February 2024 Volume 6

INDUSTRY NEWS

Autonomous Design The goal of any manufacturing process is to produce a product which meets the geometric, functional, and aesthetic requirements of its application, while balancing economic, environmental, and social costs. Hybrid manufacturing presents a myriad of processing sequences, including forging, machining, and other shaping processes. Led by Northwestern University, the HAMMER Design thrust will develop a comprehensive system-level design method that can concurrently design material, topology, and flexible manufacturing process sequences. Tool and Process Convergence Any forging process will, of necessity, have a starting workpiece geometry and material condition, one or more forming sequences, and a finishing process. HAMMER will create an extensible integrated framework for process design and manufacturing equipment control. The system will include real time workpiece condition monitoring and self-correction. Led by the University of Tennessee-Knoxville, the Tool and Process Convergence design thrust will develop the framework for design of novel machines and control strategies for individual processes as well as the sequencing and transfer processes. Material State Awareness Understanding the impact of forging and other processes on material properties is key to quality assurance. Digital twin technology will be used to inform material structure - property models and manage uncertainty in properties and performance of the manufactured part. New, fast acting models integrated with in-situ monitoring will enable real time self-correction. Led by The Ohio State University, the Material State Awareness thrust will develop materials modeling capabilities to manage both expected values and uncertainty. Control, Intelligence and Autonomy Process design is based largely on knowledge and experience, combined with an in-depth understanding of the underlying process physics. Development of an autonomous design system will include leveraging problem-centric AI methods, integrated with high-fidelity simulations and in-situ sensing data. Led by Case Western Reserve University (CWRU) the Control, Intelligence, and Autonomy thrust will improve process intelligence to enable autonomous control of a diverse set of manufacturing processes that include self-correcting strategies for realizing target shape, material properties, and function. Workforce Development and Educational Outreach The HAMMER engineering research center is well poised to provide the forging industry with degreed engineers and aligned majors who have a deep understanding of metal forming theory and 21st century manufacturing technology. With core partnerships at Case Western Reserve University, North Carolina Agricultural and Technical State University, Northwestern University, and The University of Tennessee at Knoxville, HAMMER will expose hundreds of students to forging and manufacturing through research projects,

and student work study opportunities. North Carolina A&T State University will develop a key component of educational outreach with Physical Exploration and Training Factory/Artisan Boxes (PET-FABs). PET-FABs are low cost manufacturing cells including robots, dimensional and field sensing. Programmable logic controls (PLCs) and modular design ease the addition of new process modules. Their small scale makes them ideal for education and for prototyping new features. HAMMER is working with regional Career and Technical Education partners (Community Colleges, K-12 engineering classes and vocational schools) to ensure the workforce of operators and technicians will be ready to come alongside our HAMMER engineers to make the dream of a hybrid autonomous manufacturing The HAMMER Project formally launched September 2022. Numerous events are available both in person and online. For example, free, HAMMER-Time public virtual talks occur the first and third Thursday of each month at 4PM ET. See the HAMMER website for details. Each of the partner institutions brings its own capabilities to the program. At Ohio State, HAMMER leverages the Center for Design and Manufacturing Excellence. At the University of Tennessee, there is a close collaboration with Oak Ridge’s Manufacturing Demonstration Facility. There are multiple ways to engage, from attending public meetings, to becoming a member or sponsoring research. Details are on the HAMMER website. Early Implementation: Point of Care Manufacturing Led by OSU, Point of Care Manufacturing streamlines the fabrication of personalized medical devices and implants. Metal skeletal fixation plates used in reconstructive surgery are currently shaped manually prior to or during surgery. HAMMER numerical forming technology has been demonstrated for simple processes such as numerical bending. The work will progress to increasingly complex fabrication techniques, including additive manufacturing coupled with deformation processing and machining. The target shapes will be derived from CAT scans with surgeon controlled modifications. Looking Towards the Future HAMMER represents an initial 10 year development effort, with options to extend research beyond that initial period. Forgers who are not early adopters of the full Hybrid Autonomous Manufacturing model will benefit from the underlying research and workforce education. Companies who are interested in being in the forefront of this exciting new technology are encouraged to join in this innovation ecosystem. Intellectual property protections are in place for companies who wish to gain early access to emerging technology. More information including membership or joining meetings is available at hammer.osu.edu. ecosystem a reality. Current Status

FIA MAGAZINE | FEBRUARY 2024 61