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Enhancing Manufacturing Process Education via Computer Simulation and Visualization

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2014 ASEE Annual Conference & Exposition


Indianapolis, Indiana

Publication Date

June 15, 2014

Start Date

June 15, 2014

End Date

June 18, 2014



Conference Session

Use of Technology for Education

Tagged Division


Page Count


Page Numbers

24.524.1 - 24.524.10



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Paper Authors


Priya Manohar Robert Morris University

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Dr. Priyadarshan Manohar is an Associate Professor of Engineering and Co-Director of Research and Outreach Center (ROC) at Robert Morris University, Pittsburgh, PA. He has a Ph. D. in Materials Engineering (1998) and Graduate Diploma in Computer Science (1999) from University of Wollongong, Australia and holds Bachelor of Engineering (Metallurgical Engineering) degree from Pune University, India (1985). He has worked as a post-doctoral fellow at Carnegie Mellon University, Pittsburgh (2001 – 2003) and BHP Institute for Steel Processing and Products, Australia (1998 – 2001). Dr. Manohar held the position of Chief Materials Scientist at Modern Industries, Pittsburgh (2003 – 2004) and Assistant Manager (Metallurgy Group), Engineering Research Center, Telco, India (1985 – 1993). He has published over 55 papers in peer-reviewed journals and conferences including a 2007 Best Paper Award by the Manufacturing Division of American Society for Engineering Education (ASEE), three review papers and three book chapters. He has participated in numerous national and international conferences. He is a member of ASM International, TMS, ACerS, AIST, ASEE, IMEA, and a registered Chartered Professional Engineer. Dr. Manohar’s research interests include mathematical and computer modeling of materials behavior, thermomechanical processing of steels and other metallic materials, microstructural characterization, and structure – property relationships. He has conducted a number of technical failure investigations, consulted on various materials-related problems, and acted as an expert witness in the Court of Law. Dr. Manohar is the immediate past chair of the Manufacturing Division of ASEE and the current Chair of ASM Pittsburgh Chapter.

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Sushil Acharya Robert Morris University

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Acharya joined RMU in Spring 2005 after serving 15 years in the Software Industry. With US Airways, Acharya was responsible for creating a conceptual design for a Data Warehouse which would integrate the different data servers the company used. With i2 Technologies he led the work on i2’s Data Mining product “Knowledge Discover Framework” and at CEERD (Thailand) he was the product manager of three energy software products (MEDEE-S/ENV, EFOM/ENV and DBA-VOID) which were/are used in Asian and European countries by both governmental and non-governmental organizations. Acharya has a M.Eng. in Computer Technology and a D.Eng. in Computer Science and Information Management with a concentration in knowledge discovery, both from the Asian Institute of Technology in Thailand. His teaching involvement and research interest are in the area of Software Engineering education, Software Verification & Validation, Data Mining, Neural Networks, and Enterprise Resource Planning. He also has interest in Learning Objectives based Education Material Design and Development. Acharya is a co-author of “Discrete Mathematics Applications for Information Systems Professionals- 2nd Ed., Prentice Hall”. He is a member of Nepal Engineering Association and is also a member of ASEE, and ACM. Acharya is a recipient of the “Mahendra Vidya Bhusak” a prestigious medal awarded by His Majesty the King of Nepal for academic excellence. He is a member of the Program Committee of WMSCI, MEI, and CCCT and is also a Member of the Editorial Advisory Board of the Journal of Systemics, Cybernetics and Informatics of the International Institute of Informatics and Systemics. Acharya was the Principal Investigator of the 2007 HP grant for Higher Education at RMU. In 2013 Acharya received a National Science Foundation Grant for developing course materials through an industry-academia partnership in the area of Software Verification and Validation.

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Peter Y Wu Robert Morris University

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Peter Wu obtained his Ph.D. in Computer Systems Engineering from Rensselaer Polytechnic Institute. After his post-doctoral research fellowship at the Watson Research, he became a staff member at IBM Research. He was partner and Chief Software Engineer at UJB Solutions, LLC - a start-up consulting company in manufacturing planning, for two years. He also held faculty positions at Hong Kong Polytechnic University and the University of Pittsburgh before joining Robert Morris University in Pittsburgh, Pennsylvania. His research interests include software engineering, production planning, and geographic information systems.

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Enhancing Manufacturing Process Education via Computer Simulation and VisualizationIndustrially significant metal manufacturing processes such as melting, casting, rolling, forging,machining and forming are multi-stage, complex and labor, time and capital intensive processes.Mathematical modeling of these processes provides a theoretical framework for understandingthe process variables and their effects on productivity and quality. However it is usually difficultto provide the students with hands-on experience of experimentation with process parameters toarrive at optical process design. In order to solve this problem, interdisciplinary student projectswere undertaken at author’s institution to develop computer simulation tools that would facilitateprocess visualization, experimentation, exploration, design and optimization.The first system described in this paper is the visualization of production schedule in anindustrial setting that provides a basis for interactive decisions. A metal ingot casting issimulated by designing the abstract machine models to visualize capacity and loading of theproduction schedule. The graphical user interface is created to visualize the schedule accordingto the specific characteristics of the machines. The application of computer tools may also beextended to support other important functionalities such as tracking availability of raw materials,projection of inventory due to production overage, as well as critical business analysis. Thestudents thus are exposed to the comprehensive process analysis. Another example of processsimulation presented in this paper is the design and analysis of flexible rolling technology inindustrial processing of C – Mn and Low C - microalloyed steels. Process simulation toolsdesigned by the students allow new process sequences to be generated by breaking down existingprocess routes in to key elements and then by recombining them to generate novel alternativeand more efficient hot processing sequences. This enables the identification of an optimalprocess sequence for specified steel compositions that also satisfies simultaneous design criteriasuch as process feasibility and property maximization.It is proposed that incorporation of such computer simulation tools in the pedagogy would behighly effective to enhancing and enriching undergraduate manufacturing education.

Manohar, P., & Acharya, S., & Wu, P. Y. (2014, June), Enhancing Manufacturing Process Education via Computer Simulation and Visualization Paper presented at 2014 ASEE Annual Conference & Exposition, Indianapolis, Indiana. 10.18260/1-2--20416

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