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MannFrom Modulation-Assisted Machining to Manufacturing with Modulation-Based Processes
James Mann
Research Engineer
Purdue University

Tuesday, February 9, 2016
9:30 a.m.
Santan (SANTN) 220, Polytechnic campus [map]

Abstract
The mechanics of material removal in machining-based processes with metals is unique in many respects: the formation of a continuous chip; large strains and energy dissipation unlike in other metal deformation processes; and severe tribological contact conditions at machining interfaces characterized by high stresses, elevated temperatures, and large friction and wear. These characteristics of the removal process pose barriers to improving efficiency and performance of machining processes. It is shown that the controlled application of low-frequency oscillation to machining – Modulation Assisted Machining (MAM) – can disrupt the severe contact conditions, effect discrete chip formation, and significantly reduce energy consumption (up to 60% less). MAM can increase machining feedrates up to 500% and simultaneously enhance tool life by an order of magnitude. These benefits of MAM are explained using a model for MAM chip formation that describes the underlying mechanics and chip formation regimes. The realization of these benefits is demonstrated using examples of machining advanced alloys from across the discrete products sector, encompassing aerospace, energy systems, biomedical and automotive applications. Emerging application areas of MAM in production of metal fibers and powder particulate, and texturing of surfaces over large areas are described. The talk will conclude with a discussion of MAM implementation in the discrete products manufacturing domain, future applications, and areas for new research in modulation-based processes.

Biosketch
James Mann is CEO/co-founder of M4 Sciences (2005), a manufacturing technology business; and Research Engineer in the Center for Materials Processing and Tribology at Purdue University (2004). Dr. Mann pioneered the development and commercialization of modulation-assisted machining systems. MAM technology has demonstrated 5X increases in productivity and 10X increases in tool life for drilling applications across the orthopedic, aerospace, energy and transportation sectors.
Dr. Mann’s research has led to discoveries with publications, and patents in microstructure evolution in deformation processes; creation of bulk nanocrystalline materials by large strain deformation; modulation assisted machining processes; and technology commercialization in machining and materials processing methods. Dr. Mann earned a B.S. Engineering (1990) and M.S. Engineering (1994) School of Aeronautics and Astronautics, Purdue University, and a Ph.D. (2010) School of Industrial Engineering, Purdue University. He earned a MBA Finance (1998) Kelley School of Business, Indiana University. Dr. Mann’s industry roles have intersected engineering and management in the aerospace, automotive, and contract manufacturing sectors. His research and commercialization work have been recognized by the Tibbetts Award, US Small Business Administration (2011), the R&D 100 Award (2010), and first place at the 20th Annual Burton Morgan entrepreneurial competition (2007).

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