in response to variable-demand customer generated tasking. Our objective is to present the drivers, current status
of research and development, and future trends of CM. We also discuss the potential short term and long term
impacts of CM on various sectors.
143 MSEC 2013 NAMRC 41

Virtualize manufacturing capabilities in the cloud: Requirements and architecture
MSEC2013-1046
Xi Vincent Wang, Department of Mechanical Engineering, University of Auckland, Auckland, New Zealand, Xun Xu,
University of Auckland, Auckland, New Zealand
In recent years, Cloud Manufacturing concept has been proposed by taking advantage of Cloud Computing to
improve the performance of manufacturing industry. Cloud Manufacturing attempts can be summarized as two
sectors, i.e. manufacturing version of Computing Cloud, and a distributed environment that is networked around
Manufacturing Cloud. In this paper, manufacturing resource, ability and relevant essentials are discussed in the
service-oriented perspective. The functional requirements of a Cloud Manufacturing environment are discussed,
along with an interoperable manufacturing system framework. Cloud resource integration models are developed
that are compliant with existing international standards. It is possible to achieve a collaborative, intelligent, and
distributed environment via Cloud Manufacturing technologies.
JUNE 10-14, 2013 // Madison, Wisconsin
144

Abstracts, cont.
Study on the multi-granularity virtualization of manufacturing resources
MSEC2013-1174
Chunsheng Hu, Chengdong Xu, Xiaobo Cao, Pengfei Zhang, Beijing Institute of Technology, Beijing, Beijing, China
As a new kind of networked manufacturing mode, Cloud Manufacturing needs to construct a large-scale virtual
manufacturing resources pool firstly. For a reasonable and effective construction of the virtual manufacturing
resources pool, the point of multi-granularity virtualization is proposed. Firstly, by analyzing the process of resources
virtualization, the meanings of manufacturing resources, virtualization modeling and virtualization accessing
are stated, and the relationships between them are illustrated; secondly, by analyzing the compositionality of
resources, two resources categories are deduced; thirdly, the granularity factor, which have serious impacts on the
resources-virtualization, resources-matching and resources-scheduling, are discussed; finally, a multi-granularity
virtualization method of manufacturing resources is proposed.
145 MSEC 2013 NAMRC 41

A product configurator for cloud manufacturing
MSEC2013-1250
Arthur L.K Yip, Jonathan R. Corney, Ananda P. Jagadeesan, Yi Qin, University of Strathclyde, Glasgow, United
Kingdom
Product configurators have become an important enabler for enterprises to achieve product customization in
order to address individual customers requirements. Despite adoption across a wide range of application domains
from automotive to consumer goods, even state-of-the-art product configuration systems are limited in their
ability to quickly respond to changes in the production systems that deliver the goods specified. Enabled by the
emerging paradigm of cloud manufacturing, the authors propose a configurable configurator that is automatically
updated to reflect changes in the supply chain. The paper reports the ongoing research and development towards
a dynamically generated system that supports product configuration, visualization and assessment from the cloud
manufacturing concept of Manufacturing-as-a-Service (MaaS). In addition to outlining the architecture of such
a system, an overview of its modules and integration to the cloud manufacturing platform is described. Lastly,
the case study of a customizable façade module is presented with two different scenarios to demonstrate the
prototype implementation and validate the proposed approach.
JUNE 10-14, 2013 // Madison, Wisconsin
146

Abstracts, cont.
Effects of ultrasonic vibration-assisted pelleting of biomass on sugar yield in biofuel manufacturing with different
pretreatment methods
MSEC2013-1143
Elizabeth Kennedy, Pengfei Zhang, Kansas State University, Manhattan, KS, United States, Qi Zhang, Kansas State
University, Manhattan, KS, United States, Zhijian Pei, Kansas State University, Manhattan, KS, United States, Donghai
Wang, Kansas State University, Manhattan, KS, United States
The importance of finding an alternative fuel source to petroleum based fuels is in high demand. There are many
concerns taking place due to the reliability and sustainability of these petroleum fuels. One promising alternative
is cellulosic biofuels. These cellulosic biofuels offer numerous benefits for the environment compared to those of
petroleum based and grain based fuels. Cellulosic biofuels have the capability of counteracting more gasoline and
petroleum than grain-based fuels can and the cellulosic biofuels can do this with co-benefits for the environment.
However, there are some obstacles in the way of manufacturing the cellulosic biofuels at a large scale and doing so
cost effectively. It is known that ultrasonic vibration-assisted (UV-A) pelleting increases the density of the cellulosic
material due to the compression of the biomass into a pellet. To date the pretreatment process typically involves
the use of an acid (usually sulfuric acid). At present, the effects of sugar yield on wheat straw powder and pellets
with the use of hot water instead of acid have not been tested. This paper reports an experimental investigation of
the effects on sugar yield when using hot water during the hydrolysis process compared to acid. The investigation
includes the pretreatment process using 2 mm wheat straw powder and pellets.
147 MSEC 2013 NAMRC 41

Numerical modeling of specific energy consumption in machining process
MSEC2013-1247
Tonghui Li, University of Wisconsin-Milwaukee, Milwaukee, WI, United States, Chris Yuan, University of Wisconsin
Milwaukee, Milwaukee, WI, United States
Prediction and estimation of energy consumption of machining process are important for the optimization of
the machining process and the environmental impact of manufacturing. Two energy consumption models are
proposed in this paper. A novel numerical model is presented to roughly estimate the specific energy consumption
(SEC) of a machining process based on the nameplate spindle power of the machine and the material removal rate
(MRR). This model is validated and analyzed by experimental data from a variety of sources. The application range
of the proposed model has been investigated. Another accurate SEC model, which is based on a specific machine
and machine tool, is established for accurate energy consumption prediction. The accurate model is tested to have
a confidence range of 97%.
JUNE 10-14, 2013 // Madison, Wisconsin
148

Abstracts, cont.
Analytic stochastic modeling of dynamic wheel topography in superabrasive grinding
NAMRC41-1509
Jacob Kunz, J. Mayor, Georgia Institute of Technology, Atlanta, United States
Superabrasive grinding wheels are used for machining hard materials using various grinding approaches. The
desire for improved final geometric accuracy and process reliability in new technologies such as microgrinding
leads to the need for improved process modeling that can capture the stochastic characteristics of the cutting
abrasives on the wheel. Analytic stochastic propagation is proposed as a method to calculate the expectation and
variance of the dynamic grit density in superabrasive grinding wheels utilizing only a pirori stochastic descriptions
of grit size spatial distribution. Results show that the analytic model produces statistical dynamic grit density
estimators that are consistent with both simplified and more complex numerical simulations but yields the benefits
of 97.1% decrease in modeling time without the error variances from sampling issues. The dynamic grit density was
shown to have a Gaussian distribution with a mean and standard deviation that increase with a power-law trend as
the infeed angle is increased. However, the standard deviation has more impact at lower infeed angles where fewer
grits participate in grinding. The dynamic grit density variance is seen to be as much as 45% of the dynamic grit
density mean in superabrasive microgrinding wheels where the small number of grits within the wheel allow for
large statistical variation.
149 MSEC 2013 NAMRC 41

Aluminum oxide nanoparticle mixed UV-curable resin study in fabrication of lapping plate
NAMRC41-1528
Lei Guo, University of Toledo, Toledo, OH, United States, Ioan D. Marinescu, University of Toledo, Toledo, OH, United
States
Ultraviolet-curable resins are widely applied in modern industry and recently some researchers have used them
as a bonding material in manufacturing of abrasive machining tools, such as grinding wheel, polishing pad and
lapping plate. This paper proposes a method to improve the material properties of the bonding material and the
lapping performance of resin bonded lapping plate by adding aluminum oxide nanoparticles. The material and
mechanical properties of the abrasive diamond and resin mixtures were analyzed by tensile test, hardness and
abrasion test, as well as the lapping experiments is introduced to see the improvement. The nanoparticle additives
increase the mechanical strength and elastic modulus of the resin significantly. Moreover, the wear resistance
improves due to the sufficient resin aggregation by nanoparticle. Thus, it can be concluded that it is possible to
improve the material removal efficiency and increase the service time of the UV-curable resin bonded machining
tools by adding nano particle additives.
JUNE 10-14, 2013 // Madison, Wisconsin
150

Abstracts, cont.
The effect of thermal softening on the ductile-to-brittle transition of sapphire
NAMRC41-1588
Deepak Ravindra, Micro-LAM Technologies, Battle Creek, Michigan, United States, John Patten, Western Michigan
University, Kalamazoo, MI, United States
Advanced engineered ceramics such as sapphire are increasingly being used for industrial applications as they are
are hard, strong, inert, light weight and have great optical and electrical properties. Manufacturing this material
without causing surface and subsurface damage is extremely challenging due to their high hardness, brittle
characteristics and poor machinability. However, ductile regime machining of these materials is possible due to the
high pressure phase transformation (HPPT) occurring in the material caused by the high compressive and shear
stresses induced by the single point diamond tool tip. To further augment the ductile response of the machined
material, traditional single point scratch tests are coupled with a micro-laser assisted machining (µ-LAM) technique.
This paper discusses the effect of laser heating on the ductile response of single crystal c-plane sapphire.
151 MSEC 2013 NAMRC 41

AN IMPROVED EMPIRICAL CONSTITUTIVE MODEL FOR GAMMA PRIME-STRENGTHENED NICKEL-BASED
SUPERALLOYS
NAMRC41-1598
Yujie Chen, Clemson University ICAR, Greenville, SC, United States, Cristina Bunget, Clemson University - ICAR,
Greenville, SC, United States, Laine Mears, Clemson University ICAR, Greenville, SC, United States, Thomas Kurfess,
Georgia Institute of Technology Georgia W. Woodruff School of Mechanical Engineering, Atlanta, GA, United States
Advanced superalloys were developed for high performance systems such as jet engines, internal combustion
engines and gas turbines. Nickel-based superalloys are strengthened by the Gamma Prime-phase, through
various mechanisms, such as lattice parameter mismatch, coherent strain, or anti-phase boundary. Due to the
changing of lattice parameters of Gamma-phase and Gamma Prime-phase at various temperature, the deformation
mechanisms perform anomalously. The objective of this research is to develop a constitutive model for nickelbased
superalloys, which could be further implemented in finite element analysis. In order to derive an accurate
constitutive model, strain hardening function, thermal sensitivity function, and flow softening function were
determined. Also, piece-wise method was applied as a function of the temperature ranges. The novel constitutive
model proposed for superalloys was compared with experimental results (flow stress) and a good agreement was
found for a temperature range from 294K to 1144K.
JUNE 10-14, 2013 // Madison, Wisconsin
152

Abstracts, cont.
ANALYSIS OF VARIANCE BASED PREDICTIVE MODEL FOR SURFACE ROUGHNESS IN END MILLING OF IN 718
NAMRC41-1609
Wei Li, University of Alabama, Tuscaloosa, AL, United States, Yuebin Guo, University Of Alabama, Tuscaloosa, AL,
United States
Tool flank wear during milling adversely affects surface integrity and, therefore, product performance of machined
components. Surface integrity and machining accuracy deteriorate when tool wear progresses. In this paper, the
effects of process parameters including cutting speed, feed, radial depth of cut, and tool flank wear, on surface
roughness of IN 718 alloy (45 ± 1 HRC) by milling using PVD coated tools have been studied. Surface roughness in
both feed and step-over directions under a variety of milling conditions was characterized. Three levels of tool flank
wear (VB = 0, 0.1mm, 0.2mm) were used in the experiments. At each level of tool wear, the effects of cutting speed,
feed, and radial depth-of-cut on surface roughness were investigated, respectively. Based on analysis of variance
(ANOVA), a predictive model of milled surface roughness has been developed by incorporating tool wear and
process parameters.
153 MSEC 2013 NAMRC 41

TIME-DEPENDENT EFFECTS OF CONTACT PERTURBATION IN MACHINING
NAMRC41-1610
James Mann, M4 Sciences LLC, West Lafayette, IN, United States, Christopher Saldana, Pennsylvania State University,
University Park, United States
The present study characterizes the effects of modulation amplitude on forces and specific energies in machining
of AA6061-T6. These effects are correlated with tool load duty cycles that vary directly with modulation amplitude.
Closed-form expressions were derived to evaluate fraction of time spent cutting in the presence of modulation.
The duty cycle ratio ranges from 1 to 0.5 depending on the modulation amplitude used for a specific modulation
frequency and spindle frequency combination. When the duty cycle decreased, average machining forces rise
while the apparent average machining forces and specific energies both decrease. Use of apparent average
machining forces for describing tool load profiles was found to be tenuous as maximum load on the tool
actually increases in the presence of modulation. The ability to modify the fraction of time spent cutting has
direct implications for affecting changes in thermal dissipation and interface lubrication, which are important in
characterizing the effects of machining conditions on surface integrity and cutting tool performance.
JUNE 10-14, 2013 // Madison, Wisconsin
154

Abstracts, cont.
Experimental investigation and modeling of milling burrs
MSEC2013-1176
Seyed Ali Niknam, Victor Songmene, Dept. of Mechanical Engineering, Ecole de Technologie Superieure (ETS),
Montreal, QC, Canada
The burr formation is one of the most common and undesirable phenomenon occurring in machining operations
which reduces assembly and machined part quality. Therefore, it is desired to eliminate the burrs or reduce the
effort required to remove them. This paper presents the results of an experimental study and describe the influence
of cutting parameters on slot milling burrs, namely top burrs and exit burrs. Statistical methods are also used to
determine the controllability of each burr. A computational model is then proposed to predict the exit up milling
side burr thickness based on cutting parameters and material properties such as yield strength and specific cutting
force coefficient that are the only unknown variables in the model. The proposed computational model is validated
using experimental results obtained during slot milling of 2024-T351 and 6061-T6 aluminum alloys.
155 MSEC 2013 NAMRC 41

An experimental study on edge chipping in ultrasonic vibration assisted grinding of bio-ceramic materials
MSEC2013-1188
Hayelom Tesfay Tesfay, Yuzhu Xie, North Carolina Agricultural & Technical State University, Greensboro, NC, United
States, Zhigang Xu, North Carolina Agricultural & Technical State University, Greensbroo, NC, United States, Bing
Yan, Tianjin University of Technology & Education, Tianjin, Tianjin, China, Zhichao Li, North Carolina Agricultural &
Technical State Univ., Greensboro, NC, United States
Bio-ceramics have been widely employed in dental restorations, repairing bones, and joint replacements etc.
due to their high compressive strength, superior wear resistance, and natural aesthetical appearance. Abrasive
machining processes such as grinding have been used to obtain a smooth surface and desired dimensions for
bio-ceramic parts. However, a major technical issue resulted from abrasive machining processes is edge chipping.
The edge chipping could lead to the failure of bio-ceramics and has to be removed by downstream processes
like lapping or polishing. It not only increases machining cost but also introduces potential deficiencies into the
bio-ceramic parts. This paper presents an experimental study on the edge chipping in ultrasonic vibration assisted
grinding (UVAG) of bio-ceramic materials. An innovative UVAG system is developed and employed to machine
three bio-ceramic materials (Lava, partially fired Lava, and Alumina). The effect of ultrasonic vibration on the edge
chipping is investigated by observing under scanning electron microscope (SEM). The experimental results show
that the edge chipping can be significantly reduced with the assistance of ultrasonic vibration. The UVAG system
developed has a great potential to be used in production to improve bio-ceramic materials surface integrity, in
particular, edge chipping quality.
JUNE 10-14, 2013 // Madison, Wisconsin
156

Abstracts, cont.
Analysis of 1D abrasive vibratory finishing using acoustic emission
MSEC2013-1210
Pradeep K. Prakasam, Sathyan Subbiah, Nanyang Technological University, Singapore, Singapore
Acoustic emission (AE) is one of the widely used non-destructive methods for monitoring and control of machining
processes. Vibratory finishing is a surface modification process used for polishing, deburring, and finishing of
components in aerospace, automotive and other manufacturing industries. The polishing action takes place due
to the action of abrasive particles called media on the components subjected to finishing. The media motion
is complex involving a combination of normal and oblique impacts, scratching and rolling. This work deals
with the characterization of the basic types of media contact occurring in the vibratory finishing process using
acoustic emission signals. A novel one dimensional vibratory simulator has been developed for this purpose
using a tribometer setup. The one dimensional simulator has been used to differentiate between the normal and
scratching types of media contact and corresponding AE signals have been measured. The preliminary results
shows that the AE signals obtained for the normal and scratching type of contacts are different. In addition to this,
AE signals have also been used to characterize the input parameters such as frequency of vibration and amount of
media.
157 MSEC 2013 NAMRC 41

Low volume aluminum forging using metal based rapid prototyping of dies
NAMRC41-1513
Kuldeep Agarwal, Minnesota State University, Mankato, United States, Rajiv Shivpuri, Ohio State University,
Columbus, OH, United States, Sailesh Babu, Xiaomin Cheng, The Ohio State University, Columbus, OH, United States
Closed die forgings are highly competitive for large volume production but not viable for small run aluminum
forgings commonly encountered in helicopter industry. One of the main hindrances for using forgings in this
industry is die manufacturing time. The primary objective of this study was to investigate the feasibility of die
manufacturing times using rapid prototyping (RP) techniques. Direct metal RP technique, Prometal 3D printing
was selected for this evaluation. Material validation was done for physical and mechanical properties, heat transfer
and friction under forging conditions were determined for this material system and flow stress at room and
elevated temperatures was calculated. Forging die for a component was manufactured using this technique and
forging trials were done to establish its feasibility. The results show that proper die design and selection of process
parameters can result in forging of satisfactory parts from dies made from metal based RP technique.
JUNE 10-14, 2013 // Madison, Wisconsin
158

Abstracts, cont.
Innovative hybrid process in metal forming
NAMRC41-1550
Andreas Jäger, Institute of Forming Technology and Lightweight Construction, Dortmund, Germany, Alessandro
Selvaggio, Stephan Hänisch, Matthias Haase, Christoph Becker, Jörg Kolbe, Noomane Ben Khalifa, A. Erman Tekkaya,
Institute of Forming Technology and Lightweight Construction, TU Dortmund University, Dortmund, Germany
Various hybrid metal forming processes are presented, based on the simultaneous and controlled interaction
of process mechanisms, energy sources or tools that have a significant effect on the process performance and
result. For the production of composite metal structures made of a sheet metal and a bulk metal component a
new process combination of deep drawing and cold forging was developed and tested. Curved profile extrusion
and twisted profile extrusion are used to produce curved or twisted profiles by deflecting the extrudate at the
press using a guiding tool. By applying electromagnetic compression subsequent to hot extrusion, profiles with
locally adapted cross section geometries can be manufactured. Hot extrusion and integrated equal channel
angular pressing are used to improve the mechanical properties of aluminum profiles. Simultaneous application
of injection molding and sheet metal forming process was used to produce lightweight, functional metal-plastic
hybrids. By incremental tube forming, as a combination of a tube spinning and a tube bending process, bent
structures with variable tube diameters can be produced.
159 MSEC 2013 NAMRC 41

Experimental study of electro-plastic effect on advanced high strength steels
NAMRC41-1562
Xun Liu, Shuhuai Lan, University of Michigan, Ann Arbor, United States, Jun Ni, University Of Michigan, Ann Arbor,
MI, United States
The Electro-Plastic Effect describes material softening phenomenon induced by current during plastic deformation,
which shows its potential applications in improving various traditional manufacturing processes. This paper
addressed Electro-Plastic Effect on specifically one group of Advanced High Strength Steel (AHSS), Transformation
Induced Plasticity steel, TRIP 780/800, from perspectives of both mechanical properties and microstructural
evolutions. Uniaxial tensile tests were performed under different current densities. Both a drop of plastically flow
stress and an increase of elongation have been observed. The underlying mechanism was further investigated
through X-Ray Diffraction and metallurgical observations. It was revealed that the phase transformation process
from retained austenite into martensite was retarded by the applied current pulses. Besides, finer grain distribution
with electropulsing treatment indicated accelerated dynamic recrystallization at relatively low temperature. These
microstructure analysis results were in accord with the observed mechanical behaviors.
JUNE 10-14, 2013 // Madison, Wisconsin
160

Abstracts, cont.
Melt pool flow and surface evolution during pulsed laser micro polishing of Ti6Al4V
MSEC2013-1117
Chao Ma, Madhu Vadali, University of Wisconsin - Madison, Madison, WI, United States, Neil Duffie, University Of
Wisconsin, Madison, WI, United States, Frank Pfefferkorn, University of Wisconsin- Madison, Madison, WI, United
States, Xiaochun Li, University of Wisconsin - Madison, Madison, WI, United States
Extensive experimental work has shown that pulsed laser micro polishing (PLµP) is effective for polishing micro
metallic parts. However, the process physics have not been fully understood yet, especially with respect to the
melt pool flow. A reliable physical model can be of significant assistance in understanding the fluid flow in the
melt pool and its effect on PLµP. In this paper, a two-dimensional axisymmetric transient model that couples heat
transfer and fluid flow is described that was constructed using the finite element method. The model not only
provided the solutions to the temperature and velocity fields but also predicted the surface profile evolution on a
free deformable surface. The simulated melt depth and resolidified surface profiles matched those obtained from
optical images of PLµPed sample cross-sections. The model was also used to study the effect of laser pulse duration
on the melt pool flow. The study suggests that longer pulses produce more significant fluid flows. The cut-off pulse
duration below which minimal fluid flows should be expected was estimated to be 0.66 µs for Ti6Al4V, which also
matched well with the experimental results. It is evident that the coupled model offers reliable predictions and
thus can be extended for a more complex parametric study to provide further insights for PLµP.
161 MSEC 2013 NAMRC 41

Residual stress analysis and weld bead shape study in laser welding of high strength steel
MSEC2013-1102
Wei Liu, Kong Fanrong, Radovan Kovacevic, Southern Methodist University, Dallas, TX, United States
The X-ray diffraction (XRD) technique is employed to measure residual stress induced by the laser welding of 6.7
mm thick ASTM A514 high strength steel plates. The distribution of residual stress in the weld bead is investigated.
The results indicate that the fusion zone (FZ) has the maximum tensile stress, the transition from tensile to
compressive stress tends to appear in the heat affected zone (HAZ), and the initial stress far from the weld center
are not influenced by the welding process. Based on the measurement data, the influence of the laser power and
the welding speed on residual stress is obtained. The magnitude of residual stress near the weld bead increases
with an increase in laser power or a decrease in welding speed. The welds with incomplete penetration have a
considerably lower magnitude of residual stress in FZ than ones with full penetration. Post-weld heat treatment is
utilized to relieve residual stress in the weld bead. Although residual stress is not completely relieved after the heat
treatment, a dramatically reduced magnitude and much more uniform distribution are achieved. In addition, the
effects of the laser power, the welding speed, the laser spot diameter, and the gap between two plates on the weld
shape are also studied.
JUNE 10-14, 2013 // Madison, Wisconsin
162

Abstracts, cont.
Effects of interfacial geometry on laser joining of dissimilar NiTi-SS wires
MSEC2013-1204
Grant Brandal, Gen Satoh, Columbia University, New York, NY, United States, Y. Lawrence Yao, Columbia University,
New York, NY, United States, Syed Naveed, Boston Scientific Corporation, Marlborough, MA, United States
Joining of the dissimilar metal pair NiTi to stainless steel is of great interest for implantable biomedical applications.
Formation of brittle intermetallic phases requires that the joining processes limit the amount of over-melting and
mixing along the interface. Thus, laser joining is a preferred method due to its ability to precisely control heat input.
This study explores a method of using a cup and cone interfacial geometry, with no filler material, to increase the
tensile strength of the joint. Not only does the cup and cone geometry increase the surface area of the interface,
but it also introduces a shear component, which is shown to be beneficial to tensile strength of the wire as well.
The fracture strength for various cone apex angles and laser powers is determined. Compositional profiles of the
interfaces are analyzed. A numerical model is used for explanation of the processing.
163 MSEC 2013 NAMRC 41

Mechanical behavior of Ti-6Al-4V manufactured by electron beam additive fabrication
MSEC2013-1105
Lalit Roy, University of Alabama, Tuscaloosa, United States, Leila Jannesari Ladani, University of Alabama, Tuscaloosa,
AL, United States
Additive Layer Fabrication, in particular Electron Beam Additive Fabrication (EBAF), has recently drawn much
attention for its special usability to fabricate intricately designed parts as a whole. It not only increases the
production rate which reduces the production lead time but also reduces the cost by minimizing the amount of
waste material to a great extent. Ti6Al4V is the most common type of material that is currently being fabricated
using EBAF technique. This material has been used in aerospace industry for several reasons such as excellent
mechanical properties, low density, great resistance to corrosion, and non-magnetism. The effects of build
direction of layers (namely, addition of layers along one of the x, y & z directions with respect to the build table) and
the anisotropy effect caused by it has not been explored vigorously. This anisotropy effect has been investigated in
this work. Different mechanical properties such as Yield Strength (YS), Ultimate Tensile Strength (UTS), and Modulus
of Elasticity (E) of these three types of Ti6Al4V are determined using tensile tests and are compared with literature.
The tensile test results show that YS and UTS for flat-build samples have distinguishably higher values than those of
the side-build and top-build samples.
JUNE 10-14, 2013 // Madison, Wisconsin
164

Abstracts, cont.
Characterizations of sintered Ti-6Al-4V powders in electron beam additive manufacturing
MSEC2013-1131
Xibing Gong, Y. Kevin Chou, Ph.D., The University of Alabama, Tuscaloosa, AL, United States
In the powder-based electron beam additive manufacturing (EBAM) process, preheating is applied, prior to the
melting stage, to aggregate precursor powders and to reduce the residual stresses in the build parts. Preheating
results in sintering of the powders, which serve as the initial work material for the subsequent melting stage.
In this study, sintered Ti-6Al-4V alloy powders from preheating were obtained and studied. The specimens of
sintered powders, also processed to prepare metallographic samples, were observed and characterized by optical
microscopy (OM) and scanning electron microscopy (SEM). The results show that after preheating, some powders
are partially melted and necks between adjacent particles are formed with metallurgical bonds. The sintering
evidence, necking, can be noted on both the build plane and the side surface (normal to the build plane). The
Baktetwave - structure is identified in the powders, while the martensitic structure is formed in the solid EBAM
part.
165 MSEC 2013 NAMRC 41

Improving densification of zirconium tungstate with nano tungsten trioxide and sintering aids
MSEC2013-1159
Mingang Wang, Michigan State University, East Lansing, MI, United States, Patrick Kwon, Michigan State University,
East Lansing, MI, United States
Because of the highly negative thermal expansion coefficient, zirconium tungstate (ZT) offers a unique opportunity
in engineering applications. However, processing of ZT has not been fully perfected to yield a near thoeretical
density. Thus, ZT has relatively a weak strength, which prevented its unique property to be fully utilized in
applications. This study investigates the processing methods to improve the packing and subsequent final densities
thus improving the mechanical strength. These methods include (1) use of a wide variety of powders with different
size, (2) use of nano-powders and (3) use of sintering aids. Under the same compaction and sintering condition, a
variety of powder mixtures were produced, whose initial packing density and final sintered density were measured
and compared in order to determine the optimal combination. The elastic modulus of each sample was also
tested. By adding nanopowders, the sintered density of zirconium tungstate can be enhanced by 5%. Furthermore,
with the sintering aids, the density can be improved by additional 5%. The optimal amount of nanopowders and
sintering aids were determined to improve the final density and strength.
JUNE 10-14, 2013 // Madison, Wisconsin
166

Abstracts, cont.
Modeling of multi-cell lithium-ion battery packs for electric vehicles considering effects of manufacturing
processes
MSEC2013-1120
Chongye Wang, Yong Wang, Lin Li, Ph.D., University of Illinois at Chicago, Chicago, IL, United States, Hua Shao,
Shanghai Jiao Tong University, Shanghai, Shanghai, China, Changxu Wu, State University of New York (SUNY)-
Buffalo, Buffalo, NY, United States
Electric vehicle (EV) technologies have received great attention due to the potential contributions to relieving the
energy dependence on petroleum and reducing carbon dioxide emissions. The advancement of EV technologies
greatly relies on the development of battery technologies. Lithium-ion (Li-ion) batteries have recently become the
main choice as the power source for major EV manufacturers. Previous research on EV Li-ion batteries is mainly
focused on materials and chemical properties of single cells, while the effects of manufacturing processes on
the performance of entire battery packs have almost been neglected. In practice, EV batteries are used in packs
containing multiple cells, which may not be ideally manufactured. This research proposes a novel modeling
method for analyzing the effects of manufacturing processes on the dynamics of EV Li-ion battery packs. The
method will help engineers gain a deeper understanding of the roles of manufacturing processes in improving EV
Li-ion battery performance.
167 MSEC 2013 NAMRC 41

Modeling, analysis and improvement of door production line at an automotive body shop
MSEC2013-1155
Cong Zhao, Jingshan Li, University of Wisconsin-Madison, Madison, WI, United States
In this paper, we introduce a case study of modeling, analysis, and continuous improvement of a door production
line at an automotive body shop using production systems engineering methods. Analytical models have
been developed, and recursive procedures have been derived to evaluate line production rate. An arrow-based
bottleneck analysis method is introduced to identify the bottlenecks, whose improvement can lead to the largest
improvement in system performance. Such methods provide a quantitative tool for plant engineers and managers
to operate and improve door production line to achieve high productivity, and are also applicable to other large
volume manufacturing systems.
JUNE 10-14, 2013 // Madison, Wisconsin
168

Abstracts, cont.
Beneficial effects of solid lubricant mixture assisted machining
NAMRC41-1524
Narala Suresh Kumar Reddy, BITS Pilani Hyderabad Campus, HYDERABAD, India, H A Kishawy, UOIT, Oshawa,, ON,
Canada
Machining of high strength materials is associated with generation of high Machining of high strength materials
is associated with generation of high cutting temperature, which results in premature failure of cutting tools and
hence there is a need to look into new machining methods to withstand high temperature generation. In this
research work, the feasibility of an approach for developing a new generation of machining technique namely
Solid Lubricant mixture assisted machining has been envisaged with an aim to eliminate the use of cutting fluids
in machining operation. This approach is based on a concept of supplying solid lubricant mixture as a high velocity
jet for specific hard turning of mold steel, thus meeting environmental requirements. A detailed comparison has
been made with wet, dry and MQL machining. It can concluded that the present research work helps to provide a
better understanding of solid lubricant assisted machining, to enhance the performance of machining process, and
consequently to improve productivity.
169 MSEC 2013 NAMRC 41

Cooling capability of cutting fluids in grinding
NAMRC41-1553
Guoxu Yin, Ioan D. Marinescu, University of Toledo, Toledo, OH, United States
In modern industry, cutting fluids is a good choice for cooling and lubrication in common grinding. This paper set
up a new formula to describe the cooling capability of cutting fluids and with experiment, showing the tendency
of cooling in the process and find what kind of properties can affect this capability in grinding.
JUNE 10-14, 2013 // Madison, Wisconsin
170

Abstracts, cont.
Effect of fluid concentration in titanium machining with an atomization-based cutting fluid (ACF) spray system
NAMRC41-1565
Chandra Nath, Shiv Kapoor, University of Illinois at Urbana-Champaign, Urbana, IL, United States, Anil K. Srivastava,
Jon Iverson, Techsolve Inc, Cincinnati, OH, United States
The aim of this work is to investigate the effect of metal-working fluid (MWF) concentration on the machining
responses including tool life and wear, cutting force, friction coefficient, chip morphology, and surface roughness
during the machining of titanium with the use of the ACF spray system. Five different concentrations from 5 to
15% of a water-soluble metalworking fluid (MWF) were applied during turning of a titanium alloy, Ti-6Al-4V. The
thermo-physical properties such as viscosity and surface tension of these concentrations were also measured. The
test results demonstrate that the tool life first extends with the increase in MWF concentration and then drops with
further increase. At low concentration (e.g. 5%), a lack of the lubrication effect causes to increase in a higher friction
at the tool-chip interface resulting in severe chipping and tool nose/flank wear within a short machining time. On
the other hand, at high concentration, the cooling effect is less. This increases cutting temperature and a faster
thermal softening/chipping/notching of the tool material and higher friction at the tool-chip-workpiece interaction
zones resulting in early tool failure. A good balance between the cooling and the lubrication effects seems to be
found at the 10% MWF concentration as it offers the best machining performance.
171 MSEC 2013 NAMRC 41

Chip segmentation in machining: A study of deformation localization characteristics in Ti6Al4V
MSEC2013-1070
Abhijit Chandra, Iowa State University, Ames, IA, United States, Pavan K. Karra, Trine University, Angola, IN, United
States, Jie Wang, Gap-Yong Kim, Iowa State University, Ames, IA, United States, Adam Bragg, Flint Hills Resources,
Rosemount, MN, United States
Chip segmentation by deformation localization is an important process in a certain range of velocities and might
be desirable in reducing cutting forces and by improving chip evacuation, whereas few studies of practical criteria
to calculate shear band spacing are available in literature. This paper extends nonlinear dynamics model for chip
segmentation by allowing time varying orientation of the shear plane that are pronounced in strain hardening
materials. The model extended the non-linear dynamics approach with additional state variables to the Burns
and Davis approach. The model is simulated numerically to predict the shear bands of the chip. The numerical
simulation of the model is compared with experimental observations and is in agreement with experimental
observations in Ti6Al4V. This offers guidance to predict shear band spacing of other materials.
JUNE 10-14, 2013 // Madison, Wisconsin
172

Abstracts, cont.
The establishment of coupled electromagnetic-thermal analytical model of induction heating system with
magnetic flux concentrator and the study on the effect of magnetic permeability to the modeling
MSEC2013-1140
Tianxing Zhu, Xuekun Li, Feng Li, Tsinghua University, Beijing, China, Yiming(Kevin) Rong, Worcester Polytechnic
Institute, Worcester, MA, United States
Induction heating is frequently used in the metalworking industry to heat metals for hardening, soldering, brazing,
tempering and annealing. Due to its complexity, the using of simulation to analyze the induction heating process
could become very advantageous both in design and economic aspects. In this paper, an analytical model is
established using commercial package Cedrat Flux® 10.3, and the model is verified by the experiments. After the
establishment of analytical model, an analysis on the effect of workpiece magnetic permeability to the modeling
was conducted.
173 MSEC 2013 NAMRC 41

Progressive modeling: Introducing a new system modeling and optimization paradigm and its application to the
reconfiguration and operations planning problem part I
MSEC2013-1231
Mohamed Ismail, University of Regina, Regina, SK, Canada
In this paper, the progressive modeling approach and the Reconfiguration and Operation Planning (ROP) problem
are introduced. Progressive Modeling (PM) is a forward-looking multi-disciplinary modeling approach that has
been developed to modernize the modeling process of today’s complex industrial problems and create pragmatic
solutions for many of them. Many principles and foundations of progressive modeling will be presented while
utilizing the reconfiguration and operation planning problem (ROP) as a demonstrating application. The ROP
problem describes a new approach of reconfiguration and operations planning in a reconfigurable manufacturing
environment. PM is about to spark a new paradigm of solving large-scale system problems in many engineering
and business domains in a highly pragmatic way without losing the scientific rigor.
JUNE 10-14, 2013 // Madison, Wisconsin
174

Abstracts, cont.
Joint maintenance and production planning by maintenance-optimal swapping
MSEC2013-1076
Ahmad Almuhtady, Seungchul Lee, University of Michigan, ANN ARBOR, MI, United States, Jun Ni, University Of
Michigan, Ann Arbor, MI, United States
Degradation is an inevitable course of any manufacturing tool, machine or system. The degradation of the health
state of manufacturing tools results in some sort of an ineludible maintenance action which could be both costly
and occurring during critical production time. In many manufacturing systems, a fleet of identical machines
are assigned different tasks (or products) towards satisfying production requirements. We re-introduce the
maintenance-optimal resource allocation planning scheme (presented in MSEC2012) and focus on the solution
of the generated mathematical model. The planning scheme, denoted as Degradation Based Optimal Swapping
(DBOS), incorporates the optimal implementation of swapping scheduled tasks (or products) and allocating
maintenance actions throughout a finite time horizon. The objective is to minimize projected maintenance
costs and/or utilize the manufacturing productivity towards prescribed logistics and/or production goals. A
DBOS-specific branch-and-bound-based optimization algorithm is developed to address the complexity in the
generated model. Numerical results will demonstrate the effectiveness of the algorithm in comparison to standard
optimization algorithms. DBOS planning scheme coupled with the proposed algorithm succeeds in establishing
substantial savings in the simulated case studies which amount up to 70% of the estimated maintenance costs in
comparison to the scenario where fixed scheduling is applied.
175 MSEC 2013 NAMRC 41

Multi-zone proportional hazard model for a multi-stage degradation process
MSEC2013-1113
Lin Li, Ph.D., Zeyi Sun, University of Illinois at Chicago, Chicago, United States, Xinwei Xu, U of Michigan, Ann Arbor,
MI, United States, Kaifu Zhang, Northwestern Polytechnical University, Xian, China
Conditional-based maintenance (CBM) decision-making is of high interests in recent years due to its better
performance on cost efficiency compared to other traditional policies. One of the most respected methods based
on condition-monitoring data for maintenance decision-making is Proportional Hazards Model (PHM). It utilizes
condition-monitoring data as covariates and identifies their effects on the lifetime of a component. Conventional
modeling process of PHM only treats the degradation process as a whole lifecycle. In this paper, the PHM is
advanced to describe a multi-zone degradation system considering the fact that the lifecycle of a machine can be
divided into several different degradation stages. The methods to estimate reliability and performance prognostics
are developed based on the proposed multi-zone PHM to predict the remaining time that the machine stays at
the current stage before transferring into the next stage and the remaining useful life (RUL). The results illustrate
that the multi-zone PHM effectively monitors the equipment status change and leads to a more accurate RUL
prediction compared with traditional PHM.
JUNE 10-14, 2013 // Madison, Wisconsin
176

Abstracts, cont.
Methodology for ball screw component health assessment and failure analysis
MSEC2013-1252
Wenjing Jin, Yan Chen, Ph.D., Jay Lee, University of Cincinnati, CINCINNATI, Ohio, United States
The ball screw system is one of the most critical components in advanced manufacturing and is expected to
perform with high accuracy. However, any potential failures or degradation of mechanical parts in the system
would affect its efficiency and position precision; even cause severe machining errors or breakdown. This paper
mainly focuses on the fault diagnosis of ball screw system components. In order to classify multiple failure modes,
one full size ball screw testing machine is set up to replicate different health conditions including four failure
modes — lubrication starvation, preload loss, ball nut wear, and re-circulation system failure. In this paper, the
first two failure modes are introduced. Time domain and frequency domain features have been extracted from
the vibration and temperature signals. A classification modeling method is used to establish a ball screw system
health map. The direction of the threads on the screw shaft causes different vibration patterns when ball nut
travels forward and backward. Thus, failure signatures from both traveling directions are investigated in the paper.
Based on the developed health map for the ball-screw, the health values can be calculated to quantify the failure
severity. Furthermore, from the perspectives of accuracy and online application efficiency, three health assessment
methods, Self-Organizing Map - Minimum Quantization Error (SOM-MQE), Mahalanobis distance (MD) and Gaussian
Mixture Model (GMM) are compared in the study.
177 MSEC 2013 NAMRC 41

An integrated approach to metrology
MSEC2013-1019
Brian Funtik, Chrysler LLC, Beverly Hills, MI, United States
An end-to-end integrated metrology system is a process by which the metrological requirements for a product
are defined early in the product design cycle and seamlessly communicated to downstream users. The resulting
inspection data is stored and is made available for analysis and reporting.
An integrated metrology system offers a means to improve process efficiency and data accuracy compared to a
traditional metrology system and also offers secondary benefits such as the inclusion of software-enabled best
practices and enterprise-wide transparency of information. This paper will explain one approach to an integrated
metrology system and will provide a high level overview of the metrology process: generation of nominal
dimensions with associated tolerances, measurement planning, creation of a Computer Numerical Control (CNC)
program for a Coordinate Measuring Machine (CMM), data collection, data storage, and reporting.
JUNE 10-14, 2013 // Madison, Wisconsin
178

Abstracts, cont.
Alternative control of an electrically-assisted tensile forming process using current modulation
MSEC2013-1197
Joshua Jones, Clemson University, Greenville, SC, United States, Laine Mears, Clemson University, Anderson, SC,
United States
Electrically-assisted forming is a technique whereby metal is deformed while simultaneously undergoing electric
current flow. Electric current level becomes a new degree of freedom for process control. In this work we present
some alternative control architectures allowing for new avenues of control using such a process. The primary
findings are architectures to allow for forming at constant force and forming at constant stress level by modulating
electric current to directly control material strength. These are demonstrated in a tensile forming operation, and
found to produce the desired results. Combining these control approaches with previous and contemporary efforts
in modeling of the process physics will allow for system identification of material response properties and modelbased
control of difficult-to-observe process parameters such as real time temperature gradients.
179 MSEC 2013 NAMRC 41

Empirical modeling of direct electric current effect on machining cutting force
MSEC2013-1229
Elizabeth Jones, Clemson University, Clemson, SC, United States, Joshua Jones, Clemson University, Greenville, SC,
United States, Laine Mears, Clemson University, Anderson, SC, United States
Metallic materials can be made more ductile and be formed at lower forces through the application of electrical
current during deformation, termed Electrically-Assisted Forming (EAF). The current provides a degree of resistive
heating, but also facilitates deformation by direct electrical mechanisms (termed the electroplastic effect). It is
envisioned that this approach, currently applied to deformation, could also be used to reduce the flow stress in
the deformation zone of the machining shear plane. The objective of this project is to study and model the effect
of electric current on forces in machining in order to relate the force reduction to the current level and machining
process parameters. It is shown that application of electric current does in fact reduce machining force by up to
50%.
JUNE 10-14, 2013 // Madison, Wisconsin
180

Abstracts, cont.
Ultrasonic cavitation peening of stainless steel and nickel alloy
MSEC2013-1236
Yibo Gao, Benxin Wu, Ze Liu, Yun Zhou, Illinois Institute of Technology, Chicago, IL, United States
Ultrasonic cavitation peening is a peening process utilizing the high pressure induced by ultrasonic cavitation in
liquids (typically water). However, the relevant previous investigations in the literature have been limited. In this
paper, ultrasonic cavitation peening on stainless steel and nickel alloy has been studied, including the observation
or characterization of the surface hardness, morphology, profile, roughness and oxygen contamination of treated
workpiece samples. It has been found that for the studied situations, ultrasonic cavitation peening (at a sufficiently
high horn vibration amplitude) can obviously enhance the workpiece surface hardness without significantly
increasing the surface roughness, changing surface morphology observed by scanning electron microscope (SEM),
or contaminating the surface by oxygen.
181 MSEC 2013 NAMRC 41

Quality evaluation of multistage manufacturing systems by jointly considering the incoming part quality and
system conditions
MSEC2013-1136
Faping Zhang, Beijing Institute of Technology, Being, Beijing, China, Jingjing LI, University of Hawaii, Honolulu, HI,
United States, Yan Yan, Jiping Lu, Shuiyuan tang, Beijing Institute of Technology, Being, Beijing, China
The quality performance of a multistage manufacturing systems (MMS) is jointly affected by incoming part quality,
system condition unreliability due to batch-to-batch uncertainty, making it challenging to evaluate the quality
performance of MMS. Previous research considered the incoming part quality and system conditions separately
in systematic level. This paper aims to fill the gap by considering the joint effects of these two aspects to evaluate
quality performance of a MMS from historical production data driven work. A system quality model was derived
to predict the probability of producing good parts at each stage and entire MMS when the incoming good
part quality rate and station conditions were given. To overcome the inconvenience of the quality model for its
nonlinear transfer function, the concept of quality efficiency was developed to depict the joint effectiveness of
incoming part quality and system conditions mathematically at each stage. Based on the quality model, on the
paper also discusses how to maintain high good product quality rate. The results of this study suggested a possible
approach of evaluating the impacts of system conditions on product quality. The results of the model will lead to
guidelines of quality management in multistage manufacturing systems.
JUNE 10-14, 2013 // Madison, Wisconsin
182

Abstracts, cont.
Monitoring multistage surface spatial variations using functional morphing
MSEC2013-1203
Saumuy Suriano, University of Michigan, Ann Arbor, MI, United States, Hui Wang, The University of Michigan, Ann
Arbor, MI, United States, S. Jack Hu, University of Michigan, Ann Arbor, MI, United States
In multistage manufacturing processes, the machined surface shape of a part changes as it goes through
each stage. Process monitoring at multiple stages is necessary for root cause diagnosis and surface variation
reduction. However, due to measurement time and capacity constraints, it is challenging to collect sufficient
surface measurements at all intermediate stages for monitoring. This paper proposes a functional morphing
based algorithm to monitor the surface variation propagation using end of line multi-resolution measurements
supplemented with low resolution measurements at intermediate stages. The surface changes over multiple
stages are captured by a functional morphing model which integrates geometric transformations with engineering
insights. The model estimates a morphed surface prediction at an intermediate stage of interest using end-of-line
surface measurements. This morphed surface is combined with the low-resolution measurements at that stage
to improve the surface prediction accuracy. The model can be further improved by incorporating the effects of
correlated process variables. Based on the model, abnormal surface variations can be detected and located by
a single-linkage cluster monitoring algorithm as developed in our previous work. The case study of a two-stage
machining process demonstrates that the method successfully monitors multistage surfaces using reduced
measurement resolution at intermediate stages.
183 MSEC 2013 NAMRC 41

Automated part inspection using 3D point clouds
MSEC2013-1212
Lee Wells, Mohammed Shafae, Jaime Camelio, Virginia Polytechnic Institute and State University, Blacksburg, United
States
Ever advancing sensor and measurement technologies continually provide new opportunities for knowledge
discovery and quality control (QC) strategies for complex manufacturing systems. One such state-of-the-art
measurement technology currently being implemented in industry is the 3D laser scanner, which can rapidly
provide millions of data points to represent an entire manufactured part’s surface. This gives 3D laser scanners
a significant advantage over competing technologies that typically provide tens or hundreds of data points.
Consequently, data collected from 3D laser scanners have a great potential to be used for inspecting parts for
surface and feature abnormalities. The current use of 3D point clouds for part inspection falls into two main
categories; 1) Extracting feature parameters, which does not complement the nature of 3D point clouds as it
wastes valuable data and 2) An ad-hoc manual process where a visual representation of a point cloud (usually
as deviations from nominal) is analyzed, which tends to suffer from slow, inefficient, and inconsistent inspection
results. Therefore our paper proposes an approach to automate the latter approach to 3D point cloud inspection.
The proposed approach uses a newly developed adaptive generalized likelihood ratio (AGLR) technique to identify
the most likely size, shape, and magnitude of a potential fault within the point cloud, which transforms the ad-hoc
visual inspection approach to a statistically viable automated inspection solution. In order to aid practitioners in
designing and implementing an AGLR-based inspection process, our paper also reports the performance of the
AGLR with respect to the probability of detecting specific size and magnitude faults in addition to the probability
of a false alarms. Finally, our paper discusses the future of QC in this newly developing high-density dimensional
(HDD) data environment.
JUNE 10-14, 2013 // Madison, Wisconsin
184

Abstracts, cont.
Effect of mechanical alloying on Al6061-graphene composite fabricated by semi-solid powder processing
MSEC2013-1078
Mina Bastwros, Gap-Yong Kim, Can Zhu, Iowa State University, Ames, IA, United States, Kun Zhang, Shiren Wang,
Texas Tech University, Lubbock, TX, United States
Graphene is a promising material as a reinforcing element for high-strength, lightweight metal composites due to
its extraordinary mechanical properties and low density. In this study, Al6061graphene composite was investigated
with 1.0 wt.% graphene reinforcement. The graphene was manufactured by the modified Brodies method. The
Al6061 powder and graphene flakes were ball milled at different milling times (10, 30, 60, and 90 min). The
composite was then synthesized by hot compaction in the semi-solid regime of the Al6061. Three point bending
test was performed to characterize the mechanical properties of the composites. The ball milled powder and the
fracture surfaces of the composites were investigated using the scanning electron microscopy (SEM). The results
were compared with a reference Al6061 without any graphene reinforcement. For the Al6061-1.0 wt.% graphene
composites, a maximum enhancement of 47% in the flexural strength was observed when compared with the
reference Al6061 processed at the same condition.
185 MSEC 2013 NAMRC 41

The effect of warm accumulative roll bonding and post process treatment on microstructure and mechanical
behavior of CP-TI
MSEC2013-1224
Justin Milner, Fadi Abu-Farha, Thomas Kurfess, Clemson University, Greenville, United States
Accumulative Roll Bonding (ARB), a severe plastic deformation technique, was used in this study to process
commercially pure titanium (CP-Ti) sheets at selected warm temperatures. Post-processing treatments at selected
conditions were also performed on the ARB processed material, following each ARB processing cycle. Mechanical
characterization and microstructural examination were carried out on the processed and post processed material
to track the evolution of the microstructure, the changes in strength and ductility, and their relationships with
regard to one another. Though the temperatures and processing conditions covered here are limited, it was found
that ARB processing temperature affects the resultant flow behavior of the material. Furthermore, it was shown that
post processing treatment of the ARB processed material can increase both strength and ductility of the material;
the latter can be used as an effective tool for further controlling the structure and properties of the ARB-processed
material.
JUNE 10-14, 2013 // Madison, Wisconsin
186

Abstracts, cont.
Numerical evaluations of thermal property effects in electron beam additive manufacturing
NAMRC41-1551
Kevin Chou, The University of Alabama, Tuscaloosa, AL, United States
With the rapid growth of the demand in additive manufacturing (AM), powder-based electron beam additive
manufacturing (EBAM) has been considered as one of the high-efficiency AM process to make full-density solid
metallic parts. EBAM has been reported as a cost-effective alternative to produce complex-shaped, customdesigned
Ti-6Al-4V alloy parts. It has also been investigated that EBAM may be applied for various difficult-tomachine
engineering materials such as intermetallics. However, different thermal properties will result in distinct
thermal responses including the melt pool size during the EBAM process. In previous work, a finite element (FE)
thermal model was developed by the authors to investigate the thermal behavior of Ti-6Al-4V in EBAM. In this
study, numerical simulations were extensively conducted with various materials using the developed FE thermal
model. The effect of thermal properties on the melt pool size was discussed. The melting temperature of work
materials is intuitively the most dominant factor to the melt pool size. However, if a material has a very thermal
conductivity such as copper, the role of the thermal conductivity may outweigh the melting point.
187 MSEC 2013 NAMRC 41

Material shrinkage modeling and form error prediction in additive manufacturing processes
NAMRC41-1579
Ratnadeep Paul, University of Cincinnati, Cincinnati, OH, United States, Sundararaman Anand, University Of
Cincinnati, Cincinnati, OH, United States
Material shrinkage is a major contributor to dimensional inaccuracies and errors in parts produced by Additive
Manufacturing (AM) processes. The shrinkage effect is more pronounced in metal powder based AM processes
such as Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM). This
paper investigates the effect of material shrinkage in AM processes on the dimensional accuracy of AM parts.
A discrete methodology has been developed which calculates the in-plane and out of plane shrinkages in a
single laser track. The dimensional changes in a track due to material shrinkage are then integrated to model the
modified boundary of the slice contour and the changes in the contour boundary are in turn applied to simulate
the geometry of the manufactured part. Two shrinkage based error models have been developed to calculate
the dimensional changes in an AM part due to material shrinkage: the first model uses a first principles based
computational method while the second model uses previously published experimental results. The shrinkage
based models are used to estimate the Geometric Dimensioning and Tolerancing (GD&T) form errors in AM parts.
The effect of the material shrinkage on the flatness, cylindricity and sphericity form errors has been analyzed
and the results have been presented. Based on these error models, predictive equations have been developed
which correlate the shrinkage based form errors to the part geometry, slice thickness and part orientation. These
predictive equations have been validated with the help of test parts.
JUNE 10-14, 2013 // Madison, Wisconsin
188

Abstracts, cont.
Numerical simulation of dilution in laser metal deposition by powder injection
NAMRC41-1623
Xueyang Chen, Missouri University of Science and Technology, USA, Rolla, United States, Z. Fan, Missouri University
of Science and Technology, Rolla, MO, United States, Fuewen Frank Liou, Missouri University Of Science And
Technology, Rolla, MO, United States, J. W. Newkirk, Missouri University of Science and Technology, Rolla, MO,
United States
Laser deposition is a method of depositing material by which a powdered material is melted and consolidated
by use of a laser in order to coat part of a substrate or fabricate a near-net shape part. The development of
an accurate predictive model for laser deposition is extremely complicated due to the multitude of process
parameters and materials properties involved. In this work, the metal powder used in the laser cladding/deposition
process is injected into the system by using a coaxial nozzle. The interaction of the metallic powder stream and the
laser causes melting to occur, which is known as the melt pool. The metal is deposited onto a substrate; moving
the substrate allows the melt pool to solidify and thus produces a track of solid metal. In deposition operations,
dilution is often defined as the amount of intermixing of the deposit and substrate. In this process, it is desirable
to have minimum dilution but at the same time to have a metallurgical bonding between the substrate and
deposit. Therefore, it is very critical to understand and predict the degree of dilution in the process. In this study,
a heat transfer and fluid flow model for laser deposition is developed to predict dilution under varying process
parameters. The material for both substrates and the powder is Ti-6Al-4V, but 5% of steel powder was added to
observe the actual degree of dilution. The laser used is a direct diode laser. Experimental validation of the predicted
dilution is also presented.
189 MSEC 2013 NAMRC 41

Phase transformation affected quench crack study using finite element analysis
MSEC2013-1146
Zhichao (Charlie) Li, B. Lynn Ferguson, Deformation Control Technology, Inc., Cleveland, United States
Steel components are commonly heat treated to obtain favorable mechanical properties for enhanced
performance. Quench hardening is one of the most important heat treatment processes to increase hardness and
strength. During quenching, both thermal gradients and phase transformations contribute to the evolution of
internal stresses. Higher tensile stresses in a part during quenching tend to increase the cracking possibility, which
is more problematic for components with various section sizes due to stress concentration. Heat treaters believe
that cracking possibility increases with larger difference of section size in a part. This is only true in some cases. If
the section size difference exceeds a threshold, the cracking possibility will decrease. Due to the complex parts
responses to thermal gradient, phase transformation and unbalanced geometry, there is no robust and simple
rule to characterize the cracking possibility. With the development of more advanced heat treatment computer
modeling capability, the materials response during heat treatment can be more intuitively understood. The part
geometry and heat treatment process can be designed with much less potential heat treatment defects. In this
paper, finite element based heat treatment software, DANTE, is used to investigate the relationship between
section size difference and cracking possibility by using parts with a series of section size ratios. In this specific
study, the selected part is a plain strain component made of AISI 9310. The results during oil quench process have
shown that a section size ratio of 1:2 creates the highest stress concentration and cracking possibility.
JUNE 10-14, 2013 // Madison, Wisconsin
190

Abstracts, cont.
Prediction of distortion in quenching-tempering processes for a SM256 steel component with internal thread
MSEC2013-1139
Yiming(Kevin) Rong, Worcester Polytechnic Institute, Worcester, MA, United States, Gang Wang, Zhenguo Nie,
Tsinghua University, Beijing, China
A steel component with internal thread has a few slight distortions when it undergoes quenching-tempering
processes. These small distortions affect assembly severely in the precision engineering. Using FEA software with
its user subroutines, the position and contour of distortions which will be confirmed by subsequent experimental
measurement are simulated. This result reasonably explains the assemble difficulty in enterprise manufacturing,
and then lots of suggestions are given for manufacturing improvements.
191 MSEC 2013 NAMRC 41

Key technologies of embedded gear machining CNC system
MSEC2013-1083
Jiang Han, Hefei University of Technology, Hefei, China, Xiaoqing Tian, Fugen Li, Jie Cheng, Bao Chen, Lian Xia, Hefei
University of Technology, Hefei, Anhui, China
A reconfigurable gear machining numerical control system (NC/CNC) architecture is proposed in this paper. The
CNC platform can be quickly applied to gear hobbing, shaping, milling and grinding machine, through simple
reconfiguring or parameter setting. Parametric automatic programming technology, high speed and high precision
electronic gearbox, process database technology are studied. Based on the analysis of the gear machining process,
the mathematic model on automatic programming of gear machining is established. Based on the Windows
CE operating system, the CNC gear machining automatic programming system is developed on the ARM+DSP
hardware platform, including the design of human-machine interface, automatic programming algorithm and
other modules. With the support of the automatic programming and process database modules, NC codes can
be generated automatically just by inputting gear parameters, tool parameters and process parameters, then, the
interpolation data structure can be generated by interpreter module. A new kind of software electronic gearbox
(EGB) and its implementation methods are also researched in the embedded CNC. Data flow among the modules
is analyzed. Finally, experiments are conducted, and the tracking error and contour error are analyzed. The results
show that the proposed gear machining CNC architecture is effective.
JUNE 10-14, 2013 // Madison, Wisconsin
192

Abstracts, cont.
Developing an agility model for maximum responsiveness to the changes in customer requirements for SMEs
MSEC2013-1148
Mohamed Gadalla, Alabama A&M University, Normal, United States
Small and Medium Size Enterprises (SMEs) face increased market pressure due to demand fluctuation and the shift
of the consumer focus from high volume/low mix to high mix/low volume environment. Costumer requirement
as seen by SMEs can be summarized as: quantity scaling, unpredicted and sudden demands, on-time and quicker
delivery times, and increased number of customized products. This paper proposes an agility realization model for
SMEs to achieve higher responsiveness to these requirements. The agility model is based on integrating four main
agility enablers: quick manufacturing response strategies, multi-channel manufacturing approach, high mix/low
volume techniques and collaborative networks. A case study is presented to demonstrate the proposed approach.
The framework presented in this paper represents a roadmap for SMEs to raise their internal efficiency, achieve
maximum responsiveness that will increase their competitive edge.
193 MSEC 2013 NAMRC 41

Manual precedence mapping and application of a novel precedence relationship learning technique to real-world
automotive assembly line balancing
MSEC2013-1235
Kavit R. Antani, Clemson University, Greenville, SC, United States, Laine Mears, Clemson University, Anderson, SC,
United States, Mary E. Kurz, Maria E. Mayorga, Bryan Pearce, Clemson University, Clemson, SC, United States, Kilian
Funk, BMW Manufacturing Co., Greer, SC, United States
An assembly line is a flow-oriented production system where the productive units performing the operations,
referred to as stations, are aligned in a serial manner. The work pieces visit stations successively as they are moved
along the line usually by some kind of transportation system, e.g., a conveyor belt. An important decision problem,
called Assembly Line Balancing Problem (ALBP), arises and has to be solved when (re-) configuring an assembly
line. It consists of distributing the total workload for manufacturing any unit of the product to be assembled
among the work stations along the line. The assignment of tasks to stations is constrained by task sequence
restrictions which can be expressed in a precedence graph. However, most manufacturers usually do not have
precedence graphs or if they do, the information on their precedence graphs is inadequate. As a consequence, the
elaborate solution procedures for different versions of ALBP developed by more than 50 years of intensive research
are often not applicable in practice. Unfortunately, the known approaches for precedence graph generation are
not suitable for the conditions in the automotive industry. Therefore, we describe a detailed application of a new
graph generation approach that is based on learning from past feasible production sequences. This technique
forms a sufficient precedence graph that guarantees feasible line balances. Experiments indicate that the proposed
procedure is able to approximate the real precedence graph sufficiently well to detect nearly optimal solutions
even for a real-world automotive assembly line segment with up to 317 tasks. In particular, it seems to be promising
to use interviews with experts in a selective manner by analyzing maximum and minimum graphs to identify still
assumed relations that are crucial for the graphs structure. Thus, the new approach seems to be a major step to
close the gap between theoretical line balancing research and practice of assembly line balancing.
JUNE 10-14, 2013 // Madison, Wisconsin
194

Abstracts, cont.
Nanostructural evolution of hard turning white layer during machining of through hardened 52100 steel
NAMRC41-1534
Vikram Bedekar, Rahul Chaudhari, Timken Technology Center, N. Canton, United States, Rajiv Shivpuri, Ohio State
University, Columbus, OH, United States
Transmission Electron Microscopy (TEM), Selected Area Diffraction (SAD) and X-ray Diffraction (XRD) analyses were
conducted on hard machined 52100 surfaces using varying insert wear conditions. On a surface machined using
a fresh insert, severe plastic deformation was evident by the presence of fine grains (15-30nm) in the deformation
layer that was 200-300nm thick. Grain coarsening occurred with gradual insert wear (VB). The X-ray analysis
indicated that the percent retained austenite decreased when a fresh insert was used but a slight increase was
observed with the rest of the samples. The surface residual stress was compressive until the wear reached a certain
threshold. The empirical and numerical investigations suggested that the mechanisms (plastic and/or thermal)
behind the formation of hard machined white layers could be controlled by effective usage of cutting parameters
and by controlling the insert wear. The hard machining white layer is plastically dominated when the insert is new
but it gradually transitions to a thermal phenomenon as the insert wears.
195 MSEC 2013 NAMRC 41

Thermally assisted high efficiency ductile machining of brittle materials: A numerical study
NAMRC41-1596
JIANFENG MA, Nathan Pelate, Saint Louis University, St. Louis, MO, United States, Shuting Lei, Kansas State University,
Manhattan, KS, United States
This study investigates the role of thermal assistance and tool geometry on ductile regime machining of a nHAP
bioceramic using numerical simulation. FEM is used to conduct the simulation of orthogonal machining of the
nHAP. Thermal boundary conditions are specified to approximate laser preheating of the work material. The effects
of operating conditions (preheat temperature, rake angle, and edge radius) on pressure distribution, cutting
force, and thrust force are investigated. Based on the pressure-based criterion for ductile regime machining,
the dependence of critical depth of cut on preheating temperature is examined. It is found that for different
combinations of rake angle and edge radius, the critical depth of cut increases as thermal boundary temperature
increases. In addition, it is concluded that using higher thermal boundary temperature for smaller negative or zero
rake angle, we can achieve the comparable critical depth of cut obtained by using a higher negative rake angle,
which usually generates higher thrust force and consequently deteriorates the dimensional accuracy of finished
parts.
JUNE 10-14, 2013 // Madison, Wisconsin
196

Abstracts, cont.
High speed ball nose end milling of hardened AISI A2 tool steel with PCBN and coated carbide tools
NAMRC41-1616
Zhengwen Pu, University of Kentucky, Lexington, KY, United States, Anshul Singh, Diamond Innovations, Columbus,
OH, United States
High speed machining (HSM) of tool steels in their hardened state is emerging as an attractive approach for
the mold and die industry due to its potential for significant cost savings and productivity improvement. An
experimental study was conducted to investigate the tool wear mechanism and surface integrity in high speed
ball nose end milling of hardened AISI A2 tool steel using coated tungsten carbide and polycrystalline cubic boron
nitride (PCBN) tools. It is found that coated carbide tools can only be used at low speed (120 m/min) while high
content PCBN tools are suitable for HSM range (470 m/min). PCBN tools produce a damage free workpiece with
better surface finish and less work hardening. Despite the higher tool cost, HSM with PCBN tools lead to reduction
in both total cost and production time per part.
197 MSEC 2013 NAMRC 41

A new velocity estimator for motion control systems
MSEC2013-1066
Huawen Zheng, Ningbo Industrial Technology Institute, Ningbo, Zhejiang, China, Guokun Zuo, Wenwu Zhang,
Ningbo Industrial Technology Research Institute, Ningbo, Zhejiang, China
In motion control systems, differentiated position signal is commonly used to estimate velocity, and used for speed
feedback control. Position quantization error can result in the amount of noise jamming, which affects system
control precision and stability. In this paper, a simple but reliable velocity estimator is proposed to estimate velocity
from the measured position. This estimator consists of two parts: a traditional moving-average filter for data
smoothing process, and a closed-loop PID controller to compensate the phase lag caused by smoothing process.
Simulation and experimental results demonstrate that the quantization error in the velocity feedback signal can be
reduced dramatically when the proposed estimator is used for velocity estimation, the estimated signal has fewer
phase lag than the traditional velocity estimation method, and the current noise of motor is reduced as well.
JUNE 10-14, 2013 // Madison, Wisconsin
198

Abstracts, cont.
Comparison of electrically-assisted and conventional friction stir welding processes by feed force and torque
MSEC2013-1192
Hemanth Potluri, Joshua Jones, Clemson University, Greenville, SC, United States, Laine Mears, Clemson University,
Anderson, SC, United States
The process of friction stir welding involves high tool forces and requires robust machinery; the forces involved
make tool wear a predominant problem. As a result, many alternatives have been proposed in decreasing tool
forces such as laser assisted friction stir welding and ultra-sound assisted friction stir welding. However, these
alternatives are not commercially successful on a large scale due to scalability and capital and maintenance costs.
In an attempt to reduce forces in a cost-feasible manner, electrically-assisted friction stir welding (EAFSW) is studied
in this work. EAFSW is a result of applying the concept of electrically-assisted manufacturing (i.e., passing high
electrical current through a workpiece during processing) to the conventional friction stir welding process. The
concept of EAFSW is a relatively new adaptation of conventional frictional stir welding, which is well established.
The expected benefits are reduction in the feed force and torque, which can allow for improved processing
productivity as well as the possibility for deeper penetration of the weld.
The effect of passing direct electric current through Aluminum 6061 during the welding process is studied in this
paper with respect to the feed force and torque. From this study, it is shown that the feed forces are reduced by
58% on average in the EAFSW compared to a conventional frictional stir welding process, and a decrease in torque
at the start of the feed is present in the EAFSW process as compared to conventional friction stir welding.
199 MSEC 2013 NAMRC 41

Characterization of vacuum brazing of Ti6Al4V and alumina with Cu-Ag brazing alloy via substrate-induced reactive
mechanism
MSEC2013-1218
Ravikumar Beeranur, Kiran Waghmare, Ramesh Singh, Indian Institute of Technology Bombay, Mumbai,
Maharashtra, India
Brazing of ceramic and metal components is an emerging manufacturing technology in which a furnace or a
heat source is used to join the substrates using a brazing filler material. Brazing of ceramic and metal has received
considerable attention in the field of nuclear reactor, aerospace, automobile, medical and electrical engineering.
A brazing alloy can either be a conventional brazing alloy which requires the ceramic surface to be metallized or
an active brazing alloy which does not require metallization. A sound interfacial adhesive bond is formed during
the process. The typical active elements required in the brazing alloy for bonding of alumina are Ti and Zr. It is
expected that since Ti is present in Ti6Al4V, a copper-silver alloy (Cusil”) without an active element can be used
for brazing. The Ti substrate itself could provide the reactive element because of dissolution. Vacuum brazing of
alumina and titanium with Cusil sheet has been carried out to analyze the characteristics of the joint. Behavior of
the joint under different temperature conditions has been studied by thermal cycling of the joint. Uniformity of
the joints is confirmed by observing the SEM images. The elements and phases present in the joint interface are
observed by energy dispersive spectroscopy (EDS) and XRD analyses. The maximum shear strength obtained in the
brazedTi6Al4V/Cusil sheet/alumina joint was 102MPa and the average shear stress was found to be 70±3 MPa. The
micro-Vickers hardness test showed that the micro hardness of the interface was lower than the substrates.
JUNE 10-14, 2013 // Madison, Wisconsin
200

Abstracts, cont.
Analytical modeling and experimental validation of force ripple and friction force for general direct drive systems
MSEC2013-1058
Chengying Xu, Ran Zhao, University of Central Florida, Orlando, United States
In this paper, we present a systematic modeling method of direct drive systems. Experiments are designed to
decouple and model friction and force ripple separately, which are two major sources of tracking error. Three
different optimization methods, least square method, nonlinear least square method and particle swarm
optimization are used for parameter optimization. The analytical form of the model makes it easy to use in
engineering practices. All results are obtained and verified experimentally. The method presented in this paper can
also be used to model other mechanical systems.
201 MSEC 2013 NAMRC 41

Adaptive robust control of circular machining contour error using global task coordinate frame
MSEC2013-1108
Tyler Davis, Caterpillar, Dunlap, IL, United States, Yung Shin, Purdue University, West Lafayette, IN, United States, Bin
Yao, Purdue University, West Lafayette, IN, United States
For machining processes contour error is defined as the difference between the desired and actual produced
shape. Two major factors contributing to contour error are axis position error and tool deflection. A large amount
of research work formulates the contour error in convenient locally defined task coordinate frames that are
subject to significant approximation error. The more accurate global task coordinate frame (GTCF) can be used,
but transforming the control problem to the GTCF leads to a highly nonlinear control problem. An adaptive
robust control (ARC) approach is designed to control machine position in the GTCF, while directly accounting
for tool deflection, to minimize the contour error. The combined GTCF/ARC approach is experimentally validated
by applying the control to circular contours on a three axis milling machine. The results show that the proposed
approach reduces contour error in all cases tested.
JUNE 10-14, 2013 // Madison, Wisconsin
202

Abstracts, cont.
A model-based computationally efficient method for on-line detection of chatter in milling
MSEC2013-1031
Lei Ma, Shreyes Melkote, Ph.D., Georgia Institute of Technology, Atlanta, GA, United States, James Castle, Boeing
Company, St. Louis, MO, United States
This paper presents a model-based computationally efficient method for detecting milling chatter in its incipient
stages. Based on a complex exponentials model for the dynamic chip thickness, the chip regeneration effect
is amplified and isolated from the cutting force signal for early chatter detection. The proposed method is
independent of the cutting conditions. With the aid of a one tap adaptive filter, the proposed method is also found
to be able to distinguish between chatter and the dynamic transients in the cutting forces due to sudden changes
in workpiece geometry and tool entry/exit. The proposed method is experimentally validated.
203 MSEC 2013 NAMRC 41

MICRO-MILLING RESPONSES OF HIERARCHICAL GRAPHENE COMPOSITES
MSEC2013-1099
Bryan Chu, Rensselaer Polytechnic Institute, Troy, NY, United States, Johnson Samuel, Renssalear Polytechnic
Institute, Troy, NY, United States, Nikhil Koratkar, Rensselaer Polytechnic Institute, Troy, NY, United States
The objective of this research is to examine the micro-machining responses of a hierarchical three-phase
composite made up of micro-scale glass fibers that are held together by an epoxy matrix laden with nano-scale
graphene platelets. To this end, micro-milling experiments are performed on both the hierarchical graphene
composite as well as on a baseline two-phase glass fiber composite without the graphene additive. The composite
microstructure is characterized using transmission electron microscopy and scanning electron microscopy
methods. Tool wear, chip morphology, cutting force, surface roughness and delamination are employed as
machinability measures. In general, the tool wear, cutting forces, surface roughness and extent of delamination are
all seen to be lower for the hierarchical graphene composite. These improvements are attributed to the fact that
graphene platelets improve the thermal conductivity of the matrix, provide lubrication at the tool-chip interface
and also improve the interface strength between the glass fibers and the matrix. Thus, the addition of graphene to
a conventional two-phase glass fiber epoxy composite is seen to not only improve its mechanical properties but
also its machinability.
JUNE 10-14, 2013 // Madison, Wisconsin
204

Abstracts, cont.
ULTRASOUND INDUCED SYNTHESIS OF CDS NANOCRYSTALS UNDER CONTINUOUS FLOW
MSEC2013-1225
Barath Palanisamy, Oregon State University, Corvallis, OR, United States, Brian Paul, Oregon State University, Corvallis,
OR, United States
Cadmium sulfide nanoparticles generally exhibit quantum confinement effects when the particle size is less
than 10 nm and approaches the Bohr exciton radius. It is a widely used buffer material in solar cells owing to its
wide band transmission of solar light and hence used as a window layer in photovoltaic devices. Sonochemical
synthesis permits the rapid heating of reactant baths by acoustic cavitation leading to high local temperatures.
In this research, results from batch trials for heating and synthesis are reported. These results were used to design
experiments for the continuous synthesis of CdS nanoparticles using a sonochemical reactor consisting of a flow
cell and a high intensity horn. By utilizing the continuous synthesis approach a more than hundred fold reduction
in processing time over batch synthesis for similar product was reported.
205 MSEC 2013 NAMRC 41

An experimental study of the phenomenon of surface alloying by EDM process using inconel tool electrode
MSEC2013-1014
Sanjeev Kumar, PEC University of Technology, Chandigarh, India
Electrical Discharge Machining (EDM) has emerged as a very important machining process due to its numerous
advantages. It is extensively used by the die and toolmaking industry for the accurate machining of complex
internal profiles. Due to the absence of physical contact between the tool and the workpiece, the raw material can
be machined after hardening. Although EDM is essentially a material removal process, it has been used successfully
for improving the surface properties of the work materials after machining. As the dissolution of the electrode
takes place during the process, some of its constituents may alloy with the machined surface under appropriate
machining conditions. Additive powders in the dielectric medium may form part of the plasma channel in the
molten state and produce similar alloying effect. The breakdown of the hydrocarbon dielectric under intense
heat of the spark contributes carbon to the plasma channel. Conductive powders in the dielectric medium affect
the energy distribution and sparking efficiency, and consequently the surface finish and micro-hardness. Sudden
heating and quenching in the spark region also alters the surface properties.
This paper reports the results of an experimental study into electrical discharge machining of H13 hot die steel with
Inconel (an alloy of chromium, nickel and iron) tool electrode under machining conditions favouring high electrode
wear. The experiments were conducted using L9 orthogonal array of Taguchi experimental design with three input
process parameters; namely, peak current, pulse on-time and pulse off-time. For comparison, machining was also
done with copper electrode under similar machining conditions. The results show improvement in micro-hardness
after machining by as much as 88%. Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD) analysis of
the machined surfaces show transfer of chromium and nickel from the tool electrode. Both these elements form
intermetallic compounds as well as solid solution with iron and strengthen it. The chemical composition of the
machined surface was further checked with an optical emission spectrometer to verify the results. It was found
that percentage of chromium increased from 5.39% to 6.52% and that of nickel increased from 0.19% to 4.87%. The
favourable machining conditions for surface alloying were found to be low value of peak current, shorter pulse ontime,
longer pulse off-time and negative polarity of the tool electrode.
JUNE 10-14, 2013 // Madison, Wisconsin
206

Abstracts, cont.
Experimental study of biaxial load-unload behavior of DP590 steel sheets
Experimental investigations on microchanelling through ECDM using different electrolytes
MSEC2013-1035
Apurbba Kumar Sharma, Chandrashekhar Jawalkar, Pradeep Kumar, Faraz Ansari, Indian Institute of Technology
Roorkee, Roorkee, India
The Electro Chemical Discharge Machining (ECDM) is a non-conventional machining process primarily used for
micro machining non-conducting and brittle materials. In this paper a detailed review on the existing technologies
in micro machining especially on borosilicate glass using ECDM with different electrolytes is reported. Experimental
studies on ECDM for machining fine micro channels on borosilicate glass using NaCl and NaOH electrolytes are also
presented at the end. During this study, experiments were conducted using the Taguchis standard L4 orthogonal
array (OA) individually for both the electrolytes. The variable parameters were: tool material (stainless steel and
copper), applied voltage and electrolyte concentration.
The response parameters considered were Material Removal (MR) and Tool Wear (TW). All the variables were found
to be significant. It was experimentally found that electrolyte concentration affected the material removal most
(74.9%), while the wear rate of copper tools were more as compared to stainless steel. The Field Emission Scanning
Electron Micro graphs (FESEMs) of the machined channels are reported along with the comparative results and
discussions on MR and TW.
207 MSEC 2013 NAMRC 41

Design of a 3-DOF compliant parallel mechanism for displacement amplification
MSEC2013-1095
Qiang Zeng, Northwestern University, Evanston, United States, Kornel Ehmann, Northwestern University, Evanston,
IL, United States
Prevalent general design methods and applications of compliant displacement amplifiers are focused on
1-DOF units composed into serial structures, which are limited by their output motions, stiffness, heat balance,
repeatability and resonant frequencies. To improve the output properties of compliant displacement amplifiers, a
monolithic structure is presented in the form of a compliant parallel mechanism. In the proposed moving structure,
the compliant mechanism of the displacement amplifier is designed with 3-DOF to generate uniformly magnified
output properties in all directions. High first resonant frequencies and amplification ratios are achieved in a
compact size compared to existing compliant displacement amplifiers. The related kinematics, amplification ratios
and resonant frequencies of the amplifier are analytically modeled, and the results are simulated by finite-element
analysis. The proposed design is employable for micro/nano positioning stages operating within a prismatic output
workspace.
JUNE 10-14, 2013 // Madison, Wisconsin
208

Abstracts, cont.
A study of the impact of workpiece location on machining performance of a 2-DoF PKM based machine tool
MSEC2013-1100
Abbaraju Bala Koteswara Rao, Gayatri Vidya Parishad College Of Engineering, Visakhapatnam, Andhra Pradesh, India,
Ramji K, Andhra University College of Engineering, Visakhapatnam, Andhra Pradesh, India, Sanjay Darvekar, Gayatri
Vidya Parishad College of Engineering, Visakhapatnam, Andhra Pradesh, India
This paper presents the impact of workpiece location on the machining performance of a 2 - degree of freedom
Parallel Kinematic Machine (PKM) tool. The PKM behavior is highly non-uniform and depends on the tool position
within the workspace. The structural deformation and vibration due to cutting loads affect the quality of machined
surfaces.The aim of the present study is to find the optimal tool position (workpiece location) where the workpiece
is machined to a specific quality level. End-milling operations are carried out at various locations within the
workspace and the surface roughness of machined surface (Ra) is measured at each location. A regression model
is developed to predict the surface roughness. The study shows that the workpiece location has significant impact
upon surface roughness of the machined part. Finally, a suitable workspace is defined for end-milling operation.
209 MSEC 2013 NAMRC 41

GPGPU accelerated 3-axis CNC machining simulation
MSEC2013-1096
Dmytro Konobrytskyi, Thomas Kurfess, Clemson University, Greenville, United States, Joshua Tarbutton, University of
South Carolina, Columbia, SC, United States, Tommy Tucker, Tucker Innovations, Incorporated, Waxhaw, NC, United
States
GPUs (Graphics Processing Units), traditionally used for 3D graphics calculations, have recently got an ability to
perform general purpose calculations with a GPGPU (General Purpose GPU) technology. Moreover, GPUs can
be much faster than CPUs (Central Processing Units) by performing hundreds or even thousands commands
concurrently. This parallel processing allows the GPU achieving the extremely high performance but also requires
using only highly parallel algorithms which can provide enough commands on each clock cycle.
This work formulates a methodology for selection of a right geometry representation and a data structure suitable
for parallel processing on GPU. Then the methodology is used for designing the 3-axis CNC milling simulation
algorithm accelerated with the GPGPU technology. The developed algorithm is validated by performing an
experimental machining simulation and evaluation of the performance results.
The experimental simulation shows an importance of an optimization process and usage of algorithms that
provide enough work to GPU. The used test configuration also demonstrates almost an order of magnitude
difference between CPU and GPU performance results.
JUNE 10-14, 2013 // Madison, Wisconsin
210

Abstracts, cont.
Investigation on performance of various ceramic tooling while milling nickel-based superalloy
MSEC2013-1220
Yujie Chen, Justin Milner, Clemson University ICAR, Greenville, SC, United States, Cristina Bunget, Clemson University
- ICAR, Greenville, SC, United States, Laine Mears, Clemson University, Anderson, SC, United States, Thomas Kurfess,
Clemson University, Greenville, SC, United States
One of the most cost-effective dimensionally accurate processes used in manufacturing today, that is capable of
producing a superior surface finish, is machining. As tooling wears, however, the advantages of machining greatly
diminish. In addition, the time lost changing out the tooling significantly affects the overall process efficiency.
Therefore, methods that decrease the wear rate of tooling and, thereby, increase tool longevity is essential to
improving the efficiency of machining. Optimizing the machining feeds and speeds is one method that has
been demonstrated to significantly increase the wear resistance of traditional tooling materials such as HSS,
tungsten carbide and advanced ceramic tooling. However, the effects of machining feeds and speeds are not well
established for strengthened nickel-based superalloys. In addition, round geometry inserts were studied due to
the rising popularity in industry, since there are an increased number of cutting edges. To help establish these
effects, in this work, commercial grade SiAlON (Silicon Aluminium Oxynitride) and Si-WRA (Silicon Carbide Whiskers
Reinforced Alumina) cutting inserts are compared. Milling tests were conducted on a strengthened nickel-based
superalloy. More specifically, tool life, machining forces and power were analyzed to evaluate the performance
improvements of ceramic tooling. This study found that the abrasive/adhesion flank wear was the main failure
mechanism of the ceramic inserts.
211 MSEC 2013 NAMRC 41

Correlating acoustic emission to calibration phenomena for possible measurement standard
MSEC2013-1036
James Griffin Ph.D., Universidad de Chile, Santiago, Chile
When using Acoustic Emission (AE) technologies, tensile tests can provide a detector for material deformation.
In this paper improvements are made to standardize calibration techniques. AE signatures were evaluated from
various calibration sources based on the energy from the first harmonic (dominant energy band) [1][2]. The work
presented here provides further, valuable knowledge to both the manufacturing and structural health monitoring
research communities. The effects of AE against its calibration identity are investigated: where signals are correlated
to the average energy and distance of the detected phenomena. Five sources of calibration would be required in
order to calculate an average amount. AE evaluated by a Neural Network (NN) regression classification technique
identifies how far the malformation has progressed (in terms of energy/force) during material transformation.
A genetic-fuzzy-c-clustering classifier was used as the 2nd classification technique to verify the classifications
of the NN. This calibration method can be used for legislation purposes when either machining or operating. In
summary this paper presents a new method of AE calibration through the correlation of AE and force/distance
measurements.
JUNE 10-14, 2013 // Madison, Wisconsin
212

Abstracts, cont.
Remaining useful tool life predictions using bayesian inference
MSEC2013-1152
Jaydeep Karandikar, University of North Carolina at Charlotte, Charlotte, NC, United States, Tom McLeay, Sam Turner,
Advanced Manufacturing Research Center with Boeing, Rotherham, United Kingdom, Tony Schmitz, University of
North Carolina at Charlotte, Charlotte, NC, United States
Tool wear is an important limitation to machining productivity. In this paper, remaining useful tool life predictions
using the random walk method of Bayesian inference is demonstrated. End milling tests were performed on a
titanium workpiece and spindle power was recorded. The power root mean square value in the time domain
was found to be sensitive to tool wear and was used for tool life predictions. Sample power root mean square
growth curves were generated and the probability of each curve being the true growth curve was updated using
Bayes rule. The updated probabilities were used to determine the remaining useful tool life. Results show good
agreement between the predicted tool life and the true remaining life. The proposed method takes into account
the uncertainty in tool life and the percentage of nominal power root mean square value at the end of tool life.
213 MSEC 2013 NAMRC 41

Uncertainty analysis of tool wear and surface roughness
MSEC2013-1245
A. Sequera, The University of Alabama, Tuscaloosa, AL, United States, Yuebin Guo, Ph.D., Univ. of Alabama,
Tuscaloosa, AL, United States
Tool wear development is an important parameter to control in order to obtain a specific surface integrity in
machining operations. Unfortunately, it is difficult to accurately predict the tool life since wear rates generally
exhibit a large scattering, and in consequence a scattering in the surface roughness is also present. This paper
presents an approach to evaluate uncertainty contributors for tool wear and surface roughness in end milling
of superalloy Inconel 718. Multiple regression analysis was applied to develop empirical models of tool wear
and surface roughness based on the experimental data. Principles of uncertainty in measurement were applied
and uncertainty contributors were identified. It was shown that cutting speed is the principal contributor to the
combined uncertainty of tool wear and surface roughness.
JUNE 10-14, 2013 // Madison, Wisconsin
214

Abstracts, cont.
High speed turning of AISI4140 steel using nanofluids through twin jet SQL system
MSEC2013-1067
Sougata Roy, Indian Institute of Technology Madras, India, Chennai, Tamil Nadu, India, Amitava Ghosh, Indian
Institute of Technology Madras, Chennai, Tamil Nadu, India
Application of small quantity lubrication (SQL) technology in high speed machining is being recognized as a
sustainable approach for achieving suitable cooling/lubrication in machining zone. Present investigation focused
on effectiveness of SQL with nanofluids in high speed turning of AISI 4140 steel with a TiN-top coated multilayered
carbide insert and explored the advantages of using a twin-jet SQL system instead of a single jet one. SQL system
was developed in-house with external-mix nozzles. The experiment was conducted varying the cutting velocity
at two different feed rates (0.05mm/rev and 0.10mm/rev) with conventional coolant and nanofluids. Immediate
improvement in machinability and the quality of turned surface was observed with twin-jet nanofluid SQL. A
significant reduction of force and specific energy could be achieved by using 3vol% alumina and 1vol% multi
walled carbon nano tube (MWCNT) nanofluid instead of soluble oil. The MWCNT nanofluid was found to be
superior to alumina nanofluid in reduction of tensile residual stress. Such a reduction is typically an indirect
indication of reduction of cutting zone temperature, which could be achieved due to enhanced level of lubricity
at chip-tool interface and enhanced level of heat dissipation ability of the nanofluids. Improvement in retention of
sharpness of tool cutting edges was also observed under nanofluid-SQL environment, which could have played
important role in improvement of surface quality.
215 MSEC 2013 NAMRC 41

Diluted acid pretreatment and enzymatic hydrolysis of woody biomass for biofuel manufacturing: Effects of particle
size on sugar conversion
MSEC2013-1050
Meng Zhang, Xiaoxu Song, Pengfei Zhang, Kansas State University, Manhattan, KS, United States, Zhijian Pei, Kansas
State University, Manhattan, KS, United States
Biofuels derived from cellulosic biomass offer a promising alternative to petroleum-based liquid transportation
fuels. Cellulosic biomass can be converted into biofuels through biochemical pathway. This pathway consists of
two major conversions: sugar conversion and ethanol conversion. Sugar yield in sugar conversion is critical to the
cost effectiveness of biofuel manufacturing, because it is approximately proportional to the ethanol biofuel yield.
Cellulosic biomass sugar conversion consists of pretreatment and enzymatic hydrolysis. Biomass particle size is an
important factor affecting sugar yield. The literature contains many studies investigating the relationship between
particle size and sugar yield. Many studies focused only on the sugar yield in enzymatic hydrolysis, and failed to
take into account the biomass weight loss during pretreatment. This weight loss results in a loss of the amount
of potential sugar (cellulose), which continues going into enzymatic hydrolysis. Without considering this loss,
cellulosic biomass with a higher enzymatic hydrolysis sugar yield may end up with a lower total sugar yield through
sugar conversion. The present study aims to address this issue by investigating the effects of biomass particle size
using total sugar yield, a parameter considering both the biomass weight loss in pretreatment and the sugar yield
in enzymatic hydrolysis.
JUNE 10-14, 2013 // Madison, Wisconsin
216

Abstracts, cont.
Alignment of carbon nanofibers through shear forces
MSEC2013-1060
Chengying Xu, David Webster, John Gilmore, Jinshan Yang, Jinan Deng, Marcel Ilie, University of Central Florida,
Orlando, United States
This paper presents a novel method for aligning carbon nanofibers. Using shear forces, the carbon nanofibers
displayed significant alignment under a scanning electron microscope. This paper in particular focuses on issues
of alignment in fabricating such nanocomposites and on the goal of eventually scaling up the process for mass
production. The work presented here has profound implications for future studies of carbon nanostructures, and
may be used to mass produce polymer/ceramic matrix composites reinforced with aligned carbon nanotubes.
217 MSEC 2013 NAMRC 41

Study of the effect of anode/cathode geometry on the yield rate and quality of the MWCNTs synthesized by
submerged arc discharging
MSEC2013-1079
Osama M. Awadallah, Ragaie M. Rashad, Abdalla S. Wifi, Department of Mechanical Design and Production, Giza,
Egypt
The main objective of the present paper is to clarify the effect of anode/cathode geometry combinations on
the yield rate and quality of the Multiwall Carbon Nanotubes (MWCNTs) produced by submerged arc discharge
technique. The effects of current intensity and the discharging medium (solvent) are also investigated. The
morphology and crystalline perfection of the produced MWCNTs are confirmed by transmission electron
microscopy (TEM) and Electron diffraction. Thermogravimetric analysis (TGA) is conducted to check the quality
of the MWCNTs in a quantitative manner. The flat ended anode/cathode combination of diameters 4 and 12 mm
respectively exhibited the highest yield at 70 A using deionized water as solvent. Through careful selection of the
process parameters, the yield rate of MWCNTs obtained is found to be higher than most of the reported values in
literature. However, the best quality of MWCNTs with purity as high as 95% , average thermal stability of 745°C as
well as good batch homogeneity, is obtained with KCl solution and tapered male/female anode combination. The
best quality MWCNTs is used successfully as reinforcement for A356 aluminum silicon composite.
JUNE 10-14, 2013 // Madison, Wisconsin
218

Abstracts, cont.
Fabrication and characterization of photonic crystals by two-photon polymerization using a femtosecond laser
MSEC2013-1126
Yinan Tian, Yung Shin, Galen King, Purdue University, West Lafayette, IN, United States
Two-photon polymerization is a powerful technique in fabricating three dimensional sub-diffraction-limited
structures. Recently, new sol-gel material, SZ2080, was introduced into two-photon polymerization and was proved
to be better than the conventional materials for its negligible shrinkage. In this paper, two-photon polymerization
was applied to generate woodpile structures, one kind of photonic crystal, using SZ2080. First, a relationship
between scanning speed, laser power and resolution was determined through fabricating free-hanging lines.
Based on this relationship, woodpile structures with different period distances were fabricated with high
uniformity as shown by SEM images. Then optical property of woodpile structures was investigated using Fourier
Transform Infrared Spectroscopy (FTIR) and a quantitative relationship between band gap and period distance was
established.
219 MSEC 2013 NAMRC 41

A new additive manufacturing file format using bezier patches
NAMRC41-1585
Santosh Allavarapu, Ratnadeep Paul, University of Cincinnati, Cincinnati, United States, Sundararaman Anand,
University Of Cincinnati, Cincinnati, OH, United States
Additive Manufacturing (AM) processes are used to fabricate parts with complex geometries in a layer by layer
approach. Current AM machines use Stereolithography (STL) file format to manufacture parts. An STL file format is
a discrete representation of a CAD model which uses planar triangular facets to tessellate the surface of part. Due
to this planar tessellation, the STL format does not retain the complete geometric information of a CAD model
which leads to approximation errors. The higher the curvature of a design surface, the larger is the approximation
error of the STL file. In current CAD systems, translation errors are minimized by using finer tessellations with smaller
triangular facets which increases the size and memory of the STL file. Even with finer tessellations, it is not possible
to exactly represent a CAD part with planar triangles. This paper presents a methodology for developing a new
file format using curved bi-quadratic Bezier patches which can approximate a CAD model with higher accuracy as
compared to the STL file. Two new Bezier based formats are presented in this paper: the first format uses curved
Bezier patches with linear edges and the second format uses curved Bezier patches with curved edges. In the
first format named as the linear edge format, the patches are modeled such that the edges remain coincident
with those of the original STL facets. In the second format called the curved edge format, the Bezier patch edges
are modeled as quadratic Bezier curves. The new file formats have been developed for two test surfaces and the
accuracies of the new formats have been compared to that of the existing STL format. Further validation of the file
formats has been performed by comparing the profile errors of a test surface that has been virtually manufactured
using the new Bezier formats and the STL format.
JUNE 10-14, 2013 // Madison, Wisconsin
220

Abstracts, cont.
Adaptive layering in additive manufacturing using a k-d tree approach
NAMRC41-1603
Neeraj Panhalkar, Ratnadeep Paul, University of Cincinnati, Cincinnati, United States, Sundararaman Anand,
University Of Cincinnati, Cincinnati, OH, United States
Additive Manufacturing (AM) processes are becoming popular in manufacturing high precision parts in the
aerospace and medical industries. A layer-by-layer fabrication of a part in an AM process leads to poor surface finish
due to the inherent staircase effect present in AM processes. Decreasing the thickness of the layers can increase the
surface accuracy but this leads to an increase in the number of layers resulting in increased build time. This paper
presents a k-d tree based adaptive slicing methodology for manufacturing a part in an AM process. A user defined
cusp height error criteria has been used to determine the depth of division for the k-d tree representation of the
part. The k-d tree based decomposition of the part volume is used to determine the layer thickness at each slice
level. The adaptive slice thicknesses generated from the k-d tree structure is then used to virtually manufacture
sample parts and the volumetric errors for the manufactured parts are calculated. The errors are compared with
those of the virtual parts manufactured using uniform slice thicknesses and the results are presented.
221 MSEC 2013 NAMRC 41

A reactionary process planning algorithm for an unconstrained hybrid process integrating additive, subtractive and
inspection processes
NAMRC41-1615
Zicheng Zhu, Vimal Dhokia, Stephen Newman, University of Bath, Bath, Somerset, United Kingdom
The application of present state of the art manufacturing processes has always been constrained by the capabilities
either from technical limitations such as limited materials and complex part geometries or production costs. As a
result, hybrid manufacturing processes - where varied manufacturing operations are carried out - are emerging
as a potential evolution for the current manufacturing technologies. However, there are limited process planning
methods that are able to effectively utilize manufacturing resources for hybrid processes. In this paper, a hybrid
process entitled iAtractive, combining additive, subtractive and inspection processes, along with part specific
process planning is proposed. The iAtractive process aims to accurately manufacture complex geometries
without being constrained by the capability of individual additive and subtractive processes. This process
planning algorithm enables a part to be manufactured in a way that takes into consideration, process capabilities,
production time and material consumption. This approach is also adapted for the remanufacture of existing parts.
JUNE 10-14, 2013 // Madison, Wisconsin
222

Abstracts, cont.
Mechanics of modulation assisted machining
MSEC2013-1068
Ho Yeung, Yang Guo, Narayan K Sundaram, Purdue University, West Lafayette, United States, James Mann, M4
Sciences LLC, West Lafayette, IN, United States, W. Dale Compton, Srinivasan Chandrasekar, Purdue University, West
Lafayette, IN, United States
The controlled application of low-frequency modulation to machining - Modulation Assisted Machining (MAM)
- effects discrete chip formation and disrupts the severe contact condition at the tool-chip interface. The role of
modulation in reducing the specific energy of machining with ductile alloys is demonstrated using direct force
measurements. The observed changes in energy dissipation are analyzed and explained, based on the mechanics
of chip formation.
223 MSEC 2013 NAMRC 41

Experimental investigation of chip formation and surface topology in ultrasonic-assisted milling of X20Cr13
stainless steel
MSEC2013-1115
M. Mahdi Abootorabi Zarchi, Yazd University, Yazd, Iran, Mohammad Reza Razfar, Amirkabir University of Technology
(Polytechnic of Tehran), Tehran, Tehran, Iran, Amir Abdullah, Amirkabir University Of Technology, Tehran, Iran
In the present paper, by using longitudinal one dimensional ultrasonic vibrations, characteristics of side milling of
X20Cr13 martensitic stainless steel has been investigated. In order to experimentally investigate the chip formation
and machined surface topology of workpiece, conventional milling (CM) and ultrasonic-assisted milling (UAM)
processes have been applied and compared in certain cutting conditions. Imaging by digital microscope shows
that applying ultrasonic vibrations on milling process leads to thinner and smaller formed chips and it also makes
machined surface of workpece flatter. In both CM and UAM processes, as feed rate increases, chips become thicker
and machine surface loses its flatness.
JUNE 10-14, 2013 // Madison, Wisconsin
224

Abstracts, cont.
Novel high pressure sealing system for tube hydroforming operations
MSEC2013-1194
Scott Wagner, Michigan Technological University, Atlantic Mine, MI, United States, Kenny Ng, Michigan
Technological University, Houghton, MI, United States, William J. Emblom, University of Louisiana at Lafayette,
Lafayette, LA, United States, Jaime Camelio, Virginia Polytechnic Institute and State University, Blacksburg, VA, United
States
The tube hydroforming (THF) process is a metal forming process that uses a pressurized fluid as the forming
mechanism. Recently, this process has increased in popularity in the automotive industry as a method to
consolidate parts and substantially reduce the overall automobile weight. This increase in popularity is largely due
to fuel economy incentives over the past couple of decades to manufacture automobiles that are lower in weight.
When used effectively, the THF process can reduce the number of components used in a multi-part product.
This reduction in components can lead to significant weight and overall cost reductions as well as lifetime fuel
consumption savings. In addition to creating lighter parts, in many cases these hydroformed products are also
stronger.
At the micro scale, hydroformed tubes have the potential to offer additional benefits with possible uses in medical
and MEMS (Microelectromechanical systems) applications. In many cases, micro forming processes are derived by
scaling down successful macro scale processes. This can be a challenge when the forming materials have small
mating features. In many macro scale tube hydroforming processes the supplied forming fluid is inserted into the
tubes to be formed by a filling nozzle inserted inside the inner diameter of the tubes. When considering forming
tubes with sub-millimeter features, this poses a large problem.
In many traditional style THF operations, tapered fill nozzles coupled with an applied axial force can be used.
However, due to the small inner diameter of the tubes being formed, the accuracy and precision of traditional
machining equipment lead to fabrication and operation challenges.
This paper explores the design of a new method for creating the required high pressure seal. Specifically, the
required high pressure seal is made on the outside surface of the tube ends using a flexible encompassing rubber
gasket and two proprietary designed seal cavities. In this study, stainless steel 304 micro tubes of varying outer
diameters (1.0 mm and 2.1 mm) and thickness were tested.
225 MSEC 2013 NAMRC 41

Effect of ball nose end mill geometry on high speed machining of Ti6Al4V
MSEC2013-1041
Ramesh Kuppuswamy, University of Cape Town, Rondebosch, Cape Town, South Africa, Deon Bower, Spectra Mapal
SA Pte Ltd, South Africa, South Africa, Poloko March, University of Cape Town, Cape Town, South Africa, South Africa
Use of Titanium alloys are increasingly common in the aerospace industries as the material offers higher strength
/ weight ratio that results in the increased fuel efficiency of the new age aircraft engines. However manufacturing
of components, using the Titanium alloys offer machining difficulties as the material exhibits higher thermal and
mechanical resistance. Furthermore the material has a tendency to gum up the cutting edge and reduces the
tool life. Having understood the machining difficulty of Titanium alloys, this project was proposed to develop;:
innovative ball nose end mills and operational parameters that enhance the machining efficiency. Prior research
on Titanium machining enumerates the machining difficulties and the notable past findings are; Yang and Liu[1]
reported that the high temperature of magnitude 1156oK is generated while machining titanium which induces
severe tool wear and deteriorates the surface finish. Three ways to improve machinability of Ti Alloy was proposed.
They are; use of pCBN and PCD tools, (ii) better cooling systems and (iii) change the material cutting characteristics
without reducing the strength. Rahman et al [2] proposed high pressure coolant (40 bar, water jet coolant) to
enhance the lubrication and cooling at the tool-work interface. The cooling effect tend to eliminate the adhesion
of work material on the cutting edge and improves the tool life as well as the surface finish. E.O. Ezugwu and
Z.M. Wang [3] proposed that low modulus of elasticity of titanium (110 GPa) is the main cause of chatter during
machining. Titanium deflects when subjected to cutting pressure and the spring-back induces cutting edge
failure and vibration. P.J. Arrazola et al [4] and I. Watanabe et al [5] reported that near-beta titanium alloys have a
poor machinability than the + phase Ti alloys. Ramesh et al [6] reported the use of intelligent manufacturing
system for validation of ball nose end mill on machining the Ti alloys. However no prior attempts were made
on understanding the tool geometry influence on the machining of titanium alloys. Therefore this research
was focused on understanding the influence of the ball nose end mill geometry on machining of Ti alloy. In this
research endeavour the machining behaviour of Ti alloy while using different ball nose end mill geometry were
discussed in terms of metal cutting mechanism, cutting force, surface finish and flank wear growth. The machining
results predominantly emphasize the significance of cutting edge features such as: K-Land, rake angle and cutting
edge radius. The ball nose end-mills featured with a short negative rake angle of value -5 for 0.050.06 mm i.e,
K-Land followed by positive rake angle of value 8 has produced lower cutting forces signatures for Ti-6Al-4V alloy.
JUNE 10-14, 2013 // Madison, Wisconsin
226

Abstracts, cont.
Machining of VP20ISOF steel with resharpened carbide tools in end milling
MSEC2013-1052
Ricardo Moura, Federal University of Uberlandia - Brazil, Uberlândia, MG, Brazil, Álisson Rocha Machado, Federal
University of Uberlândia, Uberlândia, MG, Brazil
The main objective of the present work is to determine the performance of resharpened integral coated cemented
carbide end milling tools. Tools as new and after they have been resharpened were tested, during machining of
hard steel used in the mold and die industry. The coatings used were TiAlN and AlCrN. The cutting speed was
varied, keeping the depth of cut, the cutting width and the feed per tooth constants. Tests were carried out dry. A
2Æ3 factorial design was used, considering the following factors (and levels): cutting speed (80 and 100 m / min),
tool coating (TiAlN and AlCrN) and the tool condition (new and reground). The output parameter considered
is the tool life (wear rate). At the end of the tool life the wear mechanisms were analyzed within a Scanning
Electron Microscopy - SEM. The results showed that in general the AlCrN coated tools outperformed the TiAlN.
The performance of resharpened tools was very similar to the new tools, and statistically there is no significant
difference between their tool lives.
227 MSEC 2013 NAMRC 41

Rapid finite element prediction on machining process
MSEC2013-1012
Long Meng, Xueping Zhang, Shanghai Jiao Tong University, Shanghai, China, Anil Srivastava, Ph.D., Techsolve Inc.,
Cincinnati, OH, United States
Finite Element Analysis (FEA) is widely used to simulate machining processes. However, in general, it is time
consuming, error-prone, and requires repeated efforts to establish a verified successful Finite Element (FE) model.
To rapidly investigate the effects of parameters such as tool angle, feed rate, cutting speed, and temperatures
generated during the machining process, an efficient approach is proposed in this paper. The technique has been
used to achieve rapid FF simulation during turning and milling processes using Python language programming
of Abaqus. Sub-model 1 is programmed to simulate the chip formation process in Abaqus/Explicit. Sub-model
2 is programmed to simulate the cooling spring-back process by importing the machined surface into Abaqus/
Implicit. The proposed method is capable of simulating the chip morphology, stress, strain and temperature of the
machining process with different parameters immediately. The established FE models are automatically solved
in batch by programming script. Post-processing is programmed by Abaqus script to easily achieve and evaluate
the simulation results. The Programmed FE models are validated in terms of the predicted chip morphology,
cutting forces and residual stresses. This method is extraordinarily efficient saving more than 33% simulation time
in comparison to existing FEA approach used for machining processes. Moreover, the script is concise, easy to
debug, and effectively avoiding interactive mistakes. The rapid programming model provides a novel, efficiency
and convenient approach to thoroughly investigate the effects of a large number of parameters on machining
processes.
JUNE 10-14, 2013 // Madison, Wisconsin
228

Abstracts, cont.
Analytical cut geometry prediction for free form surface during semi-finish milling
MSEC2013-1086
Hendriko, Universite Blaise Pascal, Aubiere, Auvergne, France, Emmanuel Duc, IFMA-Institut Français de Mécanique
Avancée, Aubiere, Auvergne, France, Gandjar Kiswanto, Universitas Indonesia, Depok, Indonesia
In five-axis milling, determination of continuously changing Cutter Workpiece Engagement (CWE) is still a
challenge. Solid model and discrete model are the most common method used to predict the engagement
region. However, both methods are suffering with the long computational time. This paper presents an analytical
method to define CWE for toroidal cutter during semi-finishing of sculpture part. The workpiece from 2 ½ rough
milling is representated by a number of blocks. The length of CWE at every engagement angle can be determined
by calculating the outermost engagement point called upper CWE point. This point was determined by initially
assummed that the workpiece surface is flat. A recalculation for CWE correction is then performed for the
engagement occurred in two workpiece blocks. The method called Z-boundary and X-boundary are employed
to obtain the upper CWE point when the engagement occurred on toroidal side. Meanwhile Cylinder-boundary
method was used when the engagement occurred on the cylinder side the developed model was examined
to ensure its accuracy. A sculptured surface part was tested by comparing the depth of cut generated by the
simulation developed and the depth of cut measured by Unigraphic. The result indicates that the proposed
method is very accurate. Moreover, due to the method is analytically, and hence it is more efficient in term of
calculation time.
229 MSEC 2013 NAMRC 41

Model learning in a multistage machining process: Online identification of force coefficients and model use in the
manufacturing enterprise
MSEC2013-1144
Parikshit Mehta, Clemson University, Clemson, SC, United States, Laine Mears, Clemson University, Anderson, SC,
United States
This work presents a systems approach in machining process control. Traditional force-based machining process
control has been focused on single machine-single operation. The force or power sensor is used to measure the
instantaneous force/power, and control action is taken by changing the feedrate in real time to follow a given force
setpoint. The application of such control has successfully been implemented to prevent chatter and to elongate
tool life by minimizing tool wear. This research seeks to extend the application of control algorithms to learn about
the machining system (comprised in this context of a workpiece being operated on by multiple processes), and
how knowledge generated by the process can be passed on to the next process for optimization. To demonstrate
this, turning of a partly hardened bar is explored. A nonlinear mechanistic force model-based control framework
attempts to control the cutting force at a designated setpoint, with material properties changing over the cut. The
force coefficients for the material are calculated offline using experimental data and Bayesian inference methods.
Since the hardened part of the bar will shift the force coefficient values, an online estimation strategy (Bayesian
Recursive Least Square estimator) is used to learn the new coefficients as well as satisfying the control objective.
With the newly learned coefficients passed downstream, the subsequent operation experiences no compromise of
control objective as well reduces the maximum values of force encountered. Numerical analyses presented show
the adaptation and control scheme performance.
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Abstracts, cont.
Estimation of milling forces from compliant sensors using a harmonic force model and kalman filter
MSEC2013-1196
Barry Fussell, Ph.D., Univ Of New Hampshire, Durham, NH, United States, Min Hyong Koh, University of New
Hampshire, Durham, NH, United States, Mehdi Nouri, University of New Hampshire, Middletown, CT, United States
Force transducers such as the piezoelectric Kistler dynamometer and the wireless strain gage Smart Tool are used
to monitor the cutting force during CNC machining. Due to sensor dynamics, there are differences between the
actual cutting force and the measured force, characterized by phase delay and additional vibrations in the cutting
profile. In this work, actual cutting forces are estimated from the measured sensor data using a Kalman filter. Since
cutting forces are composed of harmonics of the tooth passing frequency and runout frequency, both a sensor
dynamic model and harmonic cutting force model are included in the Kalman filter model in order to improve
performance of the filter. The harmonic computations of the measured cutting force are used to self-tune the
Kalman filter. Comparisons between the measured and estimated force show the ability of the Kalman filter to
reduce sensor vibration and noise with no phase delay.
231 MSEC 2013 NAMRC 41

VIDEO EVENT FAULT DETECTION WITH STVS: APPLICATION TO A HIGH SPEED ASSEMBLY MACHINE
NAMRC41-1533
Heshan Fernando, Kevin Hughes, Greg Szkilnyk, Queen’s University, Kingston, ON, Canada, Brian Surgenor, Queens
University, Kingston, ON, Canada, Michael Greenspan, Queen’s University, Kingston, ON, Canada
This paper examines the application of a video event detection method, based on spatiotemporal volumes (STVs),
to the monitoring of mechanical machine faults that are visually cued. An automated, high-speed assembly
machine was used as the source of image data. A set of image sequences from a section of the assembly machine
was captured using a single webcam while the machine was in operation. The motion was segmented in each
image creating binary frames which were stacked to build a STV. A training STV was modeled using a set of normal
operation sequences. New STVs, representing both normal operation and fault sequences, were then compared
to the training model to be classified accordingly. Test results showed that the system was very effective in the
detection of faults for the data set collected. Work continues with the assembly machine on a wider range of
mechanical faults.
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232

Abstracts, cont.
ASSEMBLY SYSTEM CONFIGURATION DESIGN FOR A PRODUCT FAMILY
NAMRC41-1604
Sha Li, Hui Wang, Jack Hu, University of Michigan, Ann Arbor, MI, United States
Traditionally, mixed-model assembly systems with a serial configuration are used to manufacture families of
products. Task variations associated with different models cause drift in such an assembly line. Drift is defined
as the deviation of system processing time from the nominal cycle time. To more effectively deal with increased
product variety, the assembly system can be set up with more complex, non-serial configurations, e.g., systems
with multiple subassembly branch lines that converge to an assembly line. Such complex configurations allow
for pre-assembly of different components on multiple lines simultaneously and thereby may potentially enhance
the system productivity and reduce drift. This paper proposes a systematic method for designing non-serial
system configurations for a family of products. A new mathematical definition for drift is introduced under both a
deterministic process using a cumulative sum (CUSUM) analysis and a stochastic process. Then the stochastic drift
model is embedded in an optimal assembly system design problem for task assignment to minimize cost and drift.
The method is developed based on a product family with tree type liaisons (no cycle in component connections).
A case study is conducted to demonstrate the method.
233 MSEC 2013 NAMRC 41

Combined temperature and force control for robotic friction stir welding
MSEC2013-1161
Axel Fehrenbacher, University of Wisconsin- Madison, Madison, WI, United States, Christopher Smith, Friction Stir
Link, Brookfield, WI, United States, Neil Duffie, University Of Wisconsin, Madison, WI, United States, Nicola Ferrier,
University of Wisconsin - Madison, Madison, WI, United States, Frank Pfefferkorn, University of Wisconsin- Madison,
Madison, WI, United States, Michael Zinn, University of Wisconsin - Madison, Madison, United States
The use of robotic friction stir welding (FSW) has gained in popularity as robotic systems can accommodate more
complex part geometries while providing high applied tool forces required for proper weld formation. However,
even the largest robotic FSW systems suffer from high compliance as compared to traditional C-frame systems.
The increased compliance of robotic FSW systems can significantly alter the process dynamics such that control of
traditional weld parameters, including plunge depth, is not sufficient to produce welds of good quality. To address
this, closed-loop control of plunge force has been proposed and implemented on a number of systems. However,
due to process parameter and condition variations commonly found in a production environment (e.g. thermal
constraints, material properties, geometry, etc.) force control can lead to oscillatory or unstable conditions and can,
in extreme cases the tool to plunge through the workpiece. To address the issues associated with robotic force
control, the use of simultaneous tool interface temperature control has been proposed.
In this paper, we describe the development and evaluation of a closed-loop control system for robotic friction stir
welding (FSW) that simultaneously controls plunge force and tool interface temperature by varying spindle speed
and commanded vertical tool position. The controller was implemented on an industrial robotic FSW system. The
system is equipped with a custom real-time wireless temperature measurement system and plunge force sensor.
In support of controller development, a linear process model has been developed that captures the dynamic
relations between the process inputs and outputs. Process identification experiments were performed to validate
the model and it was found that the interface temperature is affected by both spindle speed and commanded
vertical tool position while axial force is affected primarily by commanded vertical tool position for the range of
conditions studied in this work.
The combined control system was shown to possess good command tracking and disturbance rejection
characteristics over the range of operating conditions investigated. Axial force and interface temperature was
maintained during both thermal and geometric disturbances and thus weld quality can be maintained for a variety
of conditions in which each control strategy applied independently could fail. Finally, it was shown through the
use of a control process model described here that the robotic system closed-loop controller is primarily limited by
the inherent compliance of the robotic system, as compared to traditional C-frame systems where instrumentation
delay is the primary limiting factor.
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234

Abstracts, cont.
AFM-based nanofabrication: Modeling, simulation, and experimental verification
MSEC2013-1091
Rapeepan Promyoo, Hazim El-Mounayri, Varun Kumar Karingula, Kody Varahramyan, Indiana University Purdue
University Indianapolis, Indianapolis, United States
Recent developments in science and engineering have advanced the fabrication techniques for micro/
nanodevices. Among them, atomic force microscope (AFM) has already been used for nanomachining and
fabrication of micro/nanodevices. In this paper, a computational model for AFM-based nanofabrication processes is
being developed. Molecular Dynamics (MD) technique is used to model and simulate mechanical indentation and
scratching at the nanoscale. The effects of AFM-tip radius and crystal orientation are investigated. The simulation
is also used to study the effect of the AFM tip speed on the indentation force at the interface between the tip and
the substrate/workpiece The material deformation and indentation geometry are extracted from the final locations
of atoms, which are displaced by the rigid indenter. Material properties including modulus of elasticity and friction
coefficient are estimated. It is found that properties vary significantly at the nanoscale. AFM is used to conduct
actual nanoindentation and scratching, to validate the MD simulation. Qualitative agreement is found. Finally,
AFM-based fabrication of nanochannels/nanofluidic devices is conducted using different applied forces, scratching
length, and feed rate.
235 MSEC 2013 NAMRC 41

All solution based fabrication of CIGS solar cell
MSEC2013-1239
Robert Vittoe, Tung Ho, Sudhir Shrestha, Mangilal Agarwal, Indiana University-Purdue University Indianapolis,
Indianapolis, IN, United States, Kody Varahramyan, Indiana University Purdue University Indianapolis, Indianapolis,
IN, United States
This paper presents fabrication of copper indium gallium di-selenide (CIGS) solar cells using all solution-based
deposition processes. CIGS nanoparticles were synthesized through multi-step chemical process using copper
chloride, indium chloride, gallium chloride, and selenium in oleyamine. CIGS thin films were constructed through
layer-by-layer (LbL) self-assembly and spray-coating techniques. Chemical-bath-deposition and spray-coating
methods were used for cadmium sulfide and zinc oxide film depositions, respectively. Initial thin film solar cell
devices exhibited promising 0.3 mA short circuit current and 200 mV open circuit voltage. The solar cells fabricated
through the all solution-based processes are cost-effective, thus, have potentials of providing a viable, renewable
and sustainable energy source. The proposed processes can further be realized on flexible substrates, which may
broaden the applications range for the solar cells.
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236

Abstracts, cont.
Paper based lithium magnesium oxide battery
MSEC2013-1243
Nojan Aliahmad, Mangilal Agarwal, Sudhir Shrestha, Indiana University-Purdue University Indianapolis, Indianapolis,
IN, United States, Kody Varahramyan, Indiana University Purdue University Indianapolis, Indianapolis, IN, United
States
Replacing of metal current collectors with flexible materials has great potentials of improving flexibility, weight,
and applications of Li-ion batteries. This paper presents fabrication and experimental results of lithium magnesium
oxide (LiMn2O4) battery using conductive paper current collectors. A thin layer of LiMn2O4 was coated on paper
current collectors using air-spray method, and half-cell devices were fabricated. Experimental capacity of 130
mAh/g is reported. The porous structure of cellulous fibers in the current collector improves the adhesion of
electrode materials on the substrate, which provides higher flexibility and lighter weight.
237 MSEC 2013 NAMRC 41

Review and analysis of vibration assisted machining
MSEC2013-1017
Wenwu Zhang, Ningbo Institute of Materials Technology and Engineering, Ninngbo, China, Tianrun Zhang, Xiping
Zhang, Ningbo Institute of Materials Technology and Engineering, Ningbo, China
Direct mechanical machining runs into difficulties in machining of difficult-to-machine materials or when drilling
deep holes. Vibration has been used to reduce cutting force, increase chip-breakage, and increase machining
efficiency. This paper will review progress in this area and analyze the energy field methodologies behind these
processes. Similarities between multiple energy fields, including laser, EDM, ECM and USM are discussed.
JUNE 10-14, 2013 // Madison, Wisconsin
238

Abstracts, cont.
Mechanism of fatigue performance enhancement in a superhard nanoparticles integrated nanocomposites by a
hybrid manufacturing technique
MSEC2013-1040
Dong Lin, Purdue University, Lafayette, Indiana, United States, Chang Ye, Sergey Suslov, Yiliang Liao, Purdue
University, West Lafayette, IN, United States, C. Richard Liu, Purdue University, W. Lafayette, IN, United States, Gary
Cheng, Purdue University, West Lafayette, IN, United States
A hybrid manufacturing technique that integrates laser sintering (LS) of nanoparticles and laser shock peening
(LSP) is investigated in this study. Through laser sintering of mixture of TiN nanoparticles and Iron micro-sized
particles, TiN nanoparticles are embedded uniformly into iron matrix to form a nanocomposite layer on the surface
of AISI4140 steel. LSP is then performed on the nanocomposite layer to enhance its mechanical properties.
During the interaction with dislocations during laser-shock-induced plastic deformation, the nanoparticles exert a
pinning force to the dislocations and thus improve its stability. As a result, both dislocations and residual stress are
stabilized, leading to enhanced fatigue performance.
239 MSEC 2013 NAMRC 41

Modeling of focused ultrasound propagation in water towards a solid target and comparisons to experimental
observations on ultrasonic cavitation
MSEC2013-1246
Navid Dabir-Moghaddam, Yibo Gao, Benxin Wu, Illinois Institute of Technology, Chicago, IL, United States
A numerical model has been developed for focused ultrasound propagation in water towards a solid target, for
which the previous modeling work in the literature has been limited. The model predications are reasonably
consistent with experimental observations on the cavitation region size at the target surface in the given
ultrasound transducer power range, which has provided a verification of the model. The model calculations show
that the ultrasound-induced peak negative pressure is highly spatially non-uniform on the side surface of a studied
cylindrical target under the investigated conditions. This implies that to uniformly peen the target with focused
ultrasonic cavitation peening, a special process design and/or parameter selection may be needed, for which the
developed model may provide a useful guiding tool.
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240