Nearly 1,000 students and adults across America are taking advantage of America’s Cutting Edge (ACE) computer numerical control (CNC) machining training launched, in part, by IACMI, in December. The new initiative uses online learning and machining simulation, as well as in-person machine time, to teach essential manufacturing skills to help tackle the nation’s growing manufacturing workforce gap.
Fiber composites have unique challenges for operations such as drilling and milling, according to IACMI Chief Technology Officer Uday Vaidya, who also serves as University of Tennessee-Oak Ridge National Laboratory Governor’s Chair for Advanced Composite Manufacturing.
In an interview, Uday discusses these challenges and other aspects of composites machining.
A national initiative to restore the prominence of the U.S. machine tools sector through advances in training and technology, ACE is supported by the Department of Defense DOD Industrial Base Analysis and Sustainment Program from the Office of Industrial Policy. DOD is utilizing the scientific expertise of the Department of Energy’s Oak Ridge National Laboratory and the workforce development leadership of IACMI. IACMI is partnering with The University of Tennessee (UT) and Pellissippi State Community College (PSCC) in Knoxville to pilot the new machine tool training framework.
Q: Tell us about the training program? Why is it needed?
Vaidya: A 2018 study by Deloitte and the Manufacturing Institute predicted that by 2028 there would be 2.4 million unfilled jobs in the manufacturing industry due to such factors as shifting skill sets, the introduction of advanced technologies and an aging workforce. So, we have a workforce gap in the U.S. when it comes to machine tool resources, especially as it applies to computer-aided manufacturing (CAM). New machine tool software is needed to enable the creativity, optimization, and efficiency potential of digital manufacturing. To effectively produce tomorrow’s creator-makers, we must increase awareness of manufacturing and instill a passion for creativity and making.
In short, the ACE CNC machining training program has two components: 1) a widely accessible online portion created by University of Tennessee, Knoxville Engineering Professor Dr. Tony Schmitz that incorporates computer-aided manufacturing (CAM) software and CNC machining simulation, similar in function to a flight simulator. This curriculum lets participants work at their own pace on their own laptops using a series of video training modules, lessons and quizzes. 2) After participants complete the online component, a small group will be selected to join hands-on training sessions this summer in a CNC machining lab in Knoxville at Pellissippi State Community College.
Q: Who will benefit from this CNC machining training?
Vaidya: By raising awareness of machining capabilities and how they couple directly to part design and full supply chain execution or part production, this training program will help identify and train the next generation machine tool workforce for both incumbent workers and those entering the manufacturing workforce for the first time as creator-makers to address critical needs in machining of composites, metals, and optical materials. Also, benefitting will be component and system designers, next-generation machine tool designers, engineers, project managers, process planners and entrepreneurs.
Q: What type of challenges do fiber composites present for operations such as drilling and milling operations?
Vaidya: Fiber composites have unique challenges for operations such as drilling and milling. Carbon fiber composites react differently to traditional machining tools. For example, metals machine readily by chip formation, composites pose challenges such as tool dependency on fiber orientation & architecture, high degree of abrasion, multiple layers, resin types and sensitivity to cutting fluids to name a few. The cutting tools for composites are different from traditional tools in terms of the tool materials, specifications, and lifetimes.
In this program, we are developing a systematic way to introduce participants to these machine tools and relationships for composite materials processing and machining. This training supports ACE CNC machining development, learning trials, assessment, and preparation for a national scale-up.
Q: What aspects of composites machining are you focusing on?
Vaidya: We will focus on various aspects of composites machining in relation to design software interface. The composites machine tools and composites machining falls into two categories: (a) composite tools/molds; (b) composite parts machining with custom tools (drills, cutting blades etc.). Both continuous and discontinuous fiber composites & thermoset-thermoplastic composites have unique challenges in terms of fiber attrition, burring, edge debonding, surface blooming for operations such as drilling, milling, planning, surface textures and joints. The design software will be used to generate composite friendly geometries and tool path optimization trials. The work will include both experimental and modeling in an interactive manner with case studies included.
Q: Can this pilot program being expanded?
Vaidya: This program will help us to develop a systematic understanding for machine tools and relationships for composite materials. The training gained from program will be widely disseminated consistent with other aspects of the program. ACE’s software augmentation and training will create a program that can be expanded to industry and regional partners throughout the U.S.