Keynote and Panels

Steve Malkin Steve Malkin Symposium Opening Session
Tuesday, June 10 10-11:30 pm, Room 320B

National Academy of Engineering Tribute
by Yoram Koren

STEPHEN MALKIN, an international guiding force in manufacturing science, and a University Distinguished Professor Emeritus at the University of Massachusetts, Amherst, died on August 19, 2013, at the age of 72.

Steve, as he was generally called, was born in Malden, Massachusetts, on June 20, 1941. In his high school Steve was an ambitious student who pushed himself to excel. No doubt that he was admitted to the Massachusetts Institute of Technology and received a bachelor’s degree from MIT in 1963. Steve liked the taste of research experience in his undergraduate studies and decided to attend graduate school at MIT, and to specialize in manufacturing engineering. He earned his M.Sc. in 1965, and in 1968 he graduated from MIT with a Sc.D. in Mechanical Engineering.

In 1968 Steve became an Assistant Professor at the University of Texas, Austin, and in 1974 he moved to the University of New York in Buffalo, where he was promoted to Associate Professor. In 1976 he immigrated to Israel where he was a professor at the Technion, Israel Institute of Technology until 1986. In 1986 Steve returned back to the U.S. and became a professor of Mechanical Engineering at the University of Massachusetts in Amherst. From 1987 until 1995 he was Director of the Manufacturing Engineering Program at U-Mass, and a co-founder of the Center for Manufacturing Productivity, which paired faculty with small to medium sized manufacturers to enhance productivity and competitiveness. He was named Distinguished Professor at the University of Massachusetts in 1998. Steve served as the Head of the Department of Mechanical and Industrial Engineering from 2000 to 2006.

Steve has done a superb job in his two terms as Department Head. He was a visionary, leader, and above all, an excellent mentor to younger faculty -- as evidenced by the number of faculty who were hired/promoted and recognized nationally/internationally during his tenure.

As Department Head Steve had unique style of inclusiveness and impartiality, along with his intellectual and professional rigor – as evidenced by his several new initiatives such as the Department Seminar Series, the Department Cluster Groups embracing the department’s diversity and richness. Wind Energy and Human Performance programs came into international prominence during his tenure and have since been recognized as the two signature programs of the department and college. Under his leadership, the department’s human and fiscal resources grew significantly. Many new faculty were hired, the enrollment increased by over 50% and research expenditures increased by 44%. He retired in 2009.

Steve Malkin authored a scholarly body of papers on grinding technology that constitutes the spearhead of innovative research in this area, and it is the leading light of new research directions in modern grinding optimization technology. He has led the transformation of grinding technology from an empirical craft to an applied science by laying the foundation for grinding system theory and developing enabling technologies to improve the system efficiency. Steve is the author of the book on Grinding Technology that presents a comprehensive and consistent treatment of grinding theory and its practical aspects. It is amazing that this book was cited over 1000 times by other researchers.

A primary objective in his early research was to develop a fundamental understanding and quantitative models which describe the many diverse aspects of grinding including the mechanics of the process, temperatures, thermal damage to the workpiece, precision, and surface topography. He then realized that this fundamental processing knowledge could be more practically applied by taking a comprehensive systems approach in which the grinding model parameters are updated and intelligent control is utilized to optimize the process.

Steve developed virtual manufacturing that provides a quantitative and visual computerized simulation of the process to predict what will occur and to identify the optimal conditions. Malkin’s simulations are being used in industry. Another approach that Steve pioneered was the coupling of the knowledge base and simulation with intelligent control methodologies to achieve adaptive optimal control of grinding machines.

Industries that utilize Steve’s modeling and optimization methodologies include General Motors, Ford Motor Company, SKF, General Electric, Alcoa, Norton Company, Eaton Corp., United Technologies Pratt and Whitney, Caterpillar, Allied Signal, The Timken Company, TRW, Warner and Swasey, Iscar Blades, and many others. Experts documented millions of dollars in savings by Steve’s original grinding simulation and optimization methodology.

Steve authored 200 scientific papers, and graduated 50 students, most of which are employed in high level engineering positions and management. Steve loved his students and maintained close relationships with them.

Steve was a Life Fellow of the American Society of Mechanical Engineers (ASME), and a Fellow of the Society of Manufacturing Engineers (SME). He was a Fellow of the International Academy for Production Engineering (CIRP) since 1980. Steve received the ASME William T. Ennor Manufacturing Technology Award (ASME), the Gold Medal of SME, and the Blackall Machine Tool and Gage Award of ASME.

Steve Malkin was honored by the title Doctor Honoris Causa by the Jan Evangelists Purkyne of the Czech Republic. He was Honorary Member, Romanian Society of Mechanical Engineering, and Honorary Professor of the National Huaqiao University in China. Steve was the R.S. Springer Visiting Professor at the University of California, Berkeley. He was the Lady Davis Visiting Professor, and later the Safra Visiting Professor at the Technion – Israel Institute of Technology, Haifa, Israel. Steve continually sought opportunities to serve the community, advise, lead, and help others. He is greatly missed.

Steve is survived by his mother Jeannette, his beloved wife for 41 years Maccabit, his son Gonen and his daughter Ruth, four granddaughters: Noa, Shai, Judith and Millie, his sister Celia, a nephew and a niece.

MSEC Keynote: Forming and Joining
Tuesday 1:30-3 pm Room 310A

Extrusion of Multi-Material Components

Prof. Dr.-Ing. Dr.-Ing. E.h. A. Erman Tekkaya

Institute of Forming Technology and Lightweight Construction TU Dortmund, Germany

Three innovative extrusion processes for the manufacture of multi-material parts are discussed: co-extrusion of discontinuously steel reinforced aluminum profiles, composite extrusion of continuously steel wire reinforced profiles and composite rod extrusion. In the first two processes the embedded steel elements are not deformable while by composite rod extrusion both materials are deformable. By means of experimental and numerical analysis, the parameters that mainly influence the reinforcement ratio, the extrusion force as well as the material distribution are analyzed. On the basis of this, analytical approaches are deduced to describe the process limits for the technologies. The paper closes with examples of applications regarding the lightweight requirements as well as functional integrations by forming multi-materials.

Speaker Biography:

Since 2013 Vice Dean of the faculty of mechanical engineering
at TU Dortmund, Germany
Since 2007 Full Professor and Head (since 2009) of
the Institute of Forming Technology and Lightweight Construction (IUL),
TU Dortmund, Germany
2008 – 2013 Founding Director,
Metal Forming Center of Excellence, Atilim University, Ankara
2005 – 2009 Chairman (until Feb. 2009) and Full Professor (until Dec.2009),
Department of Manufacturing Engineering, ATILIM University,
Ankara, Turkey
1986 – 2005 Assistant Professor, Associate Professor, Full Professor
Department of Mechanical Engineering, METU, Ankara, Turkey
1983 – 1986 Head of Department "Numerical Methods and Education”
Institute of Forming Technology, University of Stuttgart, Germany
1980 – 1983 Researcher,
Institute of Forming Technology, University of Stuttgart, Germany
1978 – 1980 Student, Research and Teaching Assistant,
Department of Mechanical Engineering, METU, Ankara, Turkey

MSEC Keynote: Additive Manufacturing
Tuesday 2-3 pm Room 140B

3D Printing of Bioactive Implant Coating and Biomimetic Scaffolding for Tissue Repair
Prof Jerry Fuh

Department of Mechanical Engineering, National University of Singapore

With the advance of 3D Printing (3DP) technologies in the past 20 years, bio-printing has been increasingly accepted by clinicians and academia for possible use in tissue engineering applications. But the most successful biomedical applications still lie on printing of intricate medical models for surgery planning. The designs and development of functional 3D human tissue for medical research and therapeutic applications in which organs and body parts are built using inkjet techniques are still in its infant stage. Printing of scaffolds, organs and layers of living cells onto a gel medium or sugar matrix and slowly building up to form 3D structures aiming for tissue repair is still been challenging by many clinicians and doctors and thus facing difficulties especially for new FDA-approved medical procedures. 3DP can potentially replicate or mimic the internal structures of normal tissues which play important roles in their biological functions, e.g. musculoskeletal tissues, where specific internal structures and microstructures confer important functional characteristics that allow normal functioning of the tissues to occur. 3D printing technologies applied to develop viable and prosthetic replacement tissues and implants for human clinical applications will be an exciting and new area of biomedical research and development in the next decade. In this talk, the promising bio-printing techniques based on the Drop-on-demand (DoD) and electrohydrodynamic jetting (E-jetting) aim to create more bioactive functionally-graded coating for implants and biomimetic 3D scaffolding for soft tissue repair/re-generation will be introduced. Case studies on meniscus, cartilage and tendon tissue repair will also be discussed.

Speaker Biography:

Dr. Jerry Fuh is a professor at the Department of Mechanical Engineering, National University of Singapore (NUS). He is a Fellow of SME and ASME and a PE from California, USA. He obtained his BS degree in Mechanical Engineering in 1980 from Taiwan and MS in Manufacturing in 1985 and PhD in Mechanical Engineering in 1992 all from UCLA before joined NUS in 1993. Dr. Fuh has devoted himself to the research of rapid manufacturing processes or 3D Printing (3DP) since 1995. He and his colleagues have established the NUS’s RP/3DP research programme and set up an advanced 3DP laboratory through research grants and industrial collaborations. As a result of his research on selective laser melting for 3DP, 40 international-refereed papers were published related to the RP/3DP process and 15 to RP material developments together with 4 book chapters and 4 patents. A book entitled “Laser-Induced Materials and Processes for Rapid Prototyping” was published by Kluwer Academic, MA in 2001. In 2005, he received the IES Prestigious Engineering Achievement Award for the work on “Development of Rapid Prototyping Technologies for Precision and Biomedical Engineering” from the Institute of Engineers, Singapore (IES) in recognition of outstanding engineering skills which have made notable contributions to progress in engineering in Singapore. He has published over 300 technical papers in manufacturing and design, and supervised over 100 graduate students with over 50 are PhD students since joined NUS.

MSEC Keynote: Forming and Joining
Tuesday, June 10 1:30-3 pm, Room 310B

Multiaxial Stress Tests on Lightweight Materials in Support of Material Modeling and Accurate Sheet Forming Simulations

Prof. Toshihiko Kuwabara

Division of Advanced Mechanical Systems Engineering,
Institute of Engineering
Tokyo Univ. of Agriculture & Technology, Tokyo, Japan

This presentation is a review of mechanical test methods for accurately measuring the anisotropic plastic deformation behavior of metal sheets and tubes subjected to multiaxial stress states. A special attention is paid to the measurement and modeling of the anisotropic plastic deformation behavior of lightweight metals commonly used in industry and to the verification of the validity of the material models based on anisotropic yield functions for large plastic strain ranges. The effects of material models used in metal forming simulations on the improvement of the predictive accuracy of forming defects are also discussed.

Speaker bio:

2014 Professor,
Division of Advanced Mechanical Systems Engineering,
Institute of Engineering, Tokyo University of Agriculture and Technology (TUAT)
2013 Member of Education and Research Council (TUAT)
2010-2013 Adjunct professor of GIFT, POSTEC
1992 Associate Professor,
Department of Mechanical Systems Engineering, Faculty of Engineering, TUAT
1989 Lecturer,
Department of Mechanical Systems Engineering,
Faculty of Engineering, TUAT
1987 Research Associate,
Laboratory of Precision Machinery and Electronics,
Tokyo Institute of Technology
1987 Doctor of Engineering,
Interdisciplinary Graduate School of Science and Engineering,
Tokyo Institute of Technology

Manufacturing Innovation Institutes Panel

Thursday, June 12 8:30-10 am, M|Exchange

Dennis Kekas (North Carolina State Univ): Next Generation Power Electronics Innovation Institute
William King (Univ of Illinois): Digital Manufacturing and Design Innovation Institute
Edward Morris: America Makes (National Additive Manufacturing Innovation Institute)
Alan Taub (Univ of Michigan): American Lightweight Materials Manufacturing Innovation Institute

Moderator: Prof. Thomas Kurfess (Georgia Tech), co-lead of AMP2.0 NNMI working group

Alan Taub
Professor, Materials Science and Engineering
University of Michigan, Ann Arbor, MI

Alan Taub joined the faculty of Materials Science and Engineering at the University of Michigan in the Fall of 2012. In this role, Taub is conducting research in advanced materials and processing and leading a new initiative to establish an Advanced Manufacturing Center within the College of Engineering. Taub retired from General Motors in April 2012. Prior to his retirement, he was vice president, Global Research & Development, leading GM’s advanced technical work activity, seven science laboratories around the world, and seven global science offices. He joined GM R&D as executive director in 2001 and was named vice president in 2009. Taub serves on the boards of several small companies: Nine Sigma, CellEra and Brightway Vision and is technical advisor for a new strategic venture fund, Auto Tech Ventures. Before joining GM, Taub spent 15 years in research and development at General Electric, where he earned 26 patents and authored more than 60 papers. He also worked at Ford Motor Company for eight years.

Taub received his bachelor’s degree in materials engineering from Brown University and master’s and Ph.D. degrees in applied physics from Harvard University. Taub was elected to membership in the National Academy of Engineering in 2006. He is currently Chair for the Visiting Committee on Advanced Technology (VCAT) for the National Institute of Standards and Technology (NIST) and is a member of The Minerals, Metals & Materials Society (TMS) Energy Materials Blue Ribbon Panel. He also serves on advisory boards for the Massachusetts Institute of Technology, Northwestern University, and the University of California, Berkeley.

Taub received the 2011 Acta Materialia Materials & Society Award. In 2010, he was awarded the Charles S. Barrett Medal from ASM International’s Rocky Mountain Chapter. He received the Materials Research Society’s Special Recognition Award in 2004 and Woody White Service Award in 2002. He also received the Brown University Engineering Alumni Medal in 2002.

Cloud Manufacturing Panel

Thursday, June 12 3:30-5 pm, Room 310B

Prof. Lihui Wang (KTH Royal Institute of Technology, Sweden)
Prof. Xun Xu (University of Auckland, New Zealand)

Martin Helgoson, Senior Project Leader, Sandvik

Sweden Dr. Martin Helgoson holds a PhD from Linköping University, Institute of Technology, Sweden. His main fields of interest are related to technical product models, CAD/CAM, metrology, knowledge integration, closed loop systems and functional products. He joined Sandvik Coromant in 1998 and has had different positions e.g. as Project leader within R&D, Manager of CAD/CAM/CAE-development and integration, and Process-CIO within product development and production. He has been engaged in several internal research and development activities related to method development, process development and functional products, as well as in external national and European research projects. He is currently a Sr. Project Leader and Technology Leader within the field of intelligent machining at the Department of Business and Application Development, Intelligent Machining.

Hans-Ulrich Heidbrink, Consultant, InConTec, Germany

Hans-Ulrich Heidbrink holds an electrical engineering diploma from the University of Applied Sciences in Nuremberg and is co-founder and shareholder of InConTec GmbH an ICT Research and Innovation Company. Prior to that he hold several top positions within Mentor Graphics Corp. which had acquired “DESCON Informationssysteme GmbH”, one of both companies which he had funded before and managed as president. This company had established PLM, CIS and CAD library management systems. He was also Co-Founder and senior Vice President Field Operations of INCASES Engineering GmbH a CAD and EMI simulation company a successor for the EDA products of Computervision, He started his engineering carrier in industrial process automation and computing departments of BBC/ABB and got assigned as product manager for the first graphical process control systems. From there he changed in the CAD/CAM market at the design system pioneer Computervision Corp. His CAD/CAM experience is reached in positions in sales, marketing and international management in this company. Amongst other standardisation activities he was chairman for ECAD-MCAD collaboration at the ProStep iViP association. He holds a chair in the industrial advisory board of the Luleå University’s Faste Laboratory for Functional Product Design methods and collaboration.

Peter Everitt, Managing Director, PowerKut Group

An apprentice trained engineer with a specialist background in cutting metals and rock, Mr. Peter Everitt has developed skills in cutting tool, and fixture design and manufacture, programming in 3 languages including macro B. At an advanced stage in his manufacturing career Peter decided to pursue his entrepreneurial ambition and recognised the need to understand business more fully and so enrolled on a Btec HNC in management studies where he relieved the Reinshagen UK management studies prize for best HNC student. Peter followed this with a Chartered Management Institute Post Graduate Diploma in management. In 2002 he incorporated PowerKut Limited, supplying my own design of mining cutter for cutting hard rock on Joy continuous mining machines. Under his leadership Powerkut has since grown to being a small group employing 30 people, having some of the most advanced CNC turning, Milling and Grinding, supplying high gauges, metrology equipment, machined parts and assemblies and ISO17025 (NIST) calibration and inspection to sub-micron level.