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Advanced Manufacturing and Surface Engineering Laboratory

About

The Advanced Manufacturing and Surface Engineering research program (AMSE) at the University of Kentucky is primarily concerned with the development and modeling of advanced manufacturing processes, particularly machining and finishing operations. The overarching goal of the AMSE Lab is the development of industrially-viable, real-time processes models and tools that will enable the sustainable development of new products and improve US manufacturing competitiveness, as well as national security.

Through in-situ experimental observation using digital image correlation in ultra-high speed (~1 million frames/second) microscopy, the AMSE Lab is building computationally-efficient predictive, physics-based/machine-learning hybrid models. Such models can accurately capture the complex behaviors that characterize finishing operations, while enabling real-time industrial deployment. It is envisioned that through faster and more predictive process modeling, highly scalable manufacturing processes such as machining, polishing and grinding can be used to induce engineered surface and sub-surface properties, such as compressive residual stress profiles and micro/nano-textured surfaces.

Current research thrust of the AMSE Lab include:

  • In-situ characterization of machining and finishing processes
  • Computationally-efficient modeling of advanced manufacturing processes
  • Physics-based/Machine-learning hybrid modeling
  • Real-time quality (surface integrity) monitoring and control for machining and finishing
  • Development of advanced cutting edge microgeometries
  • Development of sustainable cooling/lubricating strategies
  • Development of novel machining strategies

For more information on AMSE research, please contact Julius Schoop.

Selected federally-funded projects

Project Title: Surface Integrity Characterization of Machined AF9628 Samples
Sponsoring Agency: Air Force Research Laboratory (AFRL) ManTech Program, RXMS
Prime Contractor: UTC (Universal Technology Company)
Project Duration: 5/2019-11/2019

Project Title: Inconel 718 SLAM Sample Characterization
Sponsoring Agency: Air Force Research Laboratory (AFRL) ManTech Program, RXMS
Prime Contractor: UTC (Universal Technology Company)
Project Duration: 2/2020-10/2020

Project Title: AI-Enabled Discovery and Physics-Based Optimization of Energy-Efficient Processing Strategies for Advanced Turbine Alloys
Sponsoring Agency: Department of Energy (DoE), Advanced Manufacturing Office (AMO)
Sub-awardee: GE Research
Project Duration: 5/2020-5/2022

Project Title: Robust Aerosol Additive Manufacturing for Advanced Next Generation Electronics
Sponsoring Agency: Army Research Laboratory (ARL)
Project Duration: 5/2021-5/2026

Project Title: STTR AF21A-TCS02 Phase I Sub-award 
Sponsoring Agency: Air Force Research Laboratory (AFRL)
Prime Recipient: Hill Engineering LLC 
Project Duration: 8/2021-6/2022

Project Title: CAREER: Thermomechanical Response and Fatigue Performance of Surface Layers Engineered by Finish Machining: In-situ Characterization and Digital Process Twin
Sponsoring Agency: National Science Foundation (NSF)
Project Duration: 5/2022-5/2027

Project Title: STTR AF21A-TCS02 Phase II Sub-award 
Sponsoring Agency: Air Force Research Laboratory (AFRL)
Prime Recipient: Hill Engineering LLC 
Project Duration: 6/2023-6/2025

Publications

Journal Papers

  • D. Adeniji, J. Schoop, S. Gunawardena, C. Hanson, and M. Jahan “Characterization and Modeling of Surface Roughness and Burr Formation in Slot Milling of Polycarbonate” Journal of Manufacturing and Materials Processing [Q2, IF = 2.573], 4, 2, (2020), pp. 59-81, doi: https://doi.org/10.3390/jmmp4020059
  • A. Uysal, J. R. Caudill, J. Schoop, and I.S. Jawahir “Minimizing carbon emissions and machining costs with improved human health in sustainable machining of austenitic stainless steel through multi-objective optimization” Invited Submission to Special Issue in the International Journal of Sustainable Manufacturing [Q4, IF = 0.200], 4, 2-4, (2020), pp. 281-299, doi: https://doi.org/10.1504/IJSM.2020.107154 
  • I.S. Jawahir, J. Schoop, Y. Kaynak, T. Lu, A.K. Balaji, and R. Ghosh “Progress Towards Modeling and Optimization of Sustainable Machining Processes” AMSE Keynote for 100th Anniversary Issue, Journal of Manufacturing Science and Engineering, [Q1, IF = 3.308], 142, 11, 110811 (31 pages), (2020) doi: https://doi-org.ezproxy.uky.edu/10.1115/1.4047926 
  • W. F. Sales, J. Schoop, L. R. R. da Silva, Á. R. Machado, and I.S. Jawahir “A Review of Surface Integrity in Machining of Hardened Steels” Journal of Manufacturing Processes, [Q1, IF = 5.587], 1, 58, (2020), pp. 136-162 doi: https://doi.org/10.1016/j.jmapro.2020.07.040 
  • I. Brown and J. Schoop “An Iterative Size Effect Model of Surface Generation in Finish Machining” Journal of Manufacturing and Materials Processing [Q2, IF = 2.573], 4, 3, (2020), pp. 63-81, doi: https://doi.org/10.3390/jmmp4030063 
  • N. Diaz-Elsayed, K.C. Morris, and J. Schoop “Realizing Environmentally Conscious Manufacturing in the Post–COVID-19 Era” Smart and Sustainable Manufacturing Systems, [Q2, IF = 1.173], 4, 3, (2020), pp. 314-318, doi: https://doi.org/10.1520/SSMS20200052 
  • J. Schoop “Real-time Modeling and In-situ Characterization of Residual Stress Formation in Machining and Sliding Contact” Invited Contribution to Special Issue, Lubricants, 9, 3, (2021) pp. 1-28 [Q2, IF = 2.487] doi: https://doi.org/10.3390/lubricants9030028 
  • J. Schoop, H. Poonawala, D. Adenij, and B. Clark “AI-enabled Dynamic Finish Machining Optimization for Sustained Surface Integrity” Manufacturing Letters [Q1, IF = 5.533], 29, 1, (2021), pp. 42-46, doi: https://doi.org/10.1016/j.mfglet.2021.04.002 
  • N. Cococcetta, M. P. Jahan, J. Schoop, J. Ma, D. Pearl, and M. Hassan “Post-processing of 3D printed thermoplastic CFRP composites using cryogenic machining” Journal of Manufacturing Processes [Q1, IF = 5.587], 68, A, (2021), pp. 332-346, doi: https://doi.org/10.1016/j.jmapro.2021.05.054 
  • D. Adeniji, and J. Schoop “In-situ Calibrated Digital Process Twin Models for Resource Efficient Manufacturing” Journal of Manufacturing Science and Engineering, [Q1, IF = 3.308], 144, 4, (2022), 041008, doi: https://doi.org/10.1115/1.4052131
  • N. Khanna, J. Wadhwa, A. Pitroda, P. Shah, J. Schoop, and M. Sarikaya “Life cycle assessment of environmentally friendly initiatives towards sustainable machining: A review and case study” Sustainable Materials and Technologies, [Q1, IF = 10.009], e00413 (2022), doi: https://doi.org/10.1016/j.susmat.2022.e00413 
  • D. Adeniji, K. Oligee, and J. Schoop “A Novel Approach for Real-time Quality Monitoring in Machining of γ-TiAl Aerospace Alloy through Scalogram Acoustic Emission Signal Transformation for Deep Neural Network” Journal of Manufacturing and Materials Processing [Q2, IF = 2.573], 6(1), 18, (2022), doi: https://doi.org/10.3390/jmmp6010018 
  • J. Schoop, M. Hasan, and H. Zannoun; “Physics-informed and Data-driven Prediction of Residual Stresses in Three-dimensional Machining Processes” Invited Contribution to Special Issue (Advances in Residual Stress Technology) in Experimental Mechanics [Q1, IF = 2.787], 62(8),  (2022), pp. 1461-1474, doi: https://doi.org/10.1007/s11340-022-00880-4 
  • G. P. Toker, J. Schoop, and H. Karaca “Machining-Induced Surface Integrity and Nanocrystalline Surface Layers in Cryogenic Finishing Turning of Inconel 718” Machining Science and Technology, [Q2, IF = 2.480], 26(4), pp.640-664, doi: https://doi.org/10.1080/10910344.2022.2129989 
  • E. Thornton, H. Zannoun, C. Vomero, D. Caudill, and J. Schoop, “A Review of Constitutive Models and Thermal Properties for Nickel-based Superalloys Across Machining-Specific Regimes” ASME Journal of Manufacturing Science and Engineering [Q1, IF = 3.901], 145(8), 080801 (31 pages), (2023), doi: https://doi.org/10.1115/1.4056749
  • H. Zannoun, and J. Schoop. "Analysis of burr formation in finish machining of nickel-based superalloy with worn tools using micro-scale in-situ techniques." International Journal of Machine Tools and Manufacture [Q1, IF = 14.122], 189 (2023): 104030, doi: https://doi.org/10.1016/j.ijmachtools.2023.104030 
  • N. Khanna, P. Raval, D. Patel, R. Prajapati, J. Schoop, and K. K. Gajrani. "Assessment of Additive and Subtractive Sustainable Manufacturing of Inconel 625." Tribology International [Q1, IF = 6.799], (2023): 108655, doi: https://doi.org/10.1016/j.triboint.2023.108655 
  • G. González, M. Plogmeyer, J. Schoop, G. Bräuer, and V. Schulze., “In-situ characterization of tool temperatures using in-tool integrated thermoresistive thin-film sensors.” Production Engineering [Q2, IF = 2.365], 17(2), (2023) pp.319-328, doi: https://doi.org/10.1007/s11740-023-01186-7 
  • A. Hartley, J. Money, and J. Schoop, “A novel approach for in-situ characterization and probabilistic prediction of cutting tool fatigue in machining of Ti-6Al-4V.” Manufacturing Letters [Q1, IF = 5.533], 38(2), (2023) pp.79-82, doi: https://doi.org/10.1016/j.mfglet.2023.10.002  
  • R.H.L. da Silva, J. Schoop, A. Hassui, and I.S. Jawahir, “Inconel 625 sustainable milling surface integrity and the dependence on alloy processing route.” The International Journal of AdvancedManufacturing Technology [Q1, IF = 4.199], 38(2), (2024) pp.4493-4512, doi: https://doi.org/10.1007/s00170-023-12938-1
  • Z. Liao, J.Schoop, J. Saelzer, B. Bergmann, P.C. Priarone, A. Splettstößer, V.M. Bedekar, F. Zanger, and Y. Kaynak, “Review of current best-practices in machinability evaluation and understanding for improving machining performance.” CIRP Journal of Manufacturing Science and Technology [Q1, IF = 5.625], 50(1), (2024) pp.151-184, doi: https://doi.org/10.1016/j.cirpj.2024.02.008
  • B. Clark, J. Schoop, and H. Poonawla “Digital process twins: a modular approach for surface conditioning and process optimization.” Production Engineering [Q2, IF = 2.365], 18(1), (2024) pp.367-380, doi: https://doi.org/10.1007/s11740-023-01250-2

Conference Papers

  • J. Schoop, D. Adeniji and I. Brown “Computationally efficient, multi-domain hybrid modeling of surface integrity in machining and related thermomechanical finishing processes” Procedia 17th CIRP CMMO, 82, (2019), pp. 356-361
  • J. Caudill, J. Schoop, and I. S. Jawahir “Numerical Modeling of Cutting Forces and Temperature Distribution in High Speed Cryogenic and Flood-cooled Milling of Ti-6Al-4V” Procedia 17th CIRP CMMO, 82, (2019), pp. 83-88
  • J. Caudill, J. Schoop, and I. S. Jawahir “Producing Sustainable Nanostructures in Ti-6Al-4V Alloys for Improved Surface Integrity and Increased Functional Life in Aerospace Applications by Cryogenic Burnishing” Procedia 26th CIRP LCE, 80, (2019), pp. 120-125
  • I. Brown and J. Schoop “The effects of nose radius and cutting edge geometry on surface integrity in finish turning of Ti-6Al4V” Procedia 5th CIRP CSI, 1, 82, (2020), pp. 356-361
  • N. Khanna, P. Shah, J. Wadhwa, A. Pitroda, J. Schoop, and F. Pusavec “Energy Consumption and Lifecycle Assessment Comparison of Cutting Fluids for Drilling Titanium Alloy” Procedia 28th CIRP LCE, 98, (2021), pp 175-180
  • G. Chen, S. Chen, J. Schoop, J. Caudill, and I.S. Jawahir “The Influence of Sustainable Cooling Strategies and Uncut Chip Thickness on Surface Integrity in Finish Machining of Ti-6Al-4V Alloy” ASME International Mechanical Engineering Congress and Exposition, 85567, (2021) V02BT02A067
  • E.L. Thornton, A. Hartley, D. Caudill, M. Gamesu, J. Schoop, and F. Badurdeen “Evaluating the Sustainability of Paper and Plastic Substitute Material LimeX” Proceedings of 18th CIRP GCSM, (2022), pp. 1082-1090
  • E. Thornton and J. Schoop “Thermal Process Signature in Machining of Ti-6Al-4V with Worn Tools” Procedia 6th CIRP CSI, 108, (2022), pp3 868-872
  • M.M. Hasan, and J. Schoop “Physics-Informed Uncertainty Quantification in Modeling of Machining-Induced Residual Stress” Procedia 19th CIRP CMMO, 117, (2023), pp.139-144
  • A. Hartley, J. Schoop, F. Welzel, H. Frank, M. Schiffler, S. Marr, and A. Wirtz “Opportunities and Challenges in Modelling of Machining Performance with Various Coatings and Lubricants in Inconel 718 Machining” Procedia 19th CIRP CMMO, 117, (2023), pp.462-467.

Julius Schoop

Julius Schoop.

Principal Investigator

Email
julius.schoop@uky.edu
Phone
859-323-8308

Stanley and Karen Pigman College of Engineering

351 Ralph G. Anderson Building
Lexington, KY 40506-0503
859-257-1687
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