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					 Introduction to Mechanical
 Engineering Program at IUPUI
 Presented to Industrial Advisory Board, October 5, 2001


H.U. Akay
Professor and Chair
Department of Mechanical Engineering
Indiana University-Purdue University Indianapolis


                  http://www.engr.iupui.edu/me
                                       Department of Mechanical Engineering, IUPUI



           Outline
              Introduction to IUPUI
              Degrees and curriculum
              Research programs and facilities
              Sample projects




10-05-01              Industrial Advisory Board Meeting
                                  Department of Mechanical Engineering, IUPUI


     IUPUI
     Urban campus of
     Indiana University
     and Purdue
     University




10-05-01         Industrial Advisory Board Meeting
                                   Department of Mechanical Engineering, IUPUI


  • IUPUI enrolls 27,000 students
    and employs 1,400 faculty and
    7,000 staff
  • Offers 179 Indiana University
    and Purdue University degrees
  • IUPUI’s 65 academic buildings
    are located on 285 acres west of
    downtown Indianapolis




10-05-01          Industrial Advisory Board Meeting
                                      Department of Mechanical Engineering, IUPUI



           ME Faculty
          13 Faculty Members (3 Biomedical
           Engineering (BME) faculty with joint
           appointments in dentistry and medicine
          2 Emeriti Faculty
          2 Associate Faculty
          2 to be hired (thermo fluids and
           mechatronics)



10-05-01             Industrial Advisory Board Meeting
                                             Department of Mechanical Engineering, IUPUI



               ME Faculty and Research Areas
              Dare Afolabi, Ph.D., Imperial College, 1982. Structural
               dynamics, structural stability, applied mechanics,
               nonlinear mechanics, control
              Hasan U. Akay, Ph.D., University of Texas at Austin,
               1974. Computational fluid dynamics, computational
               mechanics, finite element method, parallel computing,
               fatigue and creep modeling, electronic package
               reliability
              Jie Chen, Ph.D., Drexel University, 1989. System
               design and simulation, hybrid electrical vehicle
               simulation, engineering design, kinematics,
               biomechanics, implantology, joint mechanics, mechanics
               of orthodontics, dental restorations


10-05-01                    Industrial Advisory Board Meeting
                                           Department of Mechanical Engineering, IUPUI
           ME Faculty and Research Areas
           (cont’d)
          Akin Ecer, Ph.D., University of Notre Dame, 1970.
           Computational fluid dynamics, parallel computing,
           dynamic load balancing, finite element method
          Hazim El-Mounayri, Ph.D., Mc Master University, 1997.
           Advanced manufacturing, intelligent machining,
           CAD/CAM, solid modeling, machining process control,
           simulation and optimization, automation
          Andrew T. Hsu, Ph.D., Georgia Institute of Technology,
           1986. Computational fluid mechanics, combustion,
           reactive flows, turbulence and transition modeling,
           biomedical fluid mechanics
          M. Razi Nalim, Ph.D., Cornell University, 1994.
           Unsteady fluid mechanics, combustion, wave rotors,
           pollution control in combustion engines, propulsion
10-05-01                  Industrial Advisory Board Meeting
                                            Department of Mechanical Engineering, IUPUI

           ME Faculty and Research Areas
           (cont’d)
          Peter Orono, Ph.D., Wayne State University, 1991.
           Dynamics, vibrations, and controls
          Nasser H. Paydar, Ph.D., Syracuse University, 1985.
           Computational mechanics, biomechanics, electronic
           package reliability, finite element method
          Ramana M. Pidaparti, Ph.D., Purdue University, 1989.
           Composites, computational intelligence applications,
           biomechanics and biomaterials, biomedical engineering
           device design, fatigue and fracture, smart materials and
           structures, fracture mechanics, finite element method



10-05-01                   Industrial Advisory Board Meeting
                                              Department of Mechanical Engineering, IUPUI



               BME Faculty and Research Areas

              Thomas R. Katona, Ph.D., University of Pennsylvania,
               1981. Biomechanics, bone fatigue, implants, tooth
               movement, dental restorations, orthodontic bracket
               strength
              Charles Turner, Ph.D., Tulane University, 1987. Solid
               mechanics, biomechanics, biomaterials, bone biology,
               musculoskeletal biomechanics
              Hiroki Yokota, Ph.D., University of Tokyo, 1983, Ph.D.,
               Indiana University, 1993. Molecular bioengineering,
               biomechanics, biotechnology, bioinformatics, human
               genomics



10-05-01                     Industrial Advisory Board Meeting
                                        Department of Mechanical Engineering, IUPUI



           Undergraduate Program
          150 students (+~50 in Freshmen
           Engineering Program)
          Over 700 Alumni
          Bachelor of Science in Mechanical
           Engineering (BSME)
          Bachelor of Science in Engineering (BSE)
              Biomechanics
              Engineering management
              Mechatronics
          A Dual Degree Program with Butler (BSME)

10-05-01               Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI


       Undergraduate Curriculum
          Physical sciences
          Mathematics
          Computer languages and tools
          Solid mechanics
          Fluid mechanics
          Thermal sciences
          Dynamics, controls, measurements, and electro-
           mechanical systems
          Design and manufacturing
          Computer simulations (CAD/CAE)
          Technical communication
          Professional ethics
          General education (humanities/social sciences)
10-05-01                Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI



           Teaching Laboratories
          The following laboratories are maintained in
           the department for undergraduate teaching:
              Heat and Mass Transfer Laboratory
              Fluid Mechanics Laboratory
              Design Laboratory
              Mechanics of Materials Laboratory
              Dynamics and Measurements Laboratory




10-05-01                Industrial Advisory Board Meeting
                                       Department of Mechanical Engineering, IUPUI




           Graduate Program
          50 students (thesis and non-thesis
           options)
          Master of Science in Mechanical
           Engineering (MSME)
          Master of Science in Engineering (MSE)
          Master of Science (MS)
          Ph.D. – in collaboration with Purdue WL



10-05-01              Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI



           Specialty Areas in Graduate Program
           Solid Mechanics
              Includes advanced manufacturing, advanced
               materials, fracture mechanics, CAE/CAD/CAM,
               computational solid mechanics, vibrations, etc.)
           Fluid and Thermal Sciences
              Includes combustion, computational fluid
               dynamics, finite elements, nanotechnology, etc.
           Biomechanics
              Includes bone and tissue mechanics,
               computational biomechanics, dental
               mechanics, genomics, etc.

10-05-01                Industrial Advisory Board Meeting
                                        Department of Mechanical Engineering, IUPUI



           Master’s Degree
          Thesis Option – 30 credit hours (seven
           graduate courses + thesis)
          Non-Thesis Option – 30 credit hours
              Up to six credit hours (two courses) may
               be independent projects – recommended
               for part time students




10-05-01               Industrial Advisory Board Meeting
                                        Department of Mechanical Engineering, IUPUI



           Graduate Coop Program
          Designed for graduate students to:
               Work in industry during alternating
               semesters with salary paid by the
               sponsoring company
              Involved in advanced/applied projects
               while resident in company under co-
               supervision of a senior company engineer
               and a faculty member




10-05-01               Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI

           Certificate in Computer-Aided Mechanical
           Engineering - New

          Designed to address industry's increased
           needs for engineers who can model
           complex engineering design and analysis
           problems competently using computers
          12 credit hours of course work – four
           courses (as opposed to 30 credit hours for
           Master’s)
          Specialty areas:
              Computations of Mechanical Systems
              Computations of Fluid and Thermal Systems

10-05-01                Industrial Advisory Board Meeting
                                                                       Department of Mechanical Engineering, IUPUI




                                                    ME Credit Hours by Academic Year

                     4500

                     4000

                     3500

                     3000
      Credit Hours




                     2500

                     2000

                     1500

                     1000

                      500

                        0
                            90/91   91/92   92/93     93/94   94/95   95/96   96/97   97/98   98/99   99/00   00/01
                                                                Academic Year

                                                                      Note: 2000/2001 credit hours do not
                                                                      include ~400 freshman credit hours


10-05-01                                        Industrial Advisory Board Meeting
                                                                          Department of Mechanical Engineering, IUPUI




                                                        ME Graduates by Academic Year

                           70


                           60
     Number of Graduates




                           50


                           40                                                                                     BS + MS
                                                                                                                  BS
                           30                                                                                     MS


                           20


                           10


                            0
                                91/92   92/93   93/94    94/95    95/96   96/97   97/98   98/99   99/00   00/01
                                                                 Academic Year

                                                                    Note: Drop in 2000/2001 graduates is mostly due
                                                                    to ending of Malaysian 2+2 program

10-05-01                                            Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI




           Research Focus in the Department
          Three main research areas in the
           department are:
               Advanced Design and Manufacturing
               Biomechanics
               Computational Engineering




10-05-01                Industrial Advisory Board Meeting
                                           Department of Mechanical Engineering, IUPUI



           Research Laboratories
          The department maintains the following labs for
           research and graduate education:
              Advanced Computer-Aided Engineering and
               Manufacturing Laboratory (ACAEML)
              Advanced Materials Laboratory (AML)
              Biomolecular Engineering Laboratory (BEL)
              Computational Fluid Dynamics Laboratory (CFDL)
              Computational Mechanics Laboratory (CML)
              Experimental Mechanics Laboratory (EML)




10-05-01                  Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI



           Recent Sponsors/Collaborators
          National Science Foundation (NSF)
          National Institute of Health (NIH)
          NASA
          AFOSR
          Army and Navy
          DARPA
          Naval Surface Warfare Center (NSWC) - Crane
          Indiana 21st Century Science and Technology Fund
          Numerous Indiana companies




10-05-01                Industrial Advisory Board Meeting
                                                                  Department of Mechanical Engineering, IUPUI




                                    Yearly Research Expenditures (8-14-01)

                       600,000

                                                                                                  499,094
                       500,000
                                                                                        446,348


                       400,000
           Amount, $




                                                                              302,578
                       300,000
                                 228,685    217,886
                       200,000
                                                      139,015     150,273


                       100,000


                            0
                                 '94/'95    '95/'96   '96/'97      '97/'98    '98/'99   '99/'00   00/'01
                                                                Fiscal Year



10-05-01                                   Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI



           Recent Research Projects
          “Dynamic Load Balancing for Parallel Computing,”
           NASA Glenn Research Center
          “A New Computational Method for Massively
           Parallel Computational Fluid Dynamics,” NASA
           Glenn Research Center
          “Parallelization and Development of Solid-Fluid
           Interaction Models for Aeroelasticity”
          “Benchmarking of Aerodynamic Panel Methods,”
           AFOSR
          “Development of CE/SE Method for Combustion
           Simulations,” AYT Corporation


10-05-01                Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI



     Recent Research Projects (cont’d)
          “Advanced Propulsion and Power Institute:
           Innovative Propulsion Systems and High-Fidelity
           Computer Simulation,” Indiana 21st Century
           Research and Technology Fund
          “Deterministic Stress Modeling for Turbulent Mixing
           in Jet-in-Crossflow,” Pratt and Whitney
          “Steady/Unsteady Chemically Reacting Flow
           Simulation,” AYT Corporation
           “Pulse Detonation Engine Model Subroutine,”
           Allison Advanced Development Company



10-05-01                Industrial Advisory Board Meeting
                                            Department of Mechanical Engineering, IUPUI



      Recent Research Projects (cont’d)
              “Wave Fan and Hybrid Pulse Detonation,” NASA
               Glenn Research Center
              “Two-Stroke Gas Engine Simulation,” Dresser-
               Rand Corporation
              “Mechanical Effect of Induced Changes in
               Extracellular Matrix of Viceral Smooth Muscle
               Tissues,” NSF
              “3D Surface Corrosion Growth Model for Materials
               Design,” NSF
              “Fatigue Life Prediction Methods for Thermal
               Fatigue of Solder Joints of Electronic Packages,”
               Boeing Corporation

10-05-01                   Industrial Advisory Board Meeting
                                          Department of Mechanical Engineering, IUPUI




           Recent Research Projects (cont’d)
           ”Implementation of CAM Post-Processors for
            Raytheon NC Production Machines,” Raytheon
            Technical Services
       •    “CAD/CAE/CAM/PDM Integration”
       •    “Power Train Simulation for Hybrid Vehicles”
       •    “Intelligent Machining”
       •    “Geometric Dimensioning and Tolerancing,” Bishop
            Steering Technology
       •    “Using Family of Parts for Die Design Automation,”
            Overton and Sons for Dies and Molds



10-05-01                 Industrial Advisory Board Meeting
                                      Department of Mechanical Engineering, IUPUI

           Computational Fluid Dynamics (CFD)
           – Ecer, Akay, and Chien

          Parallel computing on distributed
           systems – workstations and PCs
          Dynamic load balancing for parallel
           computing
          Aerodynamics simulations
          Turbomachinery flows



10-05-01             Industrial Advisory Board Meeting
                                          Department of Mechanical Engineering, IUPUI

                Parallel Computing for Large Scale
                         Industrial Problems
          Partition the computational domain into smaller parts
          Solve each part on network of computers
          Used for large-scale computing




10-05-01                 Industrial Advisory Board Meeting
                                           Department of Mechanical Engineering, IUPUI


           Parallel Adaptive Flow Solver – PACER3D

  Grid partitions and adapted grid




10-05-01                  Industrial Advisory Board Meeting
                                            Department of Mechanical Engineering, IUPUI

           Parallel Adaptive Flow Solver – PACER3D
            Wing grid and adapted solution




10-05-01                   Industrial Advisory Board Meeting
                                       Department of Mechanical Engineering, IUPUI


                        Parallel Performance
                           T1
           Speedup  S n 
                           Tn




10-05-01              Industrial Advisory Board Meeting
                                                    Department of Mechanical Engineering, IUPUI


                         CFD Laboratory Parallel Computing Environment


                                           INTERNET


                         Indiana                                   Ohio



         IU                                                                   NASA/Glenn
   Bloomington-IN                                                             Cleveland-OH

                                            IUPUI
                                        Indianapolis-IN

      LAN (Local Area Network)             WAN (Wide Area Network)
      CFD Lab Network in Indianapolis      Indianapolis and Bloomington
              6 IBM RS/6000 (Unix)                 6 IBM RS/6000 (Unix) in Indianapolis
              16 Pentium-II/400 (NT)               20 Pentium-II/400 (NT) in Indianapolis
                                                    139 CPU IBM SP2 (Unix) in Bloomington
                                                    128 CPU PII/III (Linux) in Cleveland


10-05-01                       Industrial Advisory Board Meeting
                                                      Department of Mechanical Engineering, IUPUI

                   Multi-user Parallel Computing Environment
      In a multi-user distributed-computing environment, everybody has different needs. Whatever
      their needs, everybody wants priority in running their programs. In such an environment, an
      efficient distribution of ALL those parallel jobs should be done for benefit of all users.


           HUGE MEMORY

                                                                                  HIGH SPEED


                                   Local and Wide Area
                                   Computer Networks




                         JUST RESULTS
                                                                   Users
                                                                   Available Computers
                                                                   Unavailable Computers
                                                                   Inaccessible Computers




10-05-01                          Industrial Advisory Board Meeting
                                      Department of Mechanical Engineering, IUPUI


           Aircraft Engine Simulation with Parallelized ADPAC
           (in collaboration with Nasa/Rolls-Royce)




10-05-01             Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI


           Dynamic Load Balancing --DLB
       Objective
                                                                              START
            Move processes from ‘slow’                               Initial block
            computers to ‘fast’ computers to                         distribution

            reduce total computation time
                                                                       PTrack, CTrack
       Method




                                                        DLB Cycles
                                                                          ADPAC
            Monitor periodically the average
            communication and computation
            costs of executions on each                                Load Balancer
            computer during a pre-determined.                        New block
                                                                     distribution
            If needed, redistribute the loads by
            Load Balancer for optimum
            solution time at the end of each                                    END
            cycle

10-05-01                Industrial Advisory Board Meeting
                                                            Department of Mechanical Engineering, IUPUI

                                    DLB For A Single Parallel Job
                                              Application: ADPAC
                                            LAN 100Mb Switch
                                            6 IBM RS/6000 (UNIX)
                                            10 PII (NT4.0)

                             Initial Block Distribution 4 blocks/processor(equal-loading)

                                                                                Mesh Size : 765x25x25
           Extraneous Load
                                                                                64 Blocks
           Blocks of Parallel Job                                               Equal-Sized Blocks
                                                                                (Block Size / Interface Size) =12




10-05-01                              Industrial Advisory Board Meeting
                                 Department of Mechanical Engineering, IUPUI

           DLB For A Single Parallel Job
                    Application: ADPAC
           Improvement in 3rd cycle elapsed time =24%

                            Extraneous Load            LAN 100Mb Switch
                                                       6 IBM RS/6000 (UNIX)
                            Blocks of Parallel Job     10 PII (NT4.0)
                                                     Mesh Size : 765x25x25
                                                     64 Blocks
                                                     Equal-Sized Blocks
                                                     (Block Size / Interface Size) =12




10-05-01      Industrial Advisory Board Meeting
                                      Department of Mechanical Engineering, IUPUI


           Computational Fluid Dynamics
           – Hsu
          Molecular dynamics and nano-scale flow
           simulations for nano-machines
          Lattice Boltzmann method for multi-scale
           flow simulations
          Combustion simulation and multi-phase
           flows
          Turbulence modeling


10-05-01             Industrial Advisory Board Meeting
                                      Department of Mechanical Engineering, IUPUI

             Simulated Non-dimensional Temperature
           Distribution in a Jet-in-Crossflow Combustion
           (simulates flows in gas-turbine engine combustors)



            Cross Flow



                    Jet




10-05-01             Industrial Advisory Board Meeting
                                  Department of Mechanical Engineering, IUPUI

           Lattice Boltzmann Method for
              Turbomachinary Flows


             300

             250
                                                      p
             200                                  2.08952
                                                  1.95022
                                                  1.81092
             150
                                                  1.67162
                                                  1.53232
             100                                  1.39302
            y




                                                  1.25372
                                                  1.11441
                50
                                                  0.975113
                                                  0.835812
                 0                                0.696511
                                                  0.557209
                                                  0.417908
                -50
                                                  0.278607
                                                  0.139306
            -100

            -150

                      100   200       300
                            x


10-05-01     Industrial Advisory Board Meeting
                                      Department of Mechanical Engineering, IUPUI



           Computational Fluid Dynamics
           – Nalim
          Modeling of non-steady flow and
           combustion phenomena
          Aerospace propulsion, pulse
           detonation engines, and wave rotor
           technologies
          Computational fluid mechanics with
           StarCD


10-05-01             Industrial Advisory Board Meeting
                                                         Department of Mechanical Engineering, IUPUI

                                        Wave Rotor




                                Combustion Wave Rotor
                   Compact self-cooled design and reduced pollution.
           Wave-rotor sketches and wave diagrams with computed flow properties are courtesy of NASA.




10-05-01                         Industrial Advisory Board Meeting
                                      Department of Mechanical Engineering, IUPUI

           Simulation of Gas Flow in Complex Geometries




10-05-01             Industrial Advisory Board Meeting
                                     Department of Mechanical Engineering, IUPUI


           Computational Mechanics – Akay,
           Pidaparti, Chen, Hsu, Paydar
           Computational simulations with
            ANSYS, ABAQUS, and PATRAN for
            modeling of complex problems
           Electronic Package Reliability
           Biomechanics




10-05-01            Industrial Advisory Board Meeting
                                      Department of Mechanical Engineering, IUPUI


           Fatigue Life Prediction of Solder Joints of
           Electronic Packages
          Thermal cyclic loads
          Creep response of solder




                                           Ball Grid Solder




10-05-01             Industrial Advisory Board Meeting
                                                    Department of Mechanical Engineering, IUPUI


              Different Types of Interconnections
               Chip Carrier
                              Solder                                      Lead

                                       Copper Pad
                                                    PWB




           LLCC Type                                                        LDCC Type
                                            Chip       Overmold
            Adhesive
                                                                             Substrate


             Solder ball
                                                                            PWB

              Copper pad
                                                                             BGA Type


10-05-01                      Industrial Advisory Board Meeting
                                  Department of Mechanical Engineering, IUPUI



               Finite Element Models




     Y

           X




10-05-01         Industrial Advisory Board Meeting
                                                              Department of Mechanical Engineering, IUPUI


                                     Predicted Fatigue Lives
                      5

                      4
           Log (Nf)




                      3

                      2       Log(Nf ) = -1.0798Log(DW total) + 0.7845
                                           R2 = 0.9697
                      1

                      0
                       -3.5           -3         -2.5          -2        -1.5       -1       -0.5
                                                         Log (DWtotal)



10-05-01                                   Industrial Advisory Board Meeting
                                                Department of Mechanical Engineering, IUPUI

               Biomechanics – Chen, Hsu, Yokota,
               Turner, Katona
              Dental mechanics
                   implants
              Orthopedics
                   implants
              Blood flow
                   heart valves




10-05-01                       Industrial Advisory Board Meeting
                                      Department of Mechanical Engineering, IUPUI

                 Finite Element Model of a
                 Tooth-Mandible Structure

           Objective:
            Investigation of the
            optimal force system
            that results in a
            prescribed tooth
            movement




10-05-01             Industrial Advisory Board Meeting
                                  Department of Mechanical Engineering, IUPUI



           Numerical Simulation of Blood Flow
            Through Mechanical Heart Valves




10-05-01         Industrial Advisory Board Meeting
                                              Department of Mechanical Engineering, IUPUI



               Biomolecular Engineering - Yokota

              Development of Devices and Techniques for
               Biomolecular Uses
                   Imaging DNA and protein molecules
                   Modeling human genomics
              Analysis of Mechanical Effects on Tissue
               Integrity
                   Modeling mechanical effects
                   Evaluating physical therapy


10-05-01                     Industrial Advisory Board Meeting
                                     Department of Mechanical Engineering, IUPUI



           DNA complexes and Protein Molecules Imaged
                  by Atomic Force Microscopy




10-05-01            Industrial Advisory Board Meeting
                                          Department of Mechanical Engineering, IUPUI

           Advanced Materials – Pidaparti
          Fatigue and Fracture Predictions
          Computational Intelligence Applications
          Advanced Composites (man made and
           biological)
          Tools Used:
           •   Computational - FEA and Analytical
           •   Mechanical Testing - Static, Fatigue and NDE
           •   Intelligent Models - Neural Networks, Fuzzy
               Logic, Artificial Intelligence


10-05-01                 Industrial Advisory Board Meeting
                                 Department of Mechanical Engineering, IUPUI


           Damage Assessment System




10-05-01        Industrial Advisory Board Meeting
                                           Department of Mechanical Engineering, IUPUI


             Corrosion Damage Identification and
                        Quantification
           Eddy Current




       Ultrasound                                                Color Index
                                                              0-5% material Loss
                                                              5-10% material loss
                                                              10-15% material loss
                                                                      -
                                                              15-20% material loss




10-05-01                  Industrial Advisory Board Meeting
                                 Department of Mechanical Engineering, IUPUI
     FRACTURE MECHANICS




10-05-01        Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI


     Advanced Engineering and
     Manufacturing Lab –
     Chen and El-Mounayri

          CAD/CAE/CAM/PDM integration
          Power train simulations (hybrid or conventional)
          Product data management
          Intelligent machining
          CAD/CAM
          Solid modeling
          Finite element modeling

10-05-01                Industrial Advisory Board Meeting
                                              Department of Mechanical Engineering, IUPUI




           Advanced Engineering and
           Manufacturing
              Optimization of the tool path
              Machining process control
                  Simulation, optimization, and automation
              Virtual product development, evaluation and
               assessment
              Study of various aspects of machining (e.g.,
               Accuracy, surface finish, and chatter)



10-05-01                     Industrial Advisory Board Meeting
                                         Department of Mechanical Engineering, IUPUI




     Advanced Engineering and
     Manufacturing – Training to Industry
              CAD/CAM (Pro/ENGINEER,
               UNIGRAPHICS, I-DEAS)
              Operation of CNC machines and NC
               programming
              Geometric Dimensioning and Tolerancing
              Machining process modeling, analysis,
               control and optimization

10-05-01                Industrial Advisory Board Meeting
                                    Department of Mechanical Engineering, IUPUI

           Integrated Power Train Model for HV
               (power train performance evaluation)




10-05-01           Industrial Advisory Board Meeting
                                   Department of Mechanical Engineering, IUPUI



           Integrated CAD/CAE/CAM/PDM System




10-05-01          Industrial Advisory Board Meeting
                              Department of Mechanical Engineering, IUPUI



           CAD MODELS


                                    Transmission Assembly



                                           Casting Mold Design
                                             Gate
                                             Overflow
                                             Cooling line
                                             Part

                                             • Box



10-05-01     Industrial Advisory Board Meeting
                                           Department of Mechanical Engineering, IUPUI

           Machining Process Modeling, Simulation and
           Optimization (El-Mounayri)

              Modeling and Simulation of End Milling
                  Introduction
                  Industry needs
                  Process control through predictive models
                  ANN models
              Optimization of the cutting conditions
                  Optimization through modeling and simulation
                  Validation and benefits
                  Optimization through measurements


10-05-01                  Industrial Advisory Board Meeting
                                           Department of Mechanical Engineering, IUPUI



           ANN Based Models
          Artificial Neural Networks is used to more
           effectively map the relevant machining
           parameters to the process outputs of interest.
          Advantages/Characteristics:
              No assumptions on the functional relationship
               (e.g., quadratic, cubic etc.) are imposed. ANN
               based models are the more natural and accurate
               models for representing the metal cutting process.
              ANN Models are able to accurately predict the
               outputs for inputs which lie outside the range of
               training.
     



10-05-01                  Industrial Advisory Board Meeting
                                            Department of Mechanical Engineering, IUPUI



           An ANN Based Model




             Predictive ANN force model – Network Topology
     Model used to optimize the cutting conditions for minimum production cost

10-05-01                   Industrial Advisory Board Meeting
                                       Department of Mechanical Engineering, IUPUI



           Validation of the ANN Model




             Simulation versus Experimental Force
10-05-01              Industrial Advisory Board Meeting
                                                  Department of Mechanical Engineering, IUPUI


           Application in Industry:
           Optimization of Pocketing

                                                                         Geometric analysis of
                                                                         pocket milling cut




               Design model




                                      Various immersions and associated machining parameters
      Workpiece and toolpath

10-05-01                       Industrial Advisory Board Meeting
                                             Department of Mechanical Engineering, IUPUI



           Cutting Forces before Optimization




      Force measured experimentally                Force predicted using ANN model




10-05-01                    Industrial Advisory Board Meeting
                                             Department of Mechanical Engineering, IUPUI



           Cutting Forces after Optimization




       Force measured experimentally            Force predicted using ANN model




10-05-01                    Industrial Advisory Board Meeting
                                               Department of Mechanical Engineering, IUPUI


           Effect of Process Optimization:
           35% reduction in machining time and 40% in
           forces




   Measured force before optimization               Measured force after optimization
   (Using conservative cutting conditions)          (Using optimum cutting conditions)




10-05-01                      Industrial Advisory Board Meeting
                                        Department of Mechanical Engineering, IUPUI

           Experimental Setup for measuring Cutting
           Forces




               Experimental set-up for measuring cutting forces


10-05-01               Industrial Advisory Board Meeting
                            Department of Mechanical Engineering, IUPUI




               THE END!




10-05-01   Industrial Advisory Board Meeting

				
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