Speaker: Helmi Attia
Title: Recent Advances in Drilling Hybrid Composite-Metal Stacks
Date/Time: 06 January 2021/ 17:00 - 18:00
Zoom: Meeting ID: - https://sabanciuniv.zoom.us/webinar/register/WN_lu_AXNV3TySiq3hULgEsHQ
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Abstract:This seminar is addressing the recent advances in drilling hybrid composite-metal stacks, for aerospace applications. The unique features of vibration-assisted drilling and orbital drilling using conventional and superabrasive are presented, in terms of part quality attributes. A new cyber-physical adaptive control system (CPACS), which was recently developed at the National Research Council Canada and McGill University, Canada, is presented. A generalized approach for features recognition, and learning, of spindle power signals was developed for real-time detection of tool wear level. Subsequently, a high fidelity model predicts the drilling forces and the damage at the layers and interfaces of the stacked panel. The CPACS uses these predictions to maximize the feedrate while maintaining the damage-free force limit at each layer. The system communicates with the CNC machine controller to continuously update the drilling conditions. The following unique capabilities of the CPACS are discussed: (a) the accurate real-time tool wear detection using feature recognition of spindle power signals from nonintrusive sensors, and requiring reduced system learning and in-process learning, and (2) the accurate model predictions of force distribution along the cutting tool lip, through the stack layers for different cutting conditions and tool wear levels. Such key features enabled feed optimization based on the delamination damage prediction criterion. The experimental testing of the developed CPAC system showed up to 50% and 34% of combined reduction in the total cycle time and process cost, respectively, as well as doubling the tool life and eliminating the damage risk associated with conventional strategies.
Bio: Helmi Attia is a Principal Research Officer, and former Manager of Advanced Material Removal Processes, Aerospace Manufacturing Technology Centre (AMTC), of the National Research Council Canada (NRC). Before joining the NRC, he was a Principal Research Engineer at Ontario Hydro Research Division (1980-2002), responsible of establishing and managing the fretting wear/fatigue research program and laboratory. In his capacity as manager of Fabrication Technology at Spar Aerospace Technology Ltd. (1979-80), Helmi contributed to the manufacturing of the Canadian Satellite Subsystems ANIK-C, ANIK-D, and SATCOM. Helmi is an Adjunct Professor of Mechanical Engineering at McGill University, Canada, and Adjunct Professor of Industrial and Materials Science at Chalmers University of Technology, (Sweden). He held also Adjunct Professorship with Concordia University (1981-1990) and McMaster University (1991-2002). He is professional engineer of Ontario since 1980. He is Fellow of Society of Manufacturing Engineers (SME), Fellow of the College International pour la Recherche en Productique (CIRP), Fellow of the American Society of Mechanical Engineers (ASME), and Fellow of the International Association of Advanced Materials (IAAM). Helmi Attia is the recipient of ‘Queen Elizabeth II Diamond Jubilee Medal’ (2013), awarded to honor significant contributions and achievements by Canadians. He was awarded and the prestigious ‘ASME Blackall Machine Tools and Gage Award, (1989). He received numerous recognitions from ASME and ASTM (American Society for Testing and Materials) for being the principal organizer and editor of symposia related to manufacturing and tribology. Helmi is on the editorial board of a number of international journals, including the International Journal of Machine Tools & Manufacture, the International Journal of Sustainable Manufacturing, the International Journal of Machining Science & Technology, and the International Journal of Computational Material Science and Surface Engineering. He was also an Associate Editor of the ASME Transactions, Journal of Engineering for Industry (Metal cutting), 1990-1996. Helmi Attia is recognized by his peers in the areas of machining, thermal deformation of machine tools and fretting wear/fatigue. To his credit, he authored/coauthored some 250 papers in archival journals and refereed conference proceedings, and some 125 technical research reports. He was also the principal editor of 6 ASME and ASTM books and bound volumes.