NSF Workshop on Research Needs in Machining and Machine Tools March 5-6, 2018

1. NSF Workshop on Research Needs in Machining and Machine Tools March 5-6, 2018

3. Thanks! • Thanks to everyone who made the workshop possible • Thanks to everyone involved with the idea • Thanks to NSF for the funding and for the facilities • Thanks to all of you for coming and for sharing your ideas

4. - The purpose of this workshop is to identify fundamental research and development objectives for a resurgent US machine tool and machining industry. - The workshop will bring together key thought leaders from academia, industry, government agencies, trade organizations, and national labs for an intensive two-day meeting to identify and prioritize research needs in machining and machine tools.

5. The objectives of the workshop are to: • review the state-of-the-art in fundamental research in • machining and machine tools • identify priorities, needs, gaps, and challenges facing machine • tool builders and users across a broad range of market • segments • identify key current and key missing resources for machine tool • and machining fundamental research and development • benchmark US machine tool and machining research • investments against those from other nations • formulate recommendations for new initiatives, new policies, • and further actions necessary to create a robust US • machining and machine tool industry.

6. The product of the workshop will be a report. • We’ll share the report with you. • We want your input. • Share presentation • Send an email • Write something down • Use the web form

7. https://coefs.uncc.edu/tschmit4/machining-workshop/

11. Machine Tools and Machining for High Wage Countries

12. “Those jobs aren’t coming back.” – Steve Jobs https://9to5mac.com/2014/08/05/steve-jobs-had-plans-to-make-free-shared-wi-fi-the-norm-to-improve-iphone-experience/ The jobs aren’t coming back like they are, because they were built for low-wage countries. High-wage countries need different strategies to compete.

13. Reaping of Wheat Reaping = Cutting Threshing Threshing = detaching grain from stalks Winnowing Winnowing = separating the grain http://www.mythfolklore.net/3043mythfolklore/reading/denmark/images/flail.htm • By hand with a sickle, a worker can cut about 0.3 acres per day • Using a scythe, the worker can cut about 1.5 acres per day -The breeze blew away the chaff -Best workers hit a few times per minute -The process takes months

14. Combine “Combines” reaping, threshing and winnowing First combine 1838 Early combines were pulled by up to 16 horses GPS, stereo, air conditioning, comfortable seat, pressurized cabin Often farmers contract combining to spread the cost of equipment

15. What do machine tools for high wage countries look like? How does high-wage machining work? • Machines are highly automated • Machines are fully used • Machines are not idle • Machines are more capable • Workers are knowledge workers

16. Highly automated: • Many more machines than shop floor workers (but lots more workers than machines) • Workers are supervisory rather than operational • Sensors everywhere – self diagnosis, prediction • Connected • Data is aggregated and visual – easy to see what is going on • Analysis is automated and interactive • Guided maintenance

17. Fully used: • Machines aren’t making money when they are not cutting • Parts match machines, machines work near capacity • Performance data are well-known • Programmers know what machines can do • Programming with the specific machine in mind • No try-out • No scrap • Planned maintenance

18. Not idle: • Machines are not starved for parts • Machines don’t wait for set-ups, tools, material, programs • Production optimization • Contracting optimization

19. More capable: • Higher speed • Higher power • Higher precision • Larger, smaller work volumes • Short metrology and verification loops • Better environments

20. What about the workers? • Much more than load the parts and push the button • Make sense of complicated data • Insights into the process • Awareness of the system • Knowledge workers • Education more important than training

21. Summary from Day 1: 1. There is consensus that machining and machine tools is valued across a broad range of sectors: national security, energy, automotive, aerospace, and economic health. 2. Self-aware machining (machine tool to enterprise) is an enabling technology for next-generation manufacturing. An aspect of self-aware machining is the digital twin. The digital twin takes the form of a process twin in machining. This includes G-code, sensor data, machine characteristics, inspection data, etc. 3. Economic pressure on the machining and machine tool industry handicaps its ability to be forward thinking (beyond 1-2 years) and therefore constrains R&D funding. A related issue is that the role of system integrator tends to limit R&D efforts as well. The outcome is that it is difficult to transition basic research, even if funded by another source, into the industry.

22. Summary from Day 1: 1. Two fundamental questions were posed by Tracy Frost. a. How do we fix it? b. What are the needs right now? Our job is to describe what will define success. We need to move beyond addressing needs to generating a vision for the future of this industry. Is a road mapping activity required? Do we have this vision?