MMAE Seminar: Large-Scale Manufacturing of Materials by Machining-Based Deformation Processing

The Department of Mechanical, Materials, and Aerospace Engineering will welcome James Mann, president and co-founder of M4 Science, for a lecture titled “Large-Scale Manufacturing of Materials by Machining-Based Deformation Processing” on Wednesday, February 15, from 12:45–145 p.m. in Room 131 of Perlstein Hall. 

Abstract

Shear-based deformation processing by machining is demonstrated for manufacturing of metals and alloys in bulk and particulate forms, and at scale. This materials manufacturing is based on the unique control of deformation conditions and deformation geometry in the process zone that offer important advantages over conventional deformation processes (e.g., extrusion, rolling, drawing). The intense deformation fields and precise motion control characteristic of machining are applied to form chips (end-product) with controlled geometry, fine-grained microstructure, and crystallographic shear texture. The technological details and scientific underpinnings of this approach are discussed for two processes: hybrid cutting-extrusion (HCE), for production of metals in bulk forms, and modulation-assisted machining (MAM), for particulate metals. In HCE, an additional constraining die, located directly across from the primary cutting tool, converts the usual unconstrained chip formation to one with controlled geometrical format—thin-gauge strip in foil, sheet, and flat wire forms. Tailoring the large-strain deformation field and deformation path can achieve bulk strip with ultrafine-grained microstructure and crystallographic shear-texture favorable for formability. Potential applications of HCE materials range from electrical power systems to structural metals for weight reduction. In MAM, a low-frequency oscillation (typically <1000Hz) is superimposed onto the conventional cutting process, thereby transforming the cutting into a series of discrete chip-formation events. The discrete chip formation is used to produce metal particulate with equiaxed, fiber, and platelet shape morphologies, unique surface texture, and ultrafine grained microstructure. The metal particulates can be integrated as reinforcements in new composite materials, including applications in additive manufacturing. Implications for commercial production of metal strip for electrical motor applications and battery electrodes and a new class of composite materials utilizing MAM particulates and additive manufacturing, will be discussed.  

Biography

James Mann is president and co-founder of M4 Sciences, a designer and developer of advanced technologies for manufacturing and materials processing. He has held academic appointments at the Center for Materials Processing and Tribology in the School of Industrial Engineering at Purdue University and in the mechanical engineering department at the University of West Florida. His industry career in large corporations and small business settings intersects engineering and management in the aerospace, automotive, and contract manufacturing sectors. Mann’s research and commercialization work includes new discoveries, publications, patents, and technology innovation and commercialization. Examples include high-performance product designs, precision machining processes, modulation-assisted machining (MAM), advanced metal fiber manufacturing, innovative metrology methods, assembly and test operations, microstructure evolution and mechanics of deformation processes, creation of bulk nanocrystalline materials by large strain deformation, and metal fiber reinforced polymers for additive manufacturing. Mann pioneered the development and commercialization of modulation-assisted machining systems. MAM technology has enabled five times the increases in productivity and 10 times thee increases in tool life for mechanical drilling applications across the orthopedic, aerospace, energy, and transportation sectors. MAM technology was successfully commercialized in materials processing for metal fiber manufacturing. Mann’s contributions to engineering, research, and commercialization have been recognized in conference presentation awards, publication awards, induction to thee Purdue Innovator Hall of Fame (Purdue Research Foundation), Tibbetts Award (United States Small Business Administration), the R&D 100 Award, and first place in the 20th annual Burton Morgan entrepreneurial competition.