Professor I.S. Jawahir

James F. Hardymon Chair in Manufacturing Systems, and

Director of Institute for Sustainable Manufacturing (ISM)

University of Kentucky

 

Sustainable machining processes are generally known as environmentally benign, and economically and societally-beneficial machining operations. Sustainable machining is aimed at achieving energy-efficiency, environmental friendliness (with reduced negative environmental impact), cost-effectiveness, waste/coolant reduction or elimination, operational safety and reliability, along with no adverse personnel health effects to operators and shop floor personnel. This keynote presentation will summarize recent progress in developing predictive models and optimization techniques for sustainable machining processes. The presentation will begin with a discussion on the significance of sustainable machining, and will then justify the need for implementing dry, near-dry (MQL-based) and cryogenic machining methods as major sustainable machining processes. A metrics-based evaluation of sustainable machining processes will then be introduced for quantitative assessment of process sustainability in machining, focusing on major machining performance measures, also known as machinability elements (tool-life, surface integrity, cutting forces/power/torque, chip-forms/chip breakability, part accuracy, etc.).

 

After a brief review of dry and near-dry machining processes, recent advances from novel cryogenic machining and burnishing processes on selected materials (Ti alloys, Al alloys, AZ31B Mg alloys, Ni-Ti shape memory alloys, Inconel 718, AISI 52100, Co-Cr-Mo alloys, etc.) for achieving enhanced surface and sub-surface integrity to provide improved product quality, performance and life will be presented.  This study will include an analysis of severe plastic deformation (SPD) induced by cryogenic machining and burnishing processes on these materials, and their resulting performance enhancement through controllable ultra-fine/nano grain structures, and the associated wear and corrosion resistance properties, and the induced compressive residual stresses enabling improved fatigue life in some of these machined and burnished materials. Recent advances in modeling and optimization of sustainable machining operations will then be discussed. Experimental results are compared with numerical/analytical simulations. Encouraging trends are observed from this extensive study showing tremendous potential for applications in aerospace, automotive, and biomedical manufacturing.

 

 

Bio-summary of Professor I.S. Jawahir

 

Dr. I.S. Jawahir is a Professor of Mechanical Engineering, James F. Hardymon Endowed Chair in Manufacturing Systems, and the Founding Director of the Institute for Sustainable Manufacturing (ISM) at the University of Kentucky (Lexington, KY, USA). He received his Ph.D. from the University of New South Wales (Sydney, Australia) in 1986. His current research interests are in the areas of sustainable manufacturing, focusing on predictive modeling and optimization of sustainable machining processes aimed at improved machining performance (surface integrity, tool-wear/tool-life, chip control, etc.).  He has produced over 350 technical research papers, including 135 refereed journal papers, and has been awarded with 4 U.S. patents. He has supervised and directed the research of 34 PhD and over 80 MS graduates. He has also served as External Examiner for 48 PhD theses and dissertations from major universities worldwide. He has delivered 46 keynote papers in major international conferences and over 150 invited presentations in 32 countries.

 

Professor Jawahir has received significant research funding from U.S. Federal Agencies (NSF, NIST, US Army, DLA, etc.), and from major manufacturing companies (General Motors, Ford, General Electric – Aviation, Toyota, Sandvik, Kennametal, Lexmark and 3M).  He is a Fellow of three major professional societies: CIRP (International Academy for Production Engineering); ASME (American Society of Mechanical Engineers); and SME (Society of Manufacturing Engineers). He is the Founding Editor-in-Chief of the International Journal of Sustainable Manufacturing, and the Technical Editor of the Journal of Machining Science and Technology. He also served as the Member of the ASME Board for Research and Technology Development (BRTD) for over a decade, and in 2005, he founded the ASME Research Committee on Sustainable Products and Processes and served as the Founding Chairman of this committee for the first six years (2005-11). He is the Founder of the CIRP international conference series on Modeling of Machining Operations. He organized and hosted the first conference in this series in Atlanta, GA, USA in 1998. This series still continues with the 15th conference in the series recently held in Karlstruhe, Germany in June 2015, and the 16th conference to be held in Cluny, France in 2017. He recently served as the Chairman of the CIRP’s International Collaborative Research Working Group on Surface Integrity and Functional Performance of Components (2007-11). Professor Jawahir received the 2013 ASME Milton C. Shaw Manufacturing Research Medal for his outstanding research contributions to manufacturing processes, and the W. Johnson International Gold Medal in 2015 for his lifelong achievements and contributions to materials processing research and education.