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METU-MATIMAREN

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TUBITAK

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Prof. Dr. Francesco JOVANE
Politecnico di Milano

New Global Strategies in Manufacturing

Manufacturing Industry has long established itself as generator of wealth and jobs , directly and through related services. It originated and has enabled a historically unprecedented economic growth and development process , while causing environmental, social, economical problems .
Currently , Manufacturing Industry is going through a global revolution, that concerns at the same time globalization and the pursuit of Sustainable Development and Green Growth.
Globalization has integrated national economic systems and stimulated global economic growth, but it has led to growing inequalities within and among Countries. Moving towards Sustainable Globalization is a must.
The pursuit of Sustainable Development and Green Growth requires responding to Societal Grand Challenges, through innovative, Competitive and Sustainable, Products and Processes, Business Models. They should be supported by Key Enabling and Industrial Technologies.
A new Competitive and Sustainable Manufacturing Industry, co-optimizing Competitiveness with environmental quality and labor/employment concerns, is then required. Its development is based on a generous, strategic and proactive, commitment by Industry, Academia, Public Authorities.

Prof. Dr. Ahmet ALPAS
University of Windsor

TRIBOLOGY OF HOT AND WARM FORMING OF LIGHTWEIGHT ALLOYS

Future advances in hot and warm forming operations are closely related to the control and improvement of the tribological contact conditions between the sheet metal and the forming tool. This is especially important for low melting point lightweight Al and Mg alloys used in automotive and aerospace industries. During hot and warm forming operations Al and Mg alloy blanks that come into contact with forming tools create a tribological system whose properties determine the surface quality of the final product as well as the tool life. The tribological problems that occur during these processes tend to be numerous, and include metallic particle transfer to the tool, which leads to adhesion and surface damage to both the die and the workpiece.
A tribometer that simulate surface contact during ;hot and warm forming was designed and used to measure the coefficient of friction (COF) of AA5083 and AZ31 alloy samples;while subjecting them to tensile deformation at various temperatures and strain rates comparable to the process conditions. Friction maps were developed by plotting COF values over the ranges of dominant deformation mechanisms. The maps established general relationships between the tribological behaviour and the micromechanisms that control deformation under a set of temperature, strain and strain rate. In addition, changes in surface topography and oxide properties were determined. The results have proven to be helpful to identify the factors that control friction and adhesion and to develop effective lubricants and coatings for hot and warm formed products suitable for high automotive volumes.

Professor Toshimichi Moriwaki
Dean, Faculty of Science and Engineering,
Setsunan University

Recent Advances in Machine Tool and Machining Technologies

Advances in recent development of metal cutting machine tools and machining technologies are surveyed and introduced mainly focusing to the academic as well as industrial activities in Japan. The topics include technologies related to precision/ultraprecision machining, high speed machining, intelligent machining and multi-tasking machining.

Prof. Dr. Mustafizur Rahman
Dept. of Mechanical Engineering
National University of Singapore





Integrated compound/hybrid tool-based micro machining


In recent years, the trend in miniaturization of products is pervasive in areas such as information technology, biotechnology, environmental and medical industries.  Micro machining is the key supporting technology that has to be developed to meet the challenges posed by the requirements of product miniaturization and industrial realization of nanotechnology.  Micro machining can be carried out by techniques based on energy beams (beam-based micro machining) or by solid cutting tools (tool-based micro machining). Beam-based processes have some limitations due to poor control of 3D structures, slower material removal rate and low aspect ratio.  Some of these limitations can be overcome by tool-based techniques using ultra-precision machine tools and solid tools to produce micro-features with well controlled shapes with high tolerances.
Recently, combination of conventional material removal processes, such as turning and milling have been hybridized/compounded with non-conventional processes such as EDM, EDG and ECM to fabricate micro-structures with high dimensional accuracy.  In order to achieve meaningful implementation of such techniques three following important areas needed to be addressed: development of machine tools capable of performing hybrid/compound micro machining (i.e. micro turning, micro milling, micro EDM, etc. on the same machine and set up), understanding of process physics to provide relevant background for modeling, measurement, identification of control parameters and application of feedback control in order to control compound and hybrid processes and further development of such processes. An integrated effort in these areas in needed for successful implementation of tool-based micro machining. Current status of integrated compound/hybrid tool-based micro machining will be discussed in this presentation.

Prof. Dr. Jun Ni
Mechanical Engineering
University of Michigan

Recent Advances in High Performance Machining and Machine Tools


In today's global economy, manufacturing companies compete on three equally important fronts: cost, quality and responsiveness. High performance machining is an effective approach to achieve faster, better and cheaper manufacturing. This presentation will present some recent advances in high performance machining and machine tools research. Specifically, this talk will cover the topics of: (1) high throughput hole making processes, (2) active balancing technology for high-speed machining, (3) active chatter suppression, (4) real-time error compensation for high precision machining, and (5) high-definition metrology driven processes.





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