Proceedings of the ASME

International Mechanical Engineering

Congress and Exposition

- 2011 -

VOLUME 3

Design and Manufacturing

presented at

ASME 2011 INTERNATIONAL MECHANICAL ENGINEERING CONGRESS AND EXPOSITION

NOVEMBER 11-17, 201 1

DENVER, COLORADO, USA

ASME

Three Park Avenue * NewYork, N. Y. 10016

CONTENTS

DESIGN AND MANUFACTURING

ADVANCES IN MATERIAL FORMING, APPLICATIONS, TOOLING AND

RAPID PROTOTYPING

IMECE2011-62321 1

Simulation of Residual Stress in Lens Deposited H13 Tool Steel on Copper Substrate

Tushar K. Talukdar, Liang Wang, and Sergio D. Felicelli

IMECE2011-62372 11

Modeling and Simulation of Mecano-Welding Process for Tubular Sections

Zhengkun Feng and Henri Champliaud

IMECE2011-62445 15

Microstructure and Mechanical Properties of Electron Beam Deposits of AISI 316L

Stainless Steel

Liang Wang, Sergio D. Felicelli, Jacob Coleman, Rene Johnson, Karen M. B. Taminger,and Ratessiea L. Lett

IMECE2011-62668 23

Die Wear and Coating Galling in Stamping Advanced High Strength Steels

Hua-Chu Shin and Ming F. Shi

IMECE2011-63226 31

Optimal Central Composite Design for Manufacturing Simulation of 0.50 Caliber Projectile

Raghu Echempati, Bernadetta Kwintiana Ane, Mark E. Krueger, and Dieter Roller

IMECE2011-63701 41

Thermal Imaging of Laser Powder Deposition for Process DiagnosticsJoshua J. Hammell, Christopher J. Ludvigson, Michael A. Langerman, and

James W. Sears

CAD/CAM AND CAE SIMULATIONS, ALGORITHMS, TECHNOLOGIES AND

APLICATIONS

IMECE2011-62024 49

Path Planning for Functionally Graded Materials in Hollow Tissue Scaffold PrintingIbrahim T. Ozbolat

IMECE2011-62434 55

The Influence of the Roller Forming Path on the Neck-Spinning Process of Tube at

Elevated TemperatureChi-Chen Huang, Jung-Chung Hung, Cheng-Chan Lo, Chia-Rung Lin, and

Chinghua Hung

IMECE2011-62805 63

Minimizing Geometric Variation in Multistage Assembly Lines by Geometrical DecouplingPeter Edholm, Lars Lindkvist, and Rikard Soderberg

vii

IMECE2011-62905 73

Finite Element Modeling and Analysis of Structural Joints Using Nuts and Bolts

Prasannakumar S. Bhonge, Brian D. Foster, and Hamid M. Lankarani

IMECE2011-63388 85

A Semi-Computational Method to Predict Body Temperatures in an Automotive

Paint Bake Oven

Preetham Rao and Sreekanth Teeparthi

IMECE2011-63409 97

Artificial Neural Networks for Predicting the Performance of Novice CAD Users Based on

Their Profiled Technical Attributes

R. F. Hamade, A. H. Ammouri, and H. A. Artail

IMECE2011-63739 105

Reducing the Size of NURBs Controls Nets Using Genetic Algorithms and CUDA

Matthew J. O'Neal and Cameron J. Turner

IMECE2011-63902 113

Design and Analysis of a Car-Truck Stand

John Clark and Raghu Echempati

IMECE2011-64471 121

Non-Linear Analysis of Energy Absorption Systems Under Impact Loads Through FEM

E. R. Ledesma-Orozco, J. A. Diosdado-De la Pena, G. I. Perez-Soto, A. Salazar-Garibay,J. F, Reveles-Arredondo, G. Villalobos-Llamas, and P. Duran-Resendiz

IMECE2011-64511 129

Finite Element Analysis of the ESTELA M1 Airplane Firewall (Representative Specimen)V. Ramirez-Elias, E. Ledesma-Orozco, and H. Hernandez-Moreno

IMECE2011-65074 137

Automatic Optimization of Casting Feeders Using Feed-Paths Generated by VEM

M. Sutaria, D. Joshi, M. Jagdishwar, and B. Ravi

IMECE2011-65848 147

A New Method to Analyze Three-Dimensional Non-Repetitive Run-Out (3D-NRR0) of

Angular Contact Ball BearingsZhaohui Yang, Jun Hong, Jinhua Zhang, Micheal Yu Wang, and Baotong Li

DESIGN AND MANUFACTURING OF COMPOSITES, MAINTENANCE

CONSIDERATIONS AND RECYCLING

IMECE2011-62170 157

Sandwich Structures With Smart Composite Face Skin

Hari Prasad Konka, M. A. Wahab, and Kun Lian

IMECE2011-62498 167

Sustainability of Fiber Reinforced Composites: Status and Vision for Future

Devi K. Kalla, P. S. Dhanasekaran, Bangwei Zhang, and Ramazan Asmatulu

viii

IMECE2011-62754

Evaluation of Advanced Composites Using Destructive Testing TechniquesR. Asmatulu and V. Movva

175

IMECE2011-62821 183

An Investigation on the Mechanical Property of Unidirectional Basalt Fiber CompositesTohru Hayakawa, Zhiyuan Zhang, Yuqiu Yang, and Hiroyuki Hamada

IMECE2011-62823 189

Effect of Hot Water Immersion on the Mechanical Properties of Jute and Jute HybridReinforced Composites

Ying Yu, Shiitiro Kawabata, Yuqiu Yang, and Hiroyuki Hamada

IMECE2011-64043 197

Optimizing the Mechanical Properties of Wood Plastic Composites Using Fiber-Glass

Mahdi Ashrafi, Masoud Olia, Ashkan Vaziri, and Hamid Nayeb-Hashemi

IMECE2011-64498 203

Rheological Study on Multiple Fiber Suspensions for Fiber Reinforced CompositeMaterials Processing

Dongdong Zhang, Douglas E. Smith, David A. Jack, and Stephen Montgomery-Smith

IMECE2011-64802 213

Design and Analysis of a Smart Composite WingZeaid Hasan, Hamzeh Hammoudeh, and Ghassan Atmeh

IMECE2011-64964 223

Bending and Impact Properties of Biaxial Weft Knitted Composites0. Demircan, A. R. Torun, T. Kosui, A, Nakai, and H. Hamada

IMECE2011-65285 233

Properties of Composite Cylinders Fabricated by Bladder Assisted CompositeManufacturing (BACM)Jacob P. Anderson and M. Cengiz Altan

ENERGY EQUIPMENT AND SYSTEMS: DESIGN AND MANUFACTURING

ISSUES, TRUST, RELIABILITY AND SAFETY

IMECE2011-62128 241

System Level Design and Simulation of PV/Diesel/Battery Hybrid Power Systems for

Portable Classrooms

AtifM. Aliuddin, AbdulAziz S. Alhamoud, and Samir Mekid

IMECE2011-62965 249

Evaluating the Technical, Economic, and Environmental Impact of the Level of

Decentralization in Energy Investment Decisions

Yiwen Liu, Bryant D. Hawthorne, and Jitesh H. Panchal

IMECE2011-63906 259

Energy Harvesting From Vertical Deflection of Railroad Track Using a Hydraulic System for

Improving Railroad Track SafetyCarl A. Nelson, Abolfazl Pourghodrat, and Mahmood Fateh

ix

IMECE2011-64149 267

Towards a System Analysis and Integration Framework for Early Design Trades in

Sustainable Building DesignJoseph Piacenza, Irem Y. Turner, Robert B. Stone, Jeffrey Knighton, and lhab Elzeyadi

IMECE2011-64172 279

Ultrasonic Vibration-Assisted Pelleting in Manufacturing of Cellulosic Biofuels:

An Investigation on Biomass Particle Size

Pengfei Zhang, Qi Zhang, Z. J. Pel, and Linda Pei

IMECE2011-64304 287

Effects of Treatments on Cellulosic Biomass Structure in Ethanol Manufacturing:A Literature Review

Qi Zhang, Pengfei Zhang, Z. J. Pei, and Linda Pei

IMECE2011-64307 295

Ultrasonic-Vibration Assisted Pelleting for Cellulosic Ethanol Manufacturing:An Experimental Investigation of Power Consumption

Qi Zhang, Pengfei Zhang, Z. J. Pei, Jonathan Wilson, Leland McKinney, and

Graham Pritchett

!M ECE2011-65814 305

Design, Manufacturing and Testing of a Camera-Like Aperture Mechanism

for a Solar Reactor

Shameel Abdulla, Hussein Zahreddine, Mahmoud El-Zamli, Feras Abdul Majid, lhab Rizk,Yasser Al-Hamidi, and Nesrin Ozalp

GENERAL TOPICS IN DESIGN AND MANUFACTURING

IMECE2011-62721 321

An Experimental Investigation on Cellulosic Biofuel Manufacturing: Effects of Biomass

Particle Size on Sugar Yield

Pengfei Zhang, Qi Zhang, Z. J. Pei, and Linda Pei

IMECE2011-63757 327

Effects of Joint Preparation Angle of Single-Vee Butt Welds on the Tensile Strength of

ASTM A36 Carbon Steel

Matthew R. McClure, A. Mehran Shahhosseini, Todd Alberts, and Phillip Cochrane

IMECE2011-65208 341

The Effect of Cryogenic Cooling on White Layer Formation in Hard MachiningD. Umbrello, S. Caruso, S. Yang, F. Crea, 0. W. Dillon, Jr., and I. S. Jawahir

HIGH SPEED MACHINING MODELS, REGENERATIVE CHATTER,ANAMALIES AND MEASUREMENTS

IMECE2011-62826 349

Impact-Cutting and Regenerative Chatter in Robotic GrindingBruce Hazel, Farzad Rafieian, and Zhaoheng Liu

x

IMECE2011-63364 361

Comparison Between Feed-Forward Back-Propagation and Radial Basis Functions Networks

for Roughness Modeling in Face-Milling of Aluminum

Carlos Perez and Juan De Dios Calderon

IMECE2011-63918 373

Modeling of Serrated Chip Formation With a Fracture Locus ApproachYalla Abushawashi, Xinran Xiao, and V. P. Astakhov

INNOVATIONS IN PROCESSING, CHARACTERIZATION AND

APPLICATIONS OFBIOENGINERED MATERIALS

IMECE2011-62216 385

Buckling Behavior of Glass-Fiber Reinforced Polyester Pultruded Columns

Malur N. Srinivasan and Vanchak Chayakul

IMECE2011-62756 391

Surface Free Energy Change of UV Exposed Composites and Coatings via

Acid-Base Interactions

ft Asmatulu and M. Ghaddar

IMECE2011-64155 397

Design and Utility of Specialist Comminution Set-Up for Plastics and Organic Materials

Marek Macko, Adam Mrozinski, and Jozef Flizikowski

IMECE2011-64719 403

Novel Application of Optical Density Technique to Evaluation of Corrosion Behavior of

Metallic Thin Films

Ruben Kotoka, Sergey Yarmolenko, Devdas Pai, and Jag Sankar

JOINING TECHNOLOGIES FOR ADVANCED MATERIALS IN

SYSTEMS AND STRUCTURES

IMECE2011-62779 409

Rotation of Material Axes Effects on Free Bending Vibrations Response of CompositeMindlin Base Plates or Panels Stiffened by Three Bonded Plate Strips

U. Yuceoglu, J. Javanshir, T. Farsadi, and 0. Guvendik

IMECE2011-62972 431

Investigation of Interaction of Laser Generated Lamb Waves With Structures of Interest

Lei Yang and I. Charles Ume

IMECE2011-62984 441

FEM Stress Analysis and Strength Prediction of Stepped-Lap Adhesive Joints of Similar

Hollow Cylinders Under Static Tensile LoadingsKazunari Kotajima, Yasuhisa Sekiguchi, Takashi Kobayashi, Yuta Ueda, and

Toshiyuki Sawa

xi

IMECE2011-63038 449

Two-Dimensional FEM Stress Analysis of Adhesive Butt Joints Filled With Nano-Compositein Adhesive Subjected to Static Tensile Loading

Toshiyuki Sawa, Shougo Tanabe, Takashi Kobayashi, Kazunari Kotajima, and

Yasuhisa Sekiguchi

IMECE2011-63307 457

Cathodic Disbondment of Rubber/Steel Adhesive Bonds Modeled as Liquid-Solid Reactions

AHA. Tarhini and Ramsey F. Hamade

IMECE2011-63570 465

Fasteners at Low Temperatures: Characterization and Methods for DesignMelanie Stephan, Jens 0. Weber, Ulrich Wuttke, and Christina Berger

IMECE2011-63774 475

Standardized Calculation of Bolted Joints for Future RequirementsC. Friedrich, H. Hubbertz, and G. Dinger

IMECE2011-64613 481

Scatter of Bolt Preloads in Pipe Flange Connection Tightened by Impact Wrench and the

Effect on Sealing Performance

Koji Kondo, Takashi Kobayashi, Yuya Omiya, and Toshiyuki Sawa

1MECE2011-65102 491

A Generalized Method for Weld Load Balancing in Multi Station Sheet Metal

Assembly Lines

Johan Segeborn, Daniel Segerdahl, Fredrik Ekstedt, Johan S. Carlson, Anders Carlsson,

and Rikard Soderberg

IMECE2011-65432 501

Analytical, FEA and Experimental Methods for Computing the Resilience of TappedThread Joints

YosefAmir, John Reif, and Nicholas Konkle

IMECE2011-65548 511

Bolted Joints-Stochastic ModelingYosefAmir

IMECE2011-65693 523

Texture Modification and Ductility Enhancement in Mg Alloy Through Friction

Stir ProcessingZhenzhen Yu, Zhili Feng, Hahn Choo, and Sven Vogel

LIGHTWEIGHT DESIGN AND MANUFACTURING OF AEROSPACE AND

TRANSPORTATION APPLICATIONS

IMECE2011-63545 529

Application of Finite Strip Method in Vehicle Design: Part 1 of 2 — Linear Buckling Analysisof Thin Walled Structures

Umesh Gandhi, Stephane Roussel, K, Furusu, and T. Nakagawa

xii

IMECE2011-63553 533

Application of Finite Strip Method in Vehicle Design: Part 2 of 2 — Post Buckling Analysis of

Thin Walled Structures

Umesh Gandhi, Stephane Roussel, K. Furusu, and Toshiaki Nakagawa

IMECE2011-63571 539

Clamp Load Retention of Bolted Joints Under Alternating and Superposed Thermal Stress

Markus Duchardt, Christina Berger, and Ulrich Wuttke

IMECE2011-64059 547

Size Reduction of Cellulosic Biomass in Biofuel Manufacturing: Effects of Biomass

Crystallinity and Particle Size

Meng Zhang, Xiaoxu Song, P. F. Zhang, Z. J. Pei, and T. Deines

MACHINES AND SYSTEMS: THEIR DESIGN AND

SERVICE MANUFACTURING

IMECE2011-62200 555

Analysis and Optimization of Rotor Housing Assembly

Yang Wang, Yulian Kin, Krasimir Zahariev, and Brian Smith

IMECE2011-62480 565

Metamodel-Assisted Ice Detection for Wind Turbine Blades

Veruska Malave and Cameron J. Turner

IMECE2011-62628 573

An Industrial Robot System for Pocket Machining of Large Size Engine Cylinder Covers

T. Y. Noh and C. W. Jung

IMECE2011-62691 579

Human Powered Press for Raw Earth Blocks

C. Ferraresi, W. Franco, and G. Quaglia

IMECE2011-62753 589

Design of an Air Pressure-Assisted Centrifugal Dewatering Method for Fine Particle

Suspensionsft Asmatulu

IMECE2011-63310 595

Feasibility Study of Using Simultaneous Motion of Two Rotary Axes to Evaluate MachiningCenter: Simulation

K. M. Muditha Dassanayake, Masaomi Tsutsumi, and Ohta Katsunori

IMECE2011-63506 603

Minimum Constraint Design Analysis and Modification of a Biaxial Tensile Test Fixture for

Hyperelastic Materials

Lowell Smoger, Mario Gomes, and Elizabeth DeBartolo

IMECE2011-63546 611

Semantic Analysis of Function-Solution DualityFrangois Christophe, Tuomas Ritola, Eric Coatanea, and Alain Bernard

xiii

IMECE2011-63922 621

Dynamic Balancing Analysis of the Armature in an Automobile Starting Motor:

An Industrial Case Study

Hugo I. Medellfn Castillo and Edgar A. Mendoza Lopez

IMECE2011-64220 629

Opto-Mechanical Methodology for Feature Detection of Contours

Devdas Shetty, Claudio Campana, Robert Dinan, Anil Gurimitkala, Nikolay Nazaryan,and Saeid Moslehpour

IMECE2011-64424 639

Development and Modeling of Water Driven StageYohichi Nakao, Toshiaki Sano, Midori Nagashima, and Kenji Suzuki

IMECE2011-64594 645

Assembly Guidelines for High Performance Meso-Flexure Linkage Mechanisms

Prasanna Gandhi, Vaibhav Soni, Kaustubh Sonawale, and Naved Patanwala

IMECE2011-64652 655

Observation of Surface Structure of Kyo-Kawara (Ceramic Material for Roof Component)Fabricated by Traditional Skillful Technique

Masahisa Asada, Masaki Sakata, Takeshi Shiono, Yuka Takai, Akihiko Goto, and

Hiroyuki Hamada

IMECE2011-64965 661

Design and Analysis of a Novel Radial Mud Pump Directly Driven by Permanent MagnetDisc Synchronous Motor

J. T. Liang, S. D. Zhao, and Y. H. Hu

IMECE2011-65302 667

Development and Validation of a Mathematical Model of Microfilm Formation in

Atomization Cooling of Micromachining

Kyle J. Boughner, John E. Wentz, and Benton J. Garske

MACHINING OF NEW MATERIALS

IMECE2011-63051 677

Viscoelastic Abrasive WaterjetNariman Ashrafi

IMECE2011-63748 683

Size Reduction of Poplar Wood Using a Lathe for Biofuel Manufacturing:A Preliminary ExperimentXiaoxu Song, Meng Zhang, Z. J. Pel, T. Deines, D. H. Wang, Q. Zhang, and P. F. Zhang

IMECE2011-63781 691

An Assessment, Definition, and Determination of the Minimum Uncut Chip Thickness of

Microcutting and Impact on Machining New Powder Metallurgy Nickel-Based SuperalloysZ. Y. Shi, Z. Q. Liu, and Y. B. Guo

xiv

MANUFACTURING AUTOMATION, PACKAGING, MATERIAL

HANDLING AND IDENTIFICATION

IMECE2011-62477 701

Simulation and Interoperability in the Planning Phase of Production Processes

Daniel Schilberg, Tobias Meisen, RudolfReinhard, and Sabina Jeschke

IMECE2011-64214 707

Smart Fasteners and Their Application in Flanged Joints

Babak Eslami, Randy Ganye, Chris Bunai, and Chandrasekhar Thamire

MECHANICAL PROPERTY CHARACTERIZATION AND MODELING OF

NOVEL MATERIALS AT DIFFERENT SIZE-SCALES

IMECE2011-63323 715

Experimental Study on Biaxial Ratcheting of SS316LN Steel Pipes Used in Fast Breeder

Reactor Structures

S. Athmanathan, Bharath Kumar Dandu, Rao C. Lakshmana, Santhana Krishnan,R. Suresh Kumar, and Chella Pandi

IMECE2011-63429 719

Electromechanical Characterization of Polyvinylidene Flouride (PVDF) Films in

Biaxial Extension

Sandhya Mohan and Rao C. Lakshmana

IMECE2011-63445 725

Estimation of Creep-Fatigue Damage Through Indentation Test Method

Raghu V. Prakash

IMECE2011-63541 731

Unit Cell Approach as a Multi Scale Modeling Technique for Predicting the Behaviour of

Fiber Reinforced High Strength Concrete Under CompressionSunir Hassan, Rao C. Lakshmana, and Babu K. Ganesh

IMECE2011-63810 737

Fiber Pull-Out Strength of Single-Walled Carbon Nanotube Reinforced Polypropylene (PP)

Composite Using Molecular Dynamics Simulation

A. Mandal, S. P. Singh, and R. Prasad

IMECE2011-64664 745

Spherical Indentation of Nickel Thin Film on Steel-4340 Substrate

Raghu V. Prakash, S. Arunkumar, and Ajith Ramesh

NATURAL REINFORCEMENTS AND PROCESSES TO PRODUCE

ENVIRONMENTALLY POLYMERIC COMPOSITES

IMECE2011-62409 751

Tensile and Bending Properties of Jute Fiber Mat Reinforced Unsaturated PolyesterMatrix Composites

E. A. Elbadry, M. S. Aly-Hassan, and H. Hamada

xv

IMECE2011-62819 761

Mechanical Properties of Jute/PLA Injection Molded Products-All Natural CompositesMasuo Murakami, Yuqiu Yang, and Hiroyuki Hamada

PHARMACEUTICAL, TISSUE AND MEDICAL EQUIPMENT

MANUFACTURING AND REGULATIONS

IMECE2011-62457 767

Reciprocating Bone Saw. Effect of Blade Speed on Cutting Rate

Timothy B. Lannin, Matthew P. Kelly, and Thomas P. James

IMECE2011-63593 773

Simulations and Measurements of Water Vapor Flow and Ice Dynamics in a

Freeze-Dryer Condenser

Arnab Ganguly, Alina Alexeenko, and Frank DeMarco

IMECE2011-65148 783

Linear Sawing Apparatus and its Evaluation for Research Into High Speed Bone SawingJohn J. Pearlman, Anil Saigal, and Thomas P. James

SIX SIGMA, DESIGN FOR SIX SIGMA, UNCERTAINTY, PROBABILITY AND

OPTIMIZATION IN MANUFACTURING

IMECE2011-62130 793

Gage Repeatability and Reproducibility Investigations of a Test Rig UsingANOVA/Xbar-R Method

Berna Balta, Fazil Onder Sonmez, and Abdiilkadir Cengiz

IMECE2011-63813 801

Process Improvement of Brake Lever Production Using DMAIC (+)

Chittaranjan Sahay, Suhash Ghosh, and Pradeep Kumar Bheemarthi

IMECE2011-65541 827

Comparison of Meta-Modeling Approaches for OptimizationSrikanth Devanathan and Patrick N. Koch

SUSTAINABLE MANUFACTURING ENGINEERING DESIGN-STRUCTURE,ANALYSIS AND PRACTICES

IMECE2011-62327 837

Knowledge Based Methodology Supporting Interoperability Increase in

Manufacture Domain

Joao P. Mendonga da Silva, Francisco Cavaco, Joao Sarraipa, and Ricardo Jardim-GoncalvesllD

IMECE2011-62605 845

A Methodology for Identifying Factors That Contribute to the Sustainability of BioinspiredEngineered Systems

Julia M. O'Rourke and Carolyn C. Seepersad

xvi

IMECE2011-64356 859

Life-Cycle Assessment of Electric Rice Cooker: A Case StudyZhenghui Sha and Gaurav Ameta

IMECE2011-64706 867

Current Rise Index (CRI) Maps of Machine Tool Motors for Tool-Wear PrognosticFt. F. Hamade and A. H. Ammouri

IMECE2011-65437 873

Cradle-to-Gate Life Cycle Analysis Comparison of Stamped Aluminum and Injection

Molded Polypropylene Vertical Axis Wind Turbine Blades

Senta Riley, John E. Wentz, and John Angeli

TRADITIONAL AND NON-TRADITIONAL MACHINING PROCESSES

IMECE2011-63240 881

Analysis of Ultrasonic Machining Using Monte Carlo Simulation

Chittaranjan Sahay, Suhash Ghosh, and Han Kiran Kammila

IMECE2011-63379 891

Parametric Influence and Optimization of Wire EDM on Oil Hardened Non Shrinking Steel

Nixon Kuruvila and H, V. Ftavindra

IMECE2011-63824 901

Milling Burr Size Estimation Using Acoustic Emission and Cutting Forces

Seyed Ali Niknam, Azziz Tiabi, Imed Zaghbani, Rene Kamguem, and Victor Songmene

IMECE2011-63850 911

HEM as an Environmental Friendly Alternative to Produce UFC

J. C. Arteaga-Arcos, J. Trujillo-Reyes, D. J. Delgado-Hernandez, A. Santamaria-Ortega,0. A. Chimal-Valencia, and H. T. Yee-Madeira

IMECE2011-64210 915

Optimization Device for Grinding Media Performance Parameters

Andrew M. Phan, Michael P. Summers, and John P. Parmigiani

IMECE2011-64817 925

Springback Evaluation of Parts Made by Single-Point Incremental Sheet FormingPaolo Bosetti and Stefania Bruschi

Author Index 933

xvii