FIXTURING AND MACHINING PROCESSES RESEARCH GROUP

Publications

 

Journal Articles

 

Micromachining: Mechanics and New Process Development

1. Singh, R. and Melkote, S.N., “Characterization and Prediction of the Heat Affected Zone in Laser-Assisted Mechanical Micromachining,” International Journal of Machine Tools and Manufacture, Vol. 48, No. 9, pp. 994-1004, 2008.

2. Subbiah, S. and Melkote, S.N., “Effect of Finite Edge Radius on Ductile Fracture Ahead of the Cutting Tool in Micro-Cutting of Al2024-T3,” Materials Science and Engineering, Series A, Vol. 474, pp. 283-300, 2008.

3. Singh, R. and Melkote, S.N., “Characterization of a Hybrid Laser-Assisted Mechanical Micromachining Process for Difficult-To-Machine Materials,” International Journal of Machine Tools and Manufacture, Vol. 47, pp. 1139-1150, 2007.

4. Singh, R. and Melkote, S.N., “Hybrid Laser-Assisted Mechanical Micromachining (LAMM) Process for Hard-To-Machine Materials,” Journal of Laser Micro/Nanoengineering, Japan Laser Processing Society, Vol. 2, No. 2, pp. 156-161, 2007.

5. Subbiah, S. and Melkote, S.N., “Evidence of Ductile Tearing Ahead of the Cutting Tool and Modeling the Energy Consumed in Material Separation in Micro-Cutting,” ASME Transactions, Journal of Engineering Materials and Technology, Vol. 129, No. 2, pp. 321-331, 2007; also in Proceedings of the 2006 ASME Manufacturing Science and Engineering Conference (MSEC), Ypsilanti, MI, Oct. 8-11, 2006.

6. Subbiah, S. and Melkote, S.N., “Evaluation of Atkins’ Model of Ductile Machining Including the Material Separation Component,” Journal of Materials Processing Technology, Vol. 182, No. 1-3, pp. 398-404, 2007.

7. Liu, K. and Melkote, S.N., “Finite Element Analysis of the Influence of Tool Edge Radius on Size Effect in Orthogonal Micro-Cutting Process,” International Journal of Mechanical Sciences, Vol. 49, No. 5, pp. 650-660, 2007.

8. Liu, K. and Melkote, S.N., “Effect of Plastic Side Flow on Surface Roughness in Micro-Turning Process,” International Journal of Machine Tools and Manufacture, Vol. 46, No. 14, pp. 1778-1785, 2006.

9. Liu, K., and Melkote, S.N., “Material Strengthening Mechanisms and Their Contribution to Size Effect in Micro-Cutting,” ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 128, No. 3, pp. 730-738, 2006.

10. Subbiah, S. and Melkote, S.N., “The Constant Force Component due to Material Separation and its Contribution to Size-Effect in Specific Cutting Energy,” ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 128, No. 3, pp. 811-815, 2006.

11. Ng, C.K., Melkote, S.N., Rahman, M., Kumar, A.S., “Experimental Study of Micro and Nano Scale Cutting of Aluminum 7075-T6,” International Journal of Machine Tools and Manufacture, Vol. 46, pp. 929-936, 2006.

12. Joshi, S., and Melkote, S.N., “An Explanation for the Size-Effect in Machining Using Strain Gradient Plasticity,” ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 126, No. 4, pp. 679-684, 2004.

 

Fixturing, Workholding, Grasping

13. Wagner, M., Morehouse, J.M., Melkote, S.N., “Prediction of Part Orientation Error Tolerance of a Robotic Gripper,” in press, International Journal of Robotics and Computer Integrated Manufacturing.

14. Brun, X. and Melkote, S.N., “Modeling and Experimental Verification of Partial Slip for Multiple Contact Problems,” Wear, Vol.265, pp.34-41, 2008.

15. Kurnadi, M., Morehouse, J., Melkote, S.N., “A Workholding Optimization Model for Turning of Ring Shaped Parts,” International Journal of Advanced Manufacturing Technology, Vol. 32, No. 7-8, pp. 656-665, 2007.

16. Deng, H. and Melkote, S.N., “Determination of Optimum Clamping Forces for Dynamically Stable Fixturing,” International Journal of Machine Tools and Manufacture, Vol. 46, No. 7/8, pp. 847-857, 2006.

17. Siebenaler, S. and Melkote, S.N., “Prediction of Workpiece Deformation in a Fixture System Using the Finite Element Method,” International Journal of Machine Tools and Manufacture, Vol. 46, No. 1, pp. 51-58, 2006.

18. Deng, H. and Melkote, S.N., “Analysis of Dynamic Stability of a Fixtured Workpiece Accounting for Material Removal Effect,” Transactions of NAMRI/SME, Vol. 33, pp. 289-296, 2005.

19. Raghu, A. and Melkote, S.N., “Workpiece Location Error Modeling as a Function of Fixture-Workpiece Related Variables,” ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 127, No. 1, pp. 75-83, 2005.

20. Satyanarayana, S., and Melkote, S.N., “Finite Element Modeling of Fixture-Workpiece Contacts: Single Contact Modeling and Experimental Verification,” International Journal of Machine Tools and Manufacture, Vol. 44, No. 9, pp. 903-913, 2004.

21. Raghu, A. and Melkote, S.N., “Analysis of the Effects of Fixture Clamping Sequence on Part Location Errors,” International Journal of Machine Tools and Manufacture, Vol. 44, No. 4, pp. 373-382, 2004.

22. Malluck, J.A. and Melkote, S.N., "Modeling of Deformation of Ring Shaped Workpieces Due to Chucking and Cutting Forces," ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 126, No. 1, pp. 141-147, 2004; also in Proceedings of the 2002 IMECE (CD-ROM), ASME, New Orleans. (Winner of Best Paper Award, ASME Manufacturing Engineering Division, 2002 IMECE, New Orleans, LA).

23. Hurtado, J.F., and Melkote, S.N., "Modeling and Analysis of the Effect of Fixture-Workpiece Conformability on Static Stability", ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 124, No. 2, pp. 234-241, 2002. (Winner of 2004 ASME Blackall Machine Tool and Gage Best Paper Award).

24. Satyanarayana, S. and Melkote, S.N., "Determination of Clamping Force Based on Minimization of Workpiece Elastic Deformation", Transactions of NAMRI/SME, Vol. 30, pp. 597-604, 2002.

25. Hurtado, J.F. and Melkote, S.N., "A Model for Synthesis of the Fixturing Configuration in Pin-Array Type Flexible Machining Fixtures," International Journal of Machine Tools and Manufacture, Vol. 42, No. 7, pp. 837-849, 2002.

26. Kulankara, K., Sathyanarayana S. and Melkote, S.N., "Iterative Fixture Layout and Clamping Force Optimization Using the Genetic Algorithm," ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 124, No. 1, pp. 119-125, 2002.

27. Hurtado, J.F. and Melkote, S.N., "Improved Algorithm for Tolerance-based Stiffness Optimization of Machining Fixtures," ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 123, No. 4, pp. 720-730, 2001.

28. Hurtado, J.F., and Melkote, S.N., "Experimental Study of Conformability and Static Stability in a Flexible Machining Fixture," Transactions of NAMRI/SME, Vol. 29, pp. 615-622, 2001.

29. Li, B. and Melkote, S.N., "Optimal Fixture Design Accounting for the Effect of Workpiece Dynamics," International Journal Advanced Manufacturing Technology, Vol. 18, No. 10, pp. 701-707, 2001.

30. Li, B., and Melkote, S.N., "Fixture Clamping Force Optimization and its Impact on Workpiece Location Accuracy," International Journal of Advanced Manufacturing Technology, Vol. 17, pp. 104-113, 2001.

31. Felix, A., Melkote, S.N., and Matsumoto, Y., "Modeling of the Holding Force in a Electromagnetic Chuck," ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 122, No. 3, pp. 569-575, 2000.

32. Li, B., and Melkote, S.N., “A Minimum Clamping Force Algorithm for Machining Fixtures,” Transactions of NAMRI/SME, Vol. 28, pp. 407-412, 2000.

33. Kulankara, K., and Melkote, S.N., “Machining Fixture Layout Optimization Using the Genetic Algorithm,” International Journal of Machine Tools and Manufacture, Vol. 40, No. 4, pp. 579-598, 2000.

34. Li, B., Melkote, S.N., and Liang, S.Y., “Analysis of Reactions and Minimum Clamping Force For Machining Fixtures With Large Contact Areas,” International Journal of Advanced Manufacturing Technology, Vol. 16, No. 2, pp. 79-84, 2000.

35. Hurtado, J.F., and Melkote, S.N., “Workpiece-Fixture Static Friction Under Dynamic Loading,” Wear, Vol. 231, pp. 139-152, 1999.

36. Felix, A., and Melkote, S.N., “Effect of Workpiece Flatness and Surface Finish on the Holding Force in a Magnetic Chuck,” ASME Transactions, Journal of Manufacturing Science and Engineering, Vol. 121, No. 4, pp. 811-814, 1999.

37. Li, B., and Melkote, S.N., “Improved Workpiece Location Accuracy through Fixture Layout Optimization,” International Journal of Machine Tools and Manufacture, Vol. 39, No. 6, pp. 871-883, 1999.

38. Li, B., and Melkote, S.N., “An Elastic Contact Model for the Prediction of Workpiece-Fixture Contact Forces in Clamping,” ASME Transactions, Journal of Manufacturing Science and Engineering, Vol. 121, pp. 485-493, 1999.

39. Hurtado, J.F., and Melkote, S.N., “A Model for the Estimation of Reaction Forces in a 3-2-1 Machining Fixture,” Transactions of NAMRI/SME, Vol. 26, pp. 335-340, 1998. (Winner of the Outstanding Paper Award at NAMRC XXVI).

40. Melkote, S.N., Athavale, S.M., DeVor, R.E., Kapoor, S.G. and Burkey, J.J., “Prediction of the Reaction Force System for Machining Fixtures Based on Machining Process Simulation,” Transactions of NAMRI/SME, Vol. 23, 325-330, 1995.

 

Precision Machined Surfaces: Integrity and Functional Properties

41. Han, S., Melkote, S.N., Haluska, M.S., and Watkins, T.R., “White Layer Formation Due to Phase Transformation in Orthogonal Machining of AISI 1045 Annealed Steel,” Materials Science and Engineering, Series A: Structural Materials, Microstructure and Processing, Vol. 488, No. 1-2, pp. 195-204, 2008.

42. Ramesh, A. and Melkote, S.N., “Modeling of White Layer Formation Under Thermally Dominant Conditions in Orthogonal Hard Machining of AISI 52100 Steel,” International Journal of Machine Tools and Manufacture, Vol. 48, pp. 402-414, 2008.

43. Han, S., Subbiah, S., and Melkote, S.N., “A Procedure for Determining the Presence of White Layer in Turning of AISI 1045 Annealed Steel,” Transactions of NAMRI/SME, Vol. 35, pp. 49-56, 2007.

44. Smith, S., Melkote, S.N., Lara-Curzio, E., Watkins, T.R., Allard, L., Riester, L., “Effect of Surface Integrity of Hard Turned AISI 52100 Steel on Fatigue Performance,” Materials Science and Engineering, Series A: Structural Materials, Microstructure and Processing, Vol. 459, No. 1-2, pp. 337-346, 2007.

45. Subbiah, S., Newton, T., Melkote, S.N., “On the Performance of Binderless cBN in Interrupted Hard Turning,” Transactions of NAMRI/SME, Vol. 34, pp. 389-396, 2006 (Winner of Best Student Presentation Award for S. Subbiah at NAMRC 34, Marquette Univ., Milwaukee, WI).

46. Anand, R., Melkote, S.N., Allard, L.F., Reister, L., and Watkins, T.R., “Analysis of White Layers in Hard Turning of AISI 52100 Steel,” Materials Science & Engineering, Series A: Structural Materials, Microstructure and Processing, Vol. A390, pp. 88-97, 2005.

47. Singh, R., Melkote, S.N., and Hashimoto, F., “Frictional Response of Precision Finished Surfaces in Pure Sliding,” Wear, Vol. 258, No. 10, pp. 1500-1509, 2005.

48. Han, S. and Melkote, S.N., “Prediction of White Layer Formation in Hardened Steel Machining,” invited paper, International Journal for Manufacturing Science and Technology, Vol. 5, No. 2, pp. 55-62, 2003/2004.

49. Subbiah, S. and Melkote, S.N., “Surface Integrity of Hardened Steel Turned with a Rotary Tool,” Transactions of NAMRI/SME, Vol. 32, pp. 359-366, May 2004.

50. Dessoly, V., Melkote, S.N., and Lescalier, C., “Modeling and Verification of Cutting Tool Temperatures in Rotary Tool Turning of Hardened Steel,” International Journal of Machine Tools and Manufacture, Vol. 44, No. 14, pp. 1463-1470, 2004.

51. Thiele, J.D., Melkote, S.N., Watkins, T.R., and Peascoe, R.A. “Effect of Cutting Edge Geometry and Workpiece Hardness on Surface Residual Stresses in Finish Hard Turning of AISI 52100 Steel,” ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 122, No. 4, pp. 642-649, 2000.

52. Thiele, J.D., and Melkote, S.N., “The Effect of Tool Edge Geometry on Workpiece Sub-Surface Deformation and Through-Thickness Residual Stresses For Hard Turning of AISI 52100 Steel,” Transactions of NAMRI/SME, Vol. 27, pp. 135-140, 1999.

53. Thiele, J.D., and Melkote, S.N., “Effect of Cutting Edge Geometry and Workpiece  Hardness on Surface Generation in Finish Hard Turning of AISI 52100 Steel,” Journal of Materials Processing Technology, Vol. 94, No. 2-3, pp. 216-226, 1999.

54. Melkote, S.N., Sutherland, J.W., and King, C., “The Effect of Tool Flexibility on Back-Cutting in End Milled Surfaces,” ASME Transactions, Journal of Manufacturing Science and Engineering, Vol. 121, No. 3, pp. 532-537, 1999; also in Proceedings of the Symposium on Concurrent Product and Process Engineering, ASME IMECE, ASME MED-Vol.1/DE-Vol. 85, pp. 201-211, November 1995.

55. Gu, F., Melkote, S.N., Kapoor, S.G. and DeVor, R.E., “A Model For The Prediction Of Surface Flatness In Face Milling,” ASME Transactions, Journal of Manufacturing Science and Engineering, Vol. 119, pp. 476-484, November 1997; also in Physics of Machining Processes - II/Materials Issues in Machining, D. Stephenson and R. Stevenson (Ed.), ASME PED/TMS, pp. 217-231, 1994.

56. Melkote, S.N. and Thangaraj, A.R., “An Enhanced End Milling Surface Texture Model Including the Effects of the Radial Rake and Relief Angles,” ASME Transactions, Journal of Engineering for Industry, Vol. 116, no. 2, pp. 166-174, 1994.

 

Other Machining Processes

57. Newton, T.R., Morehouse, J.M., Melkote, S.N., and Turner, S., “An Experimental Study of Interfacial Burr Formation in Drilling of Stacked Aluminum Sheets,”  Transactions of NAMRI/SME, Vol. 36, pp. 437-444, 2008.

58. Tomori, T., Melkote, S.N., and Kotnis, M., “Injection Mold Performance of Machined Ceramic Filled Epoxy Tooling Boards,” Journal of Materials Processing Technology, Vol. 145, No. 1, pp. 126-133, 2004.

59. Tomori, T., Melkote, S.N., and Kotnis, M., “Effects of Filler Concentration and Cutting Parameters on Material Properties and Machinability of SiC-Filled Tooling Board,” Materials and Manufacturing Processes, Vol. 18, No. 6, pp. 943-963, 2003.

60. Lanz, R., Melkote, S.N., and Kotnis, M., "Machinability of Rapid Tooling Composite Board", Journal of Materials Processing Technology, Vol. 127, 2002, pp. 242-245.

61. Lanz, R., Melkote, S.N., and Kotnis, M., "Effect of Process Parameters and Tool Shape on the Machinability of a Particulate-Filled Polymer Composite Material for Rapid Tooling," Machining Science and Technology, Vol. 5, No.2, pp. 217-237, 2001.

62. Melkote, S.N. and Endres, W.J., “The Importance of Including Size Effect When Modeling Slot Milling,” ASME Transactions, Journal of Manufacturing Science and Engineering, Vol. 120, No. 1, pp. 68 - 75, 1998.

63. Melkote, S.N. and Kendall, L.A., “Extraction of End Mill Cutter Engagements from CNC Tool Trajectories for Planar Surface Generation,” Transactions of NAMRI/SME, Vol. 17, pp. 152-159, 1989.

 

Award Winning Publications/Presentations and Keynote Papers/Presentations

1. Hashimoto, F., Melkote, S.N., Singh, R., and Kalil, R., “Effect of Finishing Methods on Surface Characteristics and Performance of Precision Components in Rolling/Sliding Contact,” Proceedings of the 10^th CIRP International Workshop on Modeling of Machining Operations, Calabria, Italy, August 27-28, 2007. (Keynote Paper)

2. Subbiah, S., Newton, T., Melkote, S.N., “On the Performance of Binderless cBN in Interrupted Hard Turning,” Transactions of NAMRI/SME, Vol. 34, pp. 389-396, 2006 (Winner of Best Student Presentation Award for S. Subbiah at NAMRC 34, Marquette Univ., Milwaukee, WI).

3. “Advances in Scientific Understanding of Hard Turning Process Using cBN Tools,” Keynote lecture, 2006 INTERTECH Conference of the Industrial Diamond Association, Atlanta, GA, April 24-26, 2006.

4. Subbiah, S. and Melkote, S.N., “Finite Element Study of Energy Consumed in Material Separation in Micro Cutting Process,” poster presentation at the International Conference on Advanced Materials Design & Development, Goa, India, 14-16 December 2005. (Winner of Best Poster Presentation Award for S. Subbiah).

5. Malluck, J.A. and Melkote, S.N., "Modeling of Deformation of Ring Shaped Workpieces Due to Chucking and Cutting Forces," ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 126, No. 1, pp. 141-147, 2004; also in Proceedings of the 2002 IMECE (CD-ROM), ASME, New Orleans. (Winner of Best Paper Award, ASME Manufacturing Engineering Division, 2002 IMECE, New Orleans, LA)

6. Hurtado, J.F., and Melkote, S.N., "Modeling and Analysis of the Effect of Fixture-Workpiece Conformability on Static Stability", ASME Transactions, Journal of Manufacturing Science & Engineering, Vol. 124, No. 2, pp. 234-241, 2002. (Winner of 2004 ASME Blackall Machine Tool and Gage Best Paper Award)

7. Hurtado, J.F., and Melkote, S.N., “A Model for the Estimation of Reaction Forces in a 3-2-1 Machining Fixture,” Transactions of NAMRI/SME, Vol. 26, pp. 335-340, 1998. (Winner of the Outstanding Paper Award at NAMRC XXVI).