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Title: A journey of pioneering manufacturing research from macro- to nanoscales: motivation and impact
Speaker: C. Richard Liu, Purdue University
Host: Zhang Xueping, Associate Professor
Time: 10:00 to 12:00 ,Wednesday, Jan 4, 2017
Place: F310, School of Mechanical Engineering

Abstract:  The speaker is considered a pioneer of several subareas of manufacturing research, including: (1) Manufactured surface integrity modeling and enhancement of residual stresses and microstructures, (2) Digital error modeling and enhancement of thermal and kinematic accuracies of machine tools, and (3) Digital CAD/CAM integration and automatic NC code generation. The research generally involves theory, application and implementation, and provides the fundamentals and capabilities of virtual manufacturing/quality planning, simulation, optimization and real physical process control via the Internet. These capabilities appear to have formed a base for a number of the current national manufacturing programs in the US and Germany. His surface integrity research has enabled 10 to 50 times the fatigue life improvement in machined hard surfaces while eliminating a number of additional processes. Thus this research improves the cost and reliability of manufactured load-carrying components and the safety of helicopters, bullet trains, aircrafts and the like. His digital error modeling research has enabled up to 10 times the improvement of the accuracy of components producible by machining, eliminating the need of grinding. His digital CAD/CAM research has resolved several long-standing barriers against CAD/CAM integration. Equally interesting is the fact that these technologies applied together will enable an innovative “single-equipment universal superfinish machining system”. This next generation machining “system” is competitive for the manufacturing of low/mid-volume high-variety precision components requiring high reliability. Currently the speaker is working with several PhD students researching on Laser-based additive and nanomanufacturing of components demanding high reliability, and is teaching a new course on “Structured Engineering Innovation” (among others). The speaker will review the research and teaching, and reflect on the relationship between impact and motivation. 
  
Biography:  Professor C. Richard Liu is recognized for a number of research innovations: (1) SME/NAMRI Wu Research Award, for creating the “single-step finish/superfinish hard machining, leading to a new market and a science base for engineering a new generation of processes, machine tools, cutting tools and manufacturing systems”; (2) ASME Ennor Award, “for his seminal research on surface integrity and fatigue performance of manufactured surfaces”; (3) IR100 Award, for his research leading to significant accuracy enhancement with a new software-based method and related CNC controller standards, capable of sensory feedback adaptive error compensation; and (4) ASME Blackall Award, recognizing his early work on understanding the variables affecting the integrity of a machined surface. His work has influenced U.S. national standards and global manufacturing industry. Currently he is working on laser melt additive manufacturing, a new generic high-rate scalable method of making nanomaterials and a new modeling approach for predicting fatigue initiation life. He developed an innovative process for making high-reliability bearings, which has been applied by several major U.S. bearing suppliers and users. He also served as a research engineer in industry where he developed a high performance automatic washer that has dominated its market for about three decades. He has published over 180 peer-reviewed research papers, and has taught courses on Design, Manufacturing, and Competitive Strategies for Products and Processes.