Materials Processing and Tribology Research
Group
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Introduction
The Materials Processing and Tribology Research Group is a
cross-disciplinary research group between the schools of
Industrial Engineering (IE) and
Aeronautics and Astronautics (AAE)
comprising three professors, several laboratories, and about
twenty graduate students.
The group has an active research
program in various aspects of advanced manufacturing processes
and tribology pertaining to the manufacture of precision
mechanical components such as bearings, fuel injectors,
compressors, gears, and electromechanical devices.
The principal thrusts of the research program, which is funded by
a variety of federal and industrial sources, are
- Advanced Manufacturing Process Development
- Modeling of Manufacturing Processes for Predicting
Performance and for Process Control
- Understanding the Effects of Processing on Tribological
Performance (e.g.rolling contact fatigue life, steady
state vs.running-in characteristics, wear resistance,
etc.) of Precision Mechanical Components.
A brief summary of the research projects being carried out by the
group, the students (and recent graduates along with present affiliation)
who are associated with the project, the
sponsors, and the laboratory facilities available are given
below.
Overview of Research Projects
1. Grinding Research
Grinding research is focused on centerless grinding
and high speed surface grinding of steels and ceramics; models for
grinding forces, form generation,
burn, and residual stress; and evaluation of grinding
wheel wear.
- J.B. Mann, M.S. (1994), Cummins Engine Co.
- S.A. Hucker, Ph.D. (1994), GM Powertrain
- P.N. Moulik, Ph.D. (1995), Firestone
- T.L. Dunlap, M.S. (1995), TI
- W.J. Reimann, M.S.
- Y. Ju, Ph.D.
- S. Kompella, M.S.
Relevant Papers
Supported by:
[NSF]-
[Timken]-
[GM]-
[ Cummins]-
[ Cincinnati Milacron]-
[Goldcrown]-
[ Norton]-
[CCM]
2. Mechanics of Machining
We are studying the frictional conditions at the chip-tool interface,
developing methods to measure tool temperatures using infrared sensing,
and carrying out finite element simulation of machining.
- S. Slijepcevic, M.S. (1995), Allied Signal
- V. Madhavan, Ph.D. (1996), Wichita State University
- K. Krishnamurthy, M.S.
Relevant Papers on Mechanics of Machining
Supported by:
[NSF]
3. Lapping, Polishing, and Superfinishing of steels
and ceramics
Models are developed for relating measured forces and pressure to
the material removal mechanisms.
- S.Y. Chen, Ph.D. (1994), NIST Post-doc
- Ling Lu, Ph.D. (1995), Elliott Turbomachinery Co
- V. Bulsara, Ph.D.
(1996), Cummins Engine Co.
- S.H. Chang, Ph.D.
- B. Suresh, M.S.
- K. Jayaraman, M.S.
Relevant Papers on Material Removal Mechanism
Supported by:
[NSF]-[Timken]-[CCM]
-[GE Superabrasives]-[GM ]-[Hardinge]-[TEC]
4. Slicing of Ceramics
A new manufacturing process has been developed for slicing ceramics such
as silicon carbide, silicon nitride, and aluminum oxide.
Relevant Papers on Slicing of Ceramics
Supported by:
[Coors]-[Rogers Tool Works]-[AT&T]
5. Finish Machining of Hard Materials
The unlubricated finish machining of hardened steels with CBN tools is
being studied---topics include surface quality and integrity, tool
wear, form errors, and machine tool rigidity.
- S. Swain, Ph.D. (1996), Ford Manufacturing Leadership Program
- P.S. Sista, M.S.
- J.A. Bougher, M.S.
- N.S. Akcan, M.S.
Supported by:
[Cummins Engine Co.]-[GE]-[GM
]-[Hardinge]-[TEC]
6. Surface Finishing Processes for Thermally Sprayed
Coatings
The above are being investigated to develop processes that do not damage the
coatings.
Supported by: [GM]-[CCM]
7. Microhole Electric Discharge Machining
- R.R. Hebbar, Ph.D. (1992), Cummins Engine Co
- H. Yeung, M.S. (1994), Owns Business in Hong Kong
- J. Yang, M.S. (1995), Rockwell International
- R. Ramabhadran, Ph.D. (1996), Cummins
- T. Boone, M.S.
Supported by: [Cummins Engine Co.]
8. Vibration Assisted Drilling
The effect of superimposed, low frequency vibrations on the drilling
process is being studied.
Materials of interest are aluminum and titanium alloys, steels,
and graphite/titanium sandwich structures.
Potential benefits are easier chip disposal and better hole quality.
- H.G. Toews, M.S. (1995), Lexmark
- D. Ramaswamy, M.S.
- P. Chhabra, M.S.
- B. Ackroyd, M.S.
- N. Dai, M.S.
Supported by: [Boeing]
9. Modeling of Heat Treatment Processes
These include the development of finite element codes and accompanying
experiments to predict microstructure, residual stress, and
distortion induced by quenching and carburizing.
- K.F. Wang, Ph.D. (1993), GE Aircraft Engines
- P.R. Woodard, Ph.D. (1996)
- P.T. Rajeev, M.S.
Supported by: [A Finkl & Sons]-[Horsburgh &
Scott]-[Allison]-[CCM]
11. Mechanics of Fretting Fatigue
The above is being investigated using multiaxial fatigue theories,
finite element modeling, and reduced
experiments to predict the remaining life of aging aircraft joints.
Relevant Papers on Fretting Fatigue
Supported by: [AFOSR]
12. Modeling of Tribological Performance of Surfaces
This study focuses
on development of predictive tools for the effect of manufacturing
process parameters on product performance.
- M. Liu, Ph.D. (1992), Ford Transmission Operation
- Y. Xu, Ph.D. (1994), Ford Stamping Division
- B.E. Varney, M.S. (1995), Cummins
- Y. Ju, Ph.D.
Relevant Papers
Supported by: [Association of American Railroads
(AAR)]
Naval Surface Warfare Center, and NSF
13. Microelectromechanical Sensors and
Actuators
Microelectromechanical Sensors and Actuatorsare being
investigated as potential tools for measuring torque and
localized strains induced by manufacturing processes.
- E.E. Sack, M.S. (1994), Rockwell Space Operations
- J.B. Taylor, Ph.D. (1995), NC State
- J.A. McKenna, M.S. (1996), Tyler Industries, Inc.
- L.R. Hill, Ph.D.
Relevant Papers
Supported by: [NSF]
Projects being formulated
- Diamond-like nanocomposite films
- Tribological performance of Metal-Matrix Composites
Supported by:: [ART]-[CCM]
Available Equipment
Materials Processing and Tribology Laboratory
Equipment
- Machine tools
- Hardinge High-Precision Lathe (Conquest T42SP)
- High-Speed, Precision Surface Grinder
(HEDG-MASTER from ELB Schliff)
- Cincinnati Milacron 220-8 Centerless Grinder in November 1996
- CNC milling machine and CNC lathe (Cincinnati Milacron)
- CNC machining center (Cincinnati Milacron)
- Superfinishing Machine (Seibu)
- Lapping and polishing machines (Leco and SpeedFAM)
- Microhole-EDM (Raycon)
- Vibration assisted drilling machine:
Rotational speeds up to 12,000 rpm; oscillation
frequencies up to 18,000 cpm---This machine
could be used for some fundamental studies of superfinishing
Measurement and metrology
equipment
- 22 kip computer controlled, servo-hydraulic testing machine (Instron)
- Form-Talysurf and Talyrond (252) profilometers
- Atomic force microscope (AFM)
- Multi-element Infrared Imaging System (Galileo from Raytheon)
in November 1996
- Interference Contrast Microscope in December 1996
- Laser interferometers
- Capacitance and inductive displacement measurement probes
- Newport vibration isolation table
- Newport micropositioning actuators (25 nm resolution)
- Infrared detectors for temperature measurement
- Optical (interference contrast) microscopes
- Piezo-electric actuators
- Grinding, drilling, and cutting dynamometers (Kistler)
- Coordinate measuring machine (CMM)
- Microprocessor-controlled furnace for heat treatment
- High pressure pump
- Rolling contact fatigue testers
- Scratch testing equipment; image acquisition and processing
Computers
- Three Sparc workstations, several Pentium and 486 PCs
- Three Silicon Graphics Machines in the Aerospace Post-processing and
Visualization Lab.
- Access to Engineering Computer
Network, supercomputers
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