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Dr. Steven DanylukDirectorManufacturing Research Center

Georgia Institute of TechnologyManufacturing Research CenterAtlanta, GA 30332-0560www.marc.gatech.edu

Future Manufacturing Technologies

April 7, 2010

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The Manufacturing Research Center at GT

• What is MARC and how does it work?• MARC Objectives• Description of Selected Technologies

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Snapshot of Georgia Tech

• In the top 5 graduate engineering schools in the US. (US News and World Report: MIT, Stanford, Cal-Berkeley, GT)

• #1 in Manufacturing (US News and World Report)

• GT, Multi disciplinary organizations– Major Centers– GTRI– Enterprise Innovation Institute (EI2)

Spin-off Companies

IBBMIRCMARC

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How Does MARC Work?

Industry Funds(70%)

GovernmentFunds(20%)

Startup Companies

Research ResultsStudents/Employees

MT ConnectIndustrial Consortia

MARC

Gov’tAgency

Industry

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•Design, Mfg., Support•Standards (SysML, Internet, STEP, …)•Knowledge-Based Engineering•CAD-CAE-CAX Interoperability•Ubiquitous Engineering Computing (Wireless, Mobile, …)

MARC Technology Clusters

Precision Machining•Models/ Experiments of Material Removal •Processes Grinding•Control Strategies of Machines•Condition- Based Maintenance

Rapid Prototyping/Direct Digital Manufacturing

•Development of new materials•Medical applications•Die design for injection molding

Sustainable Design and Manufacturing

•Energy/ Materials Balance in facilities•Process Modeling•Control Strategies•Machine Tools•Electronics

Product and Systems Lifecycle Management

Factory Information Systems•Machine Communication•Product Data Exchange•Human Decision-making•Recipe Generation•Line Monitoring•Manufacturing Execution Systems•Enterprise Resource Planning•Standards Development (CAMX, MTConnect)

Aerospace Manufacturing

•In Process

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MARC Objectives

• Develop technology to improve productivityUse technology to lower cost of productionDevelop technology to make better products

• Partner with industries, government on grants/contractsEducate StudentsTransfer technology to industry

• Contribute to state, region and national wealth, securitySpin out companiesDevelop next generation technologies

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Next Generation Material Processing

Precision Machining Research Consortium (PMRC)http://pmrc.marc.gatech.edu/

• Machining of Surfaces• Process Monitoring

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PMRC: Nanolubricants for Grinding and Micromachining• Objectives:

– Minimize frictional energy dissipation in grinding and micromachining

– Minimize cutting fluids and their negative environmental impact

Approach:– < 1~2wt% of nanoplatelet graphite mixed

in conventional cutting fluids applied at very low flow rates (~ml/min)

– Initial results are very promising; up to 40% reduction in specific energy consumed in grinding more energy efficient process

– Current focus on applying nano particulate solid lubricants to micromachining

Other collaborators: D. DeBra (Stanford), A. Malshe (Univ. Arkansas)

Exfoliated Graphite(Scale Bar=100 mm)

M. Alberts, K. Kalaitzidou, and Melkote, S.N., Int. J. Machine Tools & Manufacture, Vol. 49, pp. 966-970, 2009

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PMRC: Cavitation Shotless Peening

Goal: Develop flexible method/system to engineer compressive residual stress into machined aerospace parts for enhanced fatigue performance

Unpeened: 419.6 HVPeened: 468.2 HV

11.6 % Change(w/o optimization)

Side Panel View: Pumping Unit

Inside Machine: Combining Nozzle

Sponsor: Boeing/Phantom Works

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PMRC: Laser-Assisted Hard Turning Process

• Turning is more energy efficient than grinding

• Little or no cutting fluids needed minimal environmental impact

• Low-cost tools can be used (alumina vs. CBN)

FR

FF

FC

Tool

Laser treated surface

Laser Beam

Tool Feed Direction

Beam Scan Direction Beam Scan

DirectionLaser Beam

Laser treated surface

FR

Tool Feed Direction

FF

FC

Tool

Laser treated surface

A. Laser Scanning

B. Turning

Approach 2Approach 1

Sponsor: The Timken Company

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PMRC: Thin-film Wireless Sensors for Machining Process Monitoring

Goal: To improve machining performance via low-cost non-intrusive sensors fixed to the tool and transforming the data into process responses of interest using physics based models

Sponsor: Boeing/Phantom Works

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Manufacturing Process Modeling

Product & Systems Lifecycle Management Center (PSLM)http://www.pslm.gatech.edu/

• System Modeling• Design of Complex Systems

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Modeling and Simulation Testbed

ComplexSystem

SimulationModels

Solvers

Combination of Tools & Models Leading to System-Level Models of Complex Systems

SimulationTools

AssemblyModels

Factory Tools

Work Cells

}

DescriptiveTools

ReliabilityDynamic

Solver

CostsMechanical/Fluid Tools

CAD

Mechanical& FluidModels

FEASolver

SystemParticularsHydraulics

Requirements

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PSLM: Hydraulics Subsystem Simulation Model

SysML Model

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PSLM: What you can do with a SysML model ... • Describe requirements, system structure, & allocations• Generate and/or link to simulations & verify requirements• Support system trade studies• Link to domain models & analyses: S/W, M/ECAD, ...• I.e., do the Vee and more ... (e.g., support system operation)

"Vee" model by Forsberg and Mooz, 1992

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‘DNA’ Description of a 2-Spring Physics Model

InterconnectednessShows

Dependability

http://eislab.gatech.edu/pubs/conferences/2007-incose-is-1-peak-primer/

P

k1 k2

2u1u

22223

202222

2122221

11113

101112

1112111

:

:

:

:

:

:

LkFr

LLLr

xxLr

LkFr

LLLr

xxLr

Governing Equations

1226

115

24

213

21122

111

:

:

:

:

:

0:

uLubc

Lubc

PFbc

FFbc

xxbc

xbc

Analytical Model

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Broadly Applicable Technology: Executable SysML Parametrics

b. Mini Snowman

a. Snowman

c. Snowflake

d. Mouse

g. Robot

f. ?

e. Cactus

Examples of Managing “Model DNA” Using SysML Parametricsa. 2-spring physics modelb. Car gas mileage modelc. UAV road scanning system model d. Airframe mechanical part modele. 3-year company financial modelf. Design verification model (automated test for two Airframe mechanical part models)g. South Florida water mgt. (hydrology) model

Panorama Tool by Andy Scott (Undergrad Research Asst.) and Russell Peak (Director, Modeling & Simulation Lab)

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Sustainability in Manufacturing

Sustainable Design and Manufacturing Program (SDM) http://www.sdm.gatech.edu/

• Analysis of Future Factories• Lifecycle Assessment of Existing Production

Systems

19Copyright Georgia Institute of Technology, 2009

SDM: Research Thrust Areas

Sustainable MobilitySustainable movement of people AND

goods using a variety of modes & technologies

Re-X: Reuse, Remanufacturing, Recycling, Recovery, etc.

New and innovative approaches and technologies to recover, reuse,

recycle products and associated materials

Factories of the Future

New ideas and designs for “off-the-grid”, all electric, low

or carbon neutral factories

Underlying Research Themes• Systems Modeling• Life-Cycle Assessment• Bio-Inspired Design

Technologies:MaterialsProcessesParts/Products

UsersLocalitiesInteractions

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SDM: GT-Boeing Factory of the Future Project• Product: Focus on subassembly that represents

a product with different possible configurations – wing torque box with different structural

geometry & skin combinations, e.g., composite-Al, Al-Al.

• Processes: Characterize, quantify, and model fabrication and assembly processes (from mass & energy balance point of view)– Casting, forming, drilling, fastening, etc.

• Materials: Characterize, quantify, and model cradle to gate impact of materials used– Al, composite, titanium, process materials

• Identify, model, and quantify opportunities of improvement– New technologies, materials, supply chains,

etc.• Model all of the above to get unified product-

process design framework– More efficient, effective, profitable, green

manufacturing organization

Tangible Facilities

• Macon Facility to be used as case study

• Build a research and demonstration facility in Manufacturing Research Center at Georgia Tech

2121

12/21/09 21Source: Bras, Romaniw, et al. 10/2009

www.sdm.gatech.edu

“Object-Oriented Spreadsheet”

plus more ...

F-86 Wing Section Test Case in SysML ParametricsComparing Sustainability Metrics for Design Alternatives

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SDM: Life Cycle Assessment

• LCA is one means to try to investigate some of the issues for these systems• LCA examines the environmental burdens and impact of a product over its

entire life-cycle (see ISO 14040)

Disposal

MiningMaterial

processingProduct

manufactureDistribution

Product take-back

Material de-manufacture

Energy recovery with incineration

Use +

Service

Product demanufacture

Environment: air, sea, land 1234

Clean fuel production via pyrolysis

2 = Remanufacture of reusable components

3 = Reprocessing of recycled material

4 = Monomer / raw material regeneration

1 = Direct recycling / reuse

Manufacture

Demanufacture

Bras, B. (1997). "Incorporating Environmental Issues in Product Realization." United Nations Industry and Environment 20(1-2): 7-13.

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Direct Digital Manufacturing

Rapid Prototyping/Direct Digital Manufacturinghttp://ddm.me.gatech.edu/

• Repair of Airfoils

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Direct Digital Manufacturing of Airfoils• Manufacture state-of-the-art ceramic molds directly from digital data.• Cast single-crystal superalloy airfoils with serpentine internal cooling passages and film cooling holes• Eliminate over 1,000 tools and 5 major processes to create a major disruption to both cost and lead

time for defense aircraft propulsion.

Objective:

Large Area Maskless Photopolymerization (LAMP)

Airfoil investment casting process with direct digital manufacturing

Cutaway view of Honeywell ICCM design

High resolutionbitmaps ofCAD slices

1- DDM built molds

3 - Casting4 - Finishing5 – Zyglo Inspection

6 – Gauging 7 – X-Ray inspection 8 – Shipment

2 - Mold Assembly

DR. SUMAN DAS DIRECT DIGITAL MANUFACTURING LABORATORY

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Laser-Based Repair Manufacturing of Airfoils• Repair of high value nickel superalloy turbine blades in DoD and commercial jet engines.• High speed laser melting of pre-placed powder on substrate combined with partial remelting of underlying

substrate.• Utilization of sophisticated control techniques to refurbish turbine engine hardware back to flightworthy

condition.

Previously fabricated layers

Remelted substrate

Laser beam

Melt pool Epitaxial grains

Powder layer

Motion

DR. SUMAN DAS DIRECT DIGITAL MANUFACTURING LABORATORY

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Integration of the Internet to Factories

Factory Information Systems Group (FIS)http://www.fis.marc.gatech.edu/

• Development of Standards

• Working with Consortia

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MTConnect Overview

OpenOpenStandardStandard

A light-weight protocol used for transferring sensor level data using internet based protocols on the factory floor

“Bringing Manufacturing to the Internet Age”

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MTConnect• Started in 2008• Developed in Response to

the Needs of the Association for Manufacturing Technology (AMT)

• AMT Invested $2M in Development

• Technology Development Partners– Georgia Institute of

Technology– University of California,

Berkeley• Debut at International

Manufacturing Technology Show (IMTS) 2008

• MTConnect Foundation

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Summary

• GT/MARC objective is to anticipate technology needs in the long-term, yet implement technology in the short-term.

• Technology development will save the manufacturing industries by contributing to productivity gains and spur employment.

• Examples of technology being developed in MARC were presented.

Future Manufacturing Henrik I Christensen

hic@cc.gatech.edu

CCC Study

GT Coordination (0806-)Congress Presentation (0905)OSTP/White House (0912)Roll-out (10-Spring)

Job CreationHealthcareSecurity/Services

Manufacturing

• Large Scale Manufacturing• Lack of SME Focus• Flexibility is key to progress• Logistics is major target• Process consideration is key• Perception, Learning & Safety

Issues

Industry Studies

General MotorsFactory of the Future - The CoWorker

Boeing The Factory of the 21th Century

YujinThe next generation home robot

iRobotThe design parameters for new home appliances

Robot Logistics

Smart Robotic Manufacturing• Multi-Robot Interaction• Human-Robot

Interaction• Flexible Programming• Sensor Based Feedback• Small series efficiency• Safe Joint Operations

Human Robot Interaction

• PI: A. Thomaz & H.I. Christensen

• Programing by Demonstration

• Skill & Task Learning• Social Interaction Modeling• HRI Toolkit

Vision f Manipulation

• Recognition of Objects• Servo close to object (2D)• Estimate Pose of Object• Plan a grasp strategy• Execute plan under 3D servoing

AeroSpace Robotics

• Mobile Tooling• Flexible Tooling • Added Security • Integrated

Design• Dynamic

Stiffness

Summary

Robotics offers major new opportunities for manufacturing & automation

Flexible manufacturing - Lot Size 1Automating the logistics chainEasily programable automationDeployment across small and large companies

Innovation at the Interface between Technology & Business

Dr. Ron BohlanderDirector, Commercial Product Realization Office

Georgia Tech Research Institute404.407.6836 ron.bohlander@gtri.gatech.edu

In global competition, is automation … just part of answer?

It's tough to find one product today that's built by one company. It's all about partnership, alliances and affiliation. Today, it's all about strategy and service.” – Tom Koulopoulos

Where does “product” stop & “service” begin?

… & how does that affect alliances?Photo courtesy of U.S. Navy

Invention … just part of answer

Innovation

Collaboration