Theme IV

Theme IV: Adaptive Tooling/Processes and Novel Manufacturing Process/Applications
(Theme Leader: Stephen Veldhuis – McMaster University)

Contribution to Common Objectives

The objectives of Theme IV are to develop custom surface treatments primarily supported by physical vapour deposition (PVD) and novel manufacturing processes that allow processing of parts made from exotic alloys containing complex features with tight surface quality expectations. The goal is to develop a detailed framework for selecting, developing and optimizing tooling and novel processes based on adaptive concepts and innovative manufacturing processing.

Role of Theme IV in the overall Network

  • Support tooling selection and development requirements based on the specific needs of each process and material.
  • leverage the advantages of adaptive surfaces and novel processes to enhance competitiveness.

IV.A

ANALYSIS & CHARACTERIZATION OF TOOLING
IV.A.1: Tool Geometry, Edge and Wear Measurement and Processing Conditions
(Veldhuis, Koshy – McMaster)
Emamian


Deng

 

Aramesh

Fox-Rabinovich

MASc end Dec 2017

MASc end Dec 2018

PDFRes. Assoc.
IV.A.2: Methodology for Assessing Tool Wear Mechanisms
(Veldhuis – McMaster/Alpas – Windsor)
 

Aramesh

Fox-Rabinovich

MASc

PDF

Res. Assoc.


IV.B

INTEGRATED TOOL DESIGN & SURFACE ENGINEERING
IV.B.1 Modeling of Machining Temperatures for Coated Tools
(Altintas- UBC/Alpas – Windsor, Veldhuis – McMaster/
Kalhori – Sandvik Coromant)
 Islam Ph.D. 
IV.B.2: Tool Geometry Assessment and Optimization
(Veldhuis – McMaster)
Saifullah

 

Paiva

Fox-Rabinovich

MASc Sept 2017/end Aug 2019

PDF 

Res. Assoc.

IV.B.3: Edge and Tool Surface Preparation
(Veldhuis, Koshy – McMaster)
Wang

Aramesh

Fox-Rabinovich

MASc Sept 2017

PDF

Res. Assoc.

IV.B.4: Adaptive Nano-Multilayered PVD Coatings
(Veldhuis – McMaster/Alpas – Windsor)
Molaiekiya

Bose

Fox-Rabinovich

Ph.D.

PDF

Res. Assoc.

IV.B.5: Functionally Graded Multilayer Coatings
(Veldhuis – McMaster/Alpas -Windsor)
Chowdhury

 

Rawal

Fox-Rabinovich

Ph.D.  Sept 2017

PDF

Res. Assoc.

IV.B.6: Thick PVD Coatings
(Veldhuis – McMcMaster/Alpas – Windsor)
Abdoos

Rawal

Fox-Rabinovich

Ph.D.

PDF

Res. Assoc.

IV.B.7: Development of New PVD Coatings Specifically for Machining Hardened Die Steel
(Veldhuis – McMaster/Alpas – Windsor)
Patel

Rawal

Fox-Rabinovich

Ph.D. Sept 2017

PDF

Res. Assoc.

IV.B.8: Development of Lubricating Multilayer PVD Coatings for Machining of Al-Si Alloys
(Veldhuis – McMaster/Endrino – Cranfield University & Kennametal)
 

Rawal

Fox-Rabinovich

Ph.D.

PDF

Res. Assoc.

IV.B.9: Investigation of Post Treatments(wide peening and cleaning: WPC, EDM)
(Veldhuis – McMaster/Alpas – Windsor, Koshy – McMaster, Kennametal)
Nabipour

 

Aramesh

Fox-Rabinovich

MASc  end Dec 2018

PDF

Res. Assoc.

IV.B.10: Integrative Wear Assessment – project starts July 2018
(Veldhuis – McMaster)
 

Bose

Fox-Rabinovich

Ph.D.

PDF

Res. Assoc.

IV.B.11: Development of Low-Friction and Durable Tool Coatings for Machining of Aerospace Components made of Titanium Alloys
(Alpas – Windsor/ Veldhuis – McMaster, Altintas – UBC)
 Khan

 

Bhowmick

Ph.D. end fall 2019

Res. Assoc. end 2017


IV.C

SURFACE PERFORMANCE ASSESSMENT

IV.C.1: Nano Scale Tribology Investigation
(Veldhuis – McMaster/Alpas – Windsor)
Boyd

 

Aliakbari

 

Bose

Fox-Rabinovich

Ph.D. Sept 2013 PT

MASc May 2017/end Apr 2019

PDF

Res. Assoc.

IV.C.2: Micro-Nano Material Characterization
(Veldhuis – McMaster/Alpas – Windsor)
Chowdhury

 

Bose

 

Fox-Rabinovich

Ph.D.
ends Sept 2019PDF
Res. Assoc.
IV.C.3: Method for Assessing Chipping Resistance
(Veldhuis – McMaster/Alpas – Windsor)
Alam

 

Aramesh

Fox-Rabinovish

MASc     
end Dec 2018
PDFRes. Assoc.
IV.C.4: Oxidation / Corrosion Performance of Surfaces
(Veldhuis – McMaster/Alpas – Windsor, Zhitomirsky – McMaster)
 

Bose

Fox-Rabinovich

Ph.D.

PDF

Res. Assoc.

IV.C.5: Assess c-BN Tooling Performance in Machining of Grey Cast Iron
(Veldhuis – McMaster)
Yesong

 

Rawal

Fox-Rabinovich

MASc
end Aug 2018
PDFRes. Assoc.
IV.C.6: Understanding the Rold of Coolant in Grey Cast Iron Machining Utilizing c-BN Machining
(Veldhuis – McMaster/Boyle – CANMET
Shokoohi

 

Paiva

 

Fox-Rabinovich

MASc
end Dec 2018
PDF                end Dec 2018Res. Assoc.
IV.C.7: Understanding the Role of Alloying Elements in Machinability
(Veldhuis – McMaster/Alpas – Windsor, Balazinski – Ecole Polytechnique, Boyle – CANMET)
Ahmed

 

Aramesh

Fox-Rabinovich

Ph.D.
Jul 2017/end Dec 2018PDFRes. Assoc.
IV.C.8: Machining of High-Alloy Powderd Metals
(Veldhuis – McMaster/Balazinski – Ecole Polytechnique, Boyle – CANMET)
Stolf

 

Paiva

Fox-Rabinovich

MASc
Sept 217/end Aug 2019PDF Feb 2017Res. Assoc.
IV.C.9: High-Productivity Bi-Metal Machining (Aluminum and Steel)
(Veldhuis – McMaster)
Hbbani

 

Rawal

Fox-Rabinovich

MASc
started Sept 2017 PDFRes. Assoc.
IV.C.10: Investigate Improved Tapping Life in Automotive Die Cast Al-Si Applications
(Veldhuis – McMaster
Barooah

Paiva

 

Fox-Rabinovich

MASc
end Dec 2018PDF
end Dec 2018Res. Assoc.
IV.C.11: Investigation of Wear Performance during Machining of Ti Alloys
(Veldhuis – McMaster/Balazinski – Ecole Polytechnique, Koshy – McMaster)
Locks Junior

 

Paiva

 


Fox-Rabinovich

MASc Sept 2017/end Sept 2019

PDF Feb 2017/end Dec 2018

Res. Assoc.

IV.C.12: Investigation of Wear Performance during Machining of Ni-based Aerospace Alloys
(Veldhuis – McMaster/Balazinski – Ecole Polytechnique)
 

Montazeri

Aramesh

Fox-Rabinovich

MASc

Ph.D.

PDF

Res. Assoc.

IV.C.13: Investigation of Wear Behaviour during Machining of Superduplex Stainless Steel
(Veldhuis – McMaster/Boyle – CANMET)
 

Paiva

Ahmed

Fox-Rabinovich

MASc

PDF

Ph.D.end Sept 2020

Res. Assoc.

IV.C.14: Assessment of Performance in High-speed Ddry Machining of Low Carbon Steel
(Veldhuis – McMaster)
Zhang

 

Paiva

 

Fox-Rabinovich

MASc Sept 2017/end Sept 2019

PDF Feb 2017/end Dec 2018

Res. Assoc.


IV.D

NOVEL PROCESSES & APPLICATIONS
IV.D.1: Novel Application of Non-Newtonian Working Media for Polishing and Edge Preparation of Complex Milling Tools
(Koshy – McMaster/Klocke – RWTH Aachen, Germany)
 Chan MASc Sept 2017 end Sept 2019
IV.D.2: Improved Coolant Jet Coherency for Enhanced Heat Transfer in Grinding through:
(1) Computational Modeling of Nozzle Flow Conditioner, and
(2) Mixing of Polymer Additives
(Koshy – McMaster/McIntosh – P&WC)
 Starts Jul 2018 MASc
IV.D.3: Fabrication of Superhydrophobic Surfaces
(Koshy – McMaster/McIntosh – P&WC)
 Guo MASc
end Sept 2018
IV.D.4: Enhancement of Boiling Heat Transfer
(Koshy – McMaster/McIntosh – P&WC)
 Singh MASc
end Jan 2019
IV.D.5: EDM Texture for Control of Fluid Drag and Surface Traction
(Koshy – McMaster/ McIntosh – P&WC)
 Starts Jul 2019 MASc