Abstract Abrasive Water Jet Machining (AWJM) is a non-conventional machining process widely used in modern manufacturing industries due to its versatile cutting capabilities. The optimal performance of AWJM depends on the appropriate selection of process input parameters, which include water pressure, abrasive mass flow rate, material thickness, and cutting feed. However, the impact of material thickness variation on the AWJM process has been overlooked in previous research studies. To address this research gap, this study aims to investigate the effect of material thickness variation on the performance of AWJM and incorporate it as a factor in the process input parameters. The study methodology will employ the Taguchi orthogonal array and Analysis of Variance (ANOVA) to determine the optimal levels of process parameters for aluminum 6061 T65. The Design of Experiment (DoE) model will be set up based on the four input factors and their levels. Experiments will be conducted using the A-0612 WARDJet machine to achieve the best quality characteristics regarding the material removal rate (MMR) and the surface roughness Ra for different materials. By considering material thickness as a factor in the analysis of responses, this study seeks to enhance the understanding of the interrelationship between process input parameters and material thickness variation in AWJM. The study findings are expected to provide valuable insights to improve process efficiency and effectiveness, leading to better-quality outcomes in modern manufacturing industries.
With over 19 years of experience in academia, and over 12 years of industrial experience, primarily in the American automotive industry, Dr. Alsayyed has a passion for innovation in education, teaching, research, and training.Integration of academia and industry goals and activities are paramount to Dr. Alsayyed.Sensing the industry needs and preparing future engineers to meet those needs and challenges is an important
When developing new products, brand designers must analyse related products, which is a complicated and time-consuming process.Modern product design often requires complex engineering processes; product development requires extensive knowledge but there is also a demand for shorter product design cycles.Therefore, we propose a method based on extension theory and the analytic hierarchy process for identifying product-related knowledge, to aid the development of new products.First, based on our understanding of extenics, matter-element and relational meta-models of product form, function, and structure are established.Then, we define different primitives of brand identity.Finally, using an "extensional analytic hierarchy process" (EAHP), a hierarchy is established and the weights of different primitives are calculated.Various combinations of primitives are used to facilitate knowledge transfer for computer-aided intelligent design.Design data for multiple cases are analysed to verify the feasibility and effectiveness of the method.The method was verified in a physiological signal experiment, and the results show that the method can effectively accumulate product knowledge.Rapid data mining is important for market competitiveness.
Abstract In this project, we would like to explore the viability of using 3D printed injection molds to cost-effectively produce low-volume production runs. These 3D printed molds are much more cost-effective than traditional methods, however, the 3D printed molds often only withstand 50–100 cycles. Research is needed to determine how to improve the durability of the molds. This can be accomplished by measuring and documenting how injection molds made from various plastics, and various 3D printing technologies, react under the stresses of an injection molding machine. We can develop a case study using 4 different types of plastics that can be used to create the 3D printed mold. The 3 plastics would be Formlabs Ridged 10k Resin, Formlabs Clear v4, and Formlabs Tough 2000 Resin. These materials will be printed using various 3D printing technologies. This paper will focus on a literature review of the positives and negatives of 3D printing additively manufactured injection molding tooling and propose potential solutions for many of the negatives of 3D printed molds. The case study portion will be based on how we are planning to perform the case study, but it has not yet been completed.
As trade competition is getting fiercer, innovation in all areas of product realization is becoming more of a need than a want. In this paper, the authors present an innovative idea for an actual implementation of reconfigurable manufacturing, where a FlexDie is designed to manufacture sheet metal parts. The idea is to mimic the representation of graphics and text on a screen using pixels. The developed FlexDie in this paper consists of the two halves that are similar in design. It comprises pixel like pins assembled next to each other in the XY plane. The pinsâ heights in the Z-direction are designed to be adjustable to yield a desired topology. Each pixel can be altered and locked at a certain Z- coordinate. A prototype is developed to test the concept and produce preliminary results. The developed prototype consists of two-half dies, each having 8x8 square pixels, each of about 10x10 square mm. In the implemented design the Z-coordinates of the pixels are controlled and locked at desired heights via an array of screws. Sample parts consisting of three-dimensional metal sheets were manufactured using the developed FlexDie. This implementation opens the door for a new way of reconfigurable manufacturing, where the hardware is designed to be programmable.
Abstract One of the challenges for new engineering graduates is to find the dream job, and one of the challenges for industry is to find the right engineer to hire. Graduates will have to apply for many companies hoping to get interviews that will give them an opportunity to sell their skills and get the job. On the other hand, companies will have to interview many candidates hoping that they will get the right candidate to offer him/her the job. This is a tedious, time consuming, and costly process for both the industry and the new graduates. Many efforts are done by universities to offer certain general specialties to meet the industry needs. However, changes in universities curriculums are constrained by the curriculum requirements for the offered degrees. Also, curriculum changes are long processes, and by the time the changes are implemented, the industry needs may have already shifted. -Universities are educating students to have a solid skill set and inspire them to be life-long learners, and the companies can provide the training on the job for their new employees to further develop their skill sets. The authors of this paper propose building a skill portal with all three stakeholders in mind: Students (future engineers), Industry (potential employers), and Academia (educators of the potential engineers to be employed by industry or other sectors). The skill portal will allow the industry (company) to enter their desired skills via a GUI (Graphical User Interface) and save it into a database; allow students to view needed skills per different companies, and the university will design programs and activities (certification programs, in particular, given its flexibility and the potential to integrate it with some courses) to prepare students with the needed skills for certain industry needs. A pilot program is now running to solicit needed skill from the industrial partners of our university, and to encourage the students in a class to pursue a certificate, with both pieces of information to be shared among all the relevant parties. The pilot program will be used to evaluate this program's impact on shortening the time for the students to get the right job after graduation, and the time for the companies to hire the right employee.
Abstract A potential drawback of polymer injection molding is the relatively high cost of metal mold inserts. This limits a manufacturer’s ability to capitalize on smaller customized product batches and in-house cavity prototyping. To overcome this, manufacturers have found success in the use of polymer-based 3D printed molds. Professional grade stereolithography ultraviolet (SLA UV) resins have become standard materials for 3D printed molds, but there is little documentation concerning the use of other commercially available polymers. This includes materials used in inexpensive Fused Deposition Modeling (FDM) and SLA printers. The research presented in this paper explores this aspect of additive mold technology. Mold inserts composed of polylactic acid (PLA), polyethylene terephthalate glycol (PETG), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), nylon, carbon fiber polylactic acid (CF PLA) and 405 nm photopolymer resin were compared with various physical metrics. By tracking the dimensional accuracy and flash sizes over the course of 50 mold shots, the rates of cavity degradation for each insert were compared. The results of this study concluded that the most sustainable polymer mold cavity is composed of ABS or a Carbon Fiber reinforced polymer. This is followed by PC, PETG, resin, nylon, and PLA.
In this paper, the authors will present the use of a vortex tube in cooling milling operations. The focuses will be regarding the surface finish and temperature of the tool during the cutting operation. Three cooling setups, cutting without coolant, cooling with a water base traditional coolant, and cooling with vortex tube will be compared. A Flir E320 UV camera has been used to capture the heat map around the tool during the cutting process. The surface roughness has been measured and analysed for all three samples using Taylor/Hobson Precision Surtronc 3+ apparatus. The findings of this study have shown comparative efficient cooling using the vortex tubes. The vortex tube cooling is also cleaner and can be directed in such a way to collect the chips as they develop with the least mess or no mess. Vortex tubes have no moving parts, and it is very much maintenance free device. Compressed air is needed to feed the vortex tube, which is available usually in any machine shop.
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