HONORARY KEYNOTE SPEAKER:
Prof. Yusuf Altintas, Ph.D., Dr. Cau-Budapest, Hon.Dr. Ing. (Stuttgart)
Fellow of Royal Society of Canada, EC, CAE, CIRP, ASME, SME, ISNM, P&WC, Tokyo Univ.
NSERC - P&WC Industrial Research Chair Professor in Virtual Machining
The aim of our research is to develop mathematical models of metal cutting operations, machine tool vibrations and control. The science based digital models allow the virtual design of machine tools, and testing and optimization of machining operations.
In the first half of the special session, we discuss the meaning and the framework of Design Science toward the integration of design and work on sharing the same recognition will be discussed. "Design Science Dictionary", a web-based dictionary in growth form with regular updating, and its usage will also be presented.The model predicts the cutting forces, torque and power consumed in machining parts by considering material properties, cutter geometry, and cutting conditions along the tool path. The structural dynamics of the machine tool can either be imported from Finite Element analysis if the machine tool is at the design stage, or from the experimental modal measurements if the machine is already built. The simulation system predicts chatter free cutting conditions within the work volume of the machine tool, or detects the presence of chatter vibrations along the tool path. The dynamics of servo drive control systems, and trajectory generation as a function of jerk, acceleration and velocity profiles of machine tools are considered in simulating the machine tool behavior. An in-house developed virtual and real time CNC system allows the design and analysis of five axis machine tool controller.
The algorithms are published in open literature (Google Scholar h-67 with over 15800 citations), and packaged in industrial software tool box which can be used as a process planning tool by production engineers or as an analysis module by machine tool builders (over 200 companies and research centers world-wide). We are currently developing a controller for a 9 axis precision micro machine developed in our laboratory, investigating damping of machine tool vibrations, and the stability of turning, drilling, boring, micro-cutting, threading of pipes and mill turn operations.
Professor Altintas obtained his Bachelor from Istanbul Technical University (1975), M.Sc. (1980) and Ph.D. (1987) in Canada. He worked as a machine tool manufacturing engineer in Turkey (1977-1978), process development engineer in Pratt & Whitney Canada in Montreal (1980-1981), and the principal engineer of Canadian Institute of Metalworking in Hamilton (1981-1982). He joined University of British Columbia and founded Manufacturing Automation Laboratory in 1986. He conducts research on metal cutting, machine tool vibrations, control and virtual machining. He has published 141 archival journal and 95 conference articles with over 12300 citations with h index of 60 (Google Scholar), and a widely used "Manufacturing Automation: Principals of Metal Cutting Mechanics, Machine Tool Vibrations and CNC Design. 1st ed. 2000, 2nd ed.:2012. His research laboratory created advanced machining process simulation (CUTPRO), virtual part machining process simulation (MACHPRO) and open-modular 5 axis CNC system (Virtual CNC), which are used by over 180 companies and research centers in the field of machining and machine tools worldwide.
Professor Altintas is the fellow of Royal Society of Canada, CIRP, ASME, SME, CAE, EC, Tokyo University, P&WC, AvH and ISNM. He received Pratt & Whitney Canada's (P&WC) university partnership (1997), APEG BC's Meritorious Achievement (2002), APEG BC R.H. McLachlan (2010), UBC Killam Teaching Prize of Engineering (2011), Gold Medal of Engineers Canada (2011), SME Albert M. Sergent Progress Award (2012), NSERC Synergy Award, ASME Blackall Machine Tool and Gage best journal paper award, and the special scientific award of Republic of Turkey in Science and Engineering (2013). He holds an Honorary Doctorate Degrees from Stuttgart University (2009) and Budapest University of Technology (2013).
He currently directs NSERC CANRIMT Machining Research Network across Canada. He holds the NSERC - P&WC Industrial Research Chair Professorship to develop next generation Virtual High Performance Machining Technology since 2002.
Mechanical Engineering Professor Yusuf Altintas Honoured By The President Of Turkiye.
Prof. Dr.-Ing. Michael F. Zäh
Institutsleiter, Institut für Werkzeugmaschinen und Betriebswissenschaften(iwb)
Technische Universität München
NEXT GENERATION HIGH PERFORMANCE SMART MACHINE TOOLS
The next generation machine machine tools, though in appearance almost the same with today´s , will change significantly. There are new approaches such as parallel kinematics and robots replacing classical machine tools in some applications. The technological development manifests itself in many different aspects of the machine. Modern machine tools shape a platform for hybrid processes, they allow the shortening of process chains, they are advanced in terms of their dynamic behavior and damping, they use adaptronic functions, they are thermally stable, they allow for multiple technologies, they are resource efficient and environmentally friendly and they are developed by using sophisticated means of simulation. Beyond that they are intelligent in the way that they have communication interfaces to other systems in order to become part of the so called Industrie 4.0, the synonym for the future integrated production scenarios. In other words: Machine tools will be cyber-physical systems. This paper outlines these trends and uses examples out of the authors´ personal research interests.
Key Words: Smart machine tools, industry 4.0, cyber-physical systems
The research activities of Professor Zäh (b. 1963) focus on machine tools and generative production methods, production technology and cognition for engineering systems.
Professor Zäh graduated in mechanical engineering from TUM, where he also earned his doctorate degree in 1993 under the supervision of Professor Milberg, at the Institute for Machine Tools and Industrial Management (IWB). From 1994 to 1995, he was Chief Engineer and Department Head for Machine Tools and Production Technology under the direction of Professor Reinhart. In 1996, he switched over to the private sector, working for a manufacturer of machine tools used for gear wheel machining, where he held various management positions. In 2002, Professor Zäh accepted the Chair of Machine Tools and Production Technology at TUM and has held the position of Director of the IWB since then.
Stuart Barnes, Assoc. Prof. Dr.
Director of Research Degrees WMG,
International Manufacturing Centre University of Warwick, Coventry, UK
ULTRASONIC ASSISTED MACHINING
The continuous drive to develop materials with enhanced mechanical and physical properties has resulted in significant improvements in the materials available to design engineers. Examples of such developments range from high performance steels and aluminium alloys, to complex high-temperature superalloys and carbon fibre composites. However, some of these advances in performance also present an additional challenge to the manufacturing engineer when it comes to machining these materials. Improved mechanical properties can also result in reduced machinability.
In response to these challenges, tool materials and coatings have been improved and various adaptions of the conventional machining processes have been developed in order to allow economically viable machining of what are often described as "difficult-to-machine" materials. One such adaption is that of Ultrasonic Assisted Machining (UAM) which has been demonstrated to have a positive effect on certain aspects of machining, with several laboratory scale facilities being developed by researchers. However, the equipment being used at WMG is a purpose-built, commercially available, 5-axis machine tool provided by DMG MORI, the Ultrasonic 65. The availability of production equipment has enabled UAM to be investigated in order to understand the fundamental aspects of the technique as well as the practical implications of its use from the point of view of the machinist.
The work conducted to date has shown that UAM is an interesting and complex field for machining research. From the practical point of view, some variables that need to be considered in UAM such as how to hold the cutting tool, how much the tool should protrude from the holder, the mass of the tool etc., are far more important than in a conventional machining operation. Tool wear has also been found to reduce the advantages of UAM, which would be an important factor in a production process. In order to maximise the benefits of UAM, it is clear that there is a significant amount of work which needs to be done to understand how to operate the process from a practical point of view. In terms of a scientific understanding of the process, there is also much research that needs to be conducted. For example, the effect of ultrasonic oscillation on the mechanisms which take place in the cutting zone are complex and not easy to study directly. This is especially the case with materials such as CFRP, due to the heterogeneous nature of the material and absence of chips to study. However, the machining of metals provides the opportunity to study the machining mechanisms in relation to accepted metal cutting theory and develop a UAM modification of that theory. Therefore, the challenge is to continue developing a fundamental understanding of the process and its practical application so that it can be applied appropriately to improve the machinability of difficult-to-machine materials.
Dr Stuart Barnes is a metallurgist by profession; he graduated from the University of Birmingham in 1988 with a PhD in metal cutting, is a Chartered Engineer and a Fellow of the Institute of Materials, Minerals and Mining. He joined WMG (formerly Warwick Manufacturing Group), University of Warwick in 1992 to research conventional and laser machining of composite materials, having spent 13 years in industry with GKN Technology and NEI Thompson. Dr Barnes then worked on WMG's teaching programmes in the UK and overseas and in 2002 was made Director of Professional and Executive Programmes. Although heavily involved in the teaching activities, Dr Barnes maintained his involvement in machining research via MSc and PhD students.
In May 2013, Dr Barnes changed role to that of Director of Research Degrees with responsibility for all research degrees offered within WMG. Current research student numbers are in excess of 200. He also took on the leadership of WMG's Net-Shape Manufacturing group and increased the number of research students that he personally supervises in the UK and Hong Kong. Current areas of research include ultrasonic assisted machining (UAM), cryogenic machining and the development of new cutting fluids for "difficult-to-machine" materials such as titanium alloys and carbon fibre composites. In 2013, Dr Barnes led WMG's input to a successful Technology Strategy Board bid (now Innovate UK) to develop the next generation of cutting fluids (HiPAdd). He also works closely with BAE Systems on the machining of carbon fibre composites for military aerospace applications. In 2016, Dr Barnes worked with Teer Coatings Ltd, Kyocera (cutting tools division) and BAE Systems to win funding from the National Aerospace Technology Exploitation Programme (NATEP) for the development of cutting tools specifically designed for UAM. Dr Barnes presented at UMTIK 2014, is on the International Organising Committee for the UMTIK 2016 conference and has authored / co-authored over 70 publications during his time at WMG.
Dr Barnes also teaches on postgraduate programmes in the area of conventional machining and research methodology, is Module Tutor for an Engineering Materials module, which he delivers in Singapore, and Research Methodology modules which he delivers in Singapore and Kuala Lumpur. He is also an External Examiner for MSc programmes at the University of Hertfordshire.