William J. Endres |
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Michigan Technological University College of Engineering Mechanical Engineering-Engineering Mechanics Associate ProfessorAppointed: 2001 |  |
Mailing AddressDepartment of Mechanical Engineering-Engineering Mechanics 1400 Townsend Drive Houghton, Michigan 49931-1295United States | Contact Information |
Qualifications
Ph.D., University of Illinois at Urbana-Champaign, Mechanical Engineering, 1992.
M.S., University of Illinois at Urbana-Champaign, Mechanical Engineering, 1990.
B.S., University of Illinois at Urbana-Champaign, Mechanical Engineering, 1988.
Expertise and Research Interests
Basic experimental study and modeling of the effects of the blunt edge (edge radius) and flank-wear land found on most cutting tools.
Basic experimental study and analytical solutions for measures of dynamic performance in machining, including forced vibration level and stability, in the presence of multiple/parallel processes, real tooling geometry, periodic time variation, high and ultrahigh speeds, and multi-dimensional machine-tool dynamics.
Dynamic modeling of fixed interfaces and machine-tool joints under simultaneous loading in two (normal and tangential) directions via asperity contact modeling.
Innovative tooling for machining, molding, stamping and die casting.
Product and process architecture alignment -- responding to enterprise externalities such that the product and life-cycle processes (product development, manufacturing, maintenance, recycling, etc.) remain in (or brought back into) alignment at their fundamental, architectural level.
Basic experimental study and analytical solutions for measures of dynamic performance in machining, including forced vibration level and stability, in the presence of multiple/parallel processes, real tooling geometry, periodic time variation, high and ultrahigh speeds, and multi-dimensional machine-tool dynamics.
Dynamic modeling of fixed interfaces and machine-tool joints under simultaneous loading in two (normal and tangential) directions via asperity contact modeling.
Innovative tooling for machining, molding, stamping and die casting.
Product and process architecture alignment -- responding to enterprise externalities such that the product and life-cycle processes (product development, manufacturing, maintenance, recycling, etc.) remain in (or brought back into) alignment at their fundamental, architectural level.
Other Expertise
Mechanistic process modeling techniques, model-based cutting-tool development.
Future Research
Research is continuing on basic cutting mechanics as related to blunt worn tools with future efforts focusing on surface finish and residual stress in additon to forces.
Work is being re-initiated on experimentally studying and modeling of fixed interface dynamics.
Additional exploratory research is being conducted on micro-geomtrical features on cutting tools and new ways of fabricating cavity-based tooling (i.e., stamping dies, injection molds and casting dies).
Work is being re-initiated on experimentally studying and modeling of fixed interface dynamics.
Additional exploratory research is being conducted on micro-geomtrical features on cutting tools and new ways of fabricating cavity-based tooling (i.e., stamping dies, injection molds and casting dies).
Industrial Relevance
Research outcomes are centered around meaningful measures of process performance, such as dimensional and form error, stability, vibration and force variation levels, and surface integrity, with such efforts as force and thermal modeling being viewed as a means to the end, not the end itself. With a focus on process performance, the Prof. Endres aims to conduct basic research motivated by realities of practice and a need to understand qualitatively, and predict quantitatively, the performance of machine-tool systems during their development, planning and diagnosis.
Innovative tooling research is driven by repeated discussions with industry to understand their challenges/issues, and from that thinking 'out-of-the-box' to formulate creative concepts, conduct proof-of-concept testing, then research to address issues and to support concept implementation and optimization.
Much of his research finds its way to the classroom and industry through industry short courses and two other university courses hehas developed in modeling and analysis of machining.
Innovative tooling research is driven by repeated discussions with industry to understand their challenges/issues, and from that thinking 'out-of-the-box' to formulate creative concepts, conduct proof-of-concept testing, then research to address issues and to support concept implementation and optimization.
Much of his research finds its way to the classroom and industry through industry short courses and two other university courses hehas developed in modeling and analysis of machining.
Keywords
COS Keywords:
Machine Design, Manufacturing (Mechanical Engineering), Micromachining.Additional Terms:
Ceramics Machining, Chatter, Cutting Mechanics, Cutting Tools, Edge Preparation, Joint Dynamics, Machine Design, Machine Tools, Machining Dynamics, Machining Stability, Manufacturing Processes, Mechanical Design, Mechanistic Modeling, Process Modeling, Tool Life, Tool Wear.Languages
(Reading, Writing, Speaking)
English: (Fluent, Fluent, Fluent)
Memberships
American Society of Mechanical Engineers - Bioengineering Division
Society of Manufacturing Engineers
Honors and Awards
1999, Milton C. Shaw Outstanding Young Manufacturing Engineer Award,
Society of Manufacturing Engineers
1998, Outstanding Reviewer,
J. of Manuf. Sci. and Eng.,
American Society of Mechanical Engineers
1998, CAREER Award,
Div. of Design, Manufacture and Industrial Innovation,
National Science Foundation
1997, Blackall Machine Tool and Gage Award,
Manufacturing Engineering Division,
American Society of Mechanical Engineers,
Best Paper
1991, Amoco Foundation Teaching Fellowship,
Dept. of Mechanical Engineering,
University of Illinois at Urbana-Champaign
1988-1991,
University Fellowship,
University of Illinois at Urbana-Champaign
Previous Positions
2001-2001, Visiting Researcher,
Lamb Technicon Machining Systems,
Research and New Product Development
1994-2001, Assistant Professor,
University of Michigan,
Engineering,
Mechanical Engineering & Applied Mechanics
1989-1992, Independent Contractor,
Process Design and Control, Inc., Champaign, IL
1988-1994, Research Assistant to Visiting Assistant Professor,
University of Illinois at Urbana-Champaign,
College of Engineering,
Mechanical and Industrial Engineering
Patents
System for Improving the Wearability of a Surface and Related Method,
Patent Number: Pending,
2005,
Industry,
United States of America.
Funding Received
- National Science Foundation (NSF): Mechanics-Based Analysis of the Cutting Process and Surface Generation in Hard-Tool Machining – REU Supplement, $10,000, Sep 1996 to Aug 1997.
- Michigan/NSF ERC for Reconfigurable Machining Systems: Analysis Tools for Parallel-Process Machining – Turning and Boring, $165,000, Sep 1996 to Apr 2000.
- National Science Foundation (NSF): Mechanics-Based Analysis of the Cutting Process and Surface Generation in Hard-Tool Machining, $229,431, Sep 1995 to Jul 1999.
- National Center for Manufacturing Sciences – High-Throughput Hole Making Consortium: Variable Hone Performance on Corner-Radiused Gun Drills, $35,000, Oct 2000 to Sep 2001.
- National Science Foundation (NSF): GOALI: Process Modeling and Analysis for “Smart Tool” Redevelopment in Flexible Line Boring, $50,000, May 2001 to Sep 2002.
- Lamb Technicon Machining Systems: GOALI: Process Modeling and Analysis for “Smart Tool” Redevelopment in Flexible Line Boring, $16,750, May 2001 to Sep 2002.
- MTU Research Excellence Fund: Cooling of Cutting Tools for Increased Productivity via the Application of Micro-Geometric Features — Proof of Concept, 38000, Jun 1, 2003 to Jun 30, 2004.
- MTU Research Excellence Fund: Nationally Visible Infrastructure: Industry-Directed Planning of Centers, 15000, Jun 1, 2003 to Jun 30, 2004.
- SME Education Foundation (Research Initiation Grant): Research and Curriculum Development in Machining Process Analysis, $10,000, Jul 1996 to Jun 1997.
- SME Education Foundation: Research and Curriculum Development in Machining Process Analysis, $10,400, Jul 1995 to Jun 1996.
- Michigan/NSF ERC for Reconfigurable Machining Systems: Modeling of Machine-Tool Joint Dynamics, $120,000, Jan 1999 to Dec 2001.
- National Science Foundation (NSF): Merging Dynamics and Mechanics for Integrated Machine-Tool, Tooling and Process Analysis (CAREER Grant - Industry Match Supplement), $25,000, Apr 2000 to Mar 2001.
- National Science Foundation (NSF): Merging Dynamics and Mechanics for Integrated Machine-Tool, Tooling and Process Analysis (CAREER Grant - Industry Match Supplement), $25,000, Apr 1999 to Mar 2000.
- National Science Foundation (NSF): Merging Dynamics and Mechanics for Integrated Machine-Tool, Tooling, and Process Analysis (CAREER Grant ), $200,000, Apr 1998 to Mar 2002.
- National Science Foundation (NSF): Merging Dynamics and Mechanics for Integrated Machine-Tool, Tooling and Process Analysis (CAREER Grant - Industry Match Supplement), $25,000, Apr 1998 to Mar 1999.
- NSF SBIR Phase I + MEDC: SBIR Phase I: Micro-quantity Internal Cooling (MQuIC) of Cutting Tools for Increased Productivity via Micro-ducts, $99,875 + $15,000, 2005 to 2006.
- NSF SBIR Phase I + MEDC: SBIR Phase I: Reduced-Friction Cutting Tools for Increased Productivity via Micro-Fluidic Lubrication (MFL), $99,795 + $15,000, 2005 to 2006.
- Confidential Sponsor: Mechanics-Based Design of Metal-Cutting Circular Saws, $83,640, 2004 to 2005.
- MTU REF: Nationally Visible Infrastructure: The MTU Machining Education and Research Laboratories (MERL), $34,700, 2004 to 2005.
Publications
- Corpus, W. T., and Endres, W. J., Added Stability Lobes for Machining Processes that Exhibit Periodic Time Variation - Part 1: An Analytical Solution, ASME Journal of Manufacturing Science and Engineering, 126, 467-474, 2004
- Corpus, W. T., and Endres, W. J., Added Stability Lobes for Machining Processes that Exhibit Periodic Time Variation - Part 2: Experimental Validation, ASME Journal of Manufacturing Science and Engineering, 126, 475-480, 2004
- Kountanya, R. K., and Endres, W. J., Flank Wear of Edge-Radiused Cutting Tools under Ideal Straight-Edged Orthogonal Conditions, ASME Journal of Manufacturing Science and Engineering, 126, 496-505, 2004
- Li, C.-J., Ulsoy, A. G., and Endres, W. J., The Effect of Flexible-Tool Rotation on Regenerative Chatter in Machining, ASME Journal of Manufacturing Science and Engineering, 125, 39-47, 2003
- Endres, W. J., and Kountanya, R. K., The Effects of Corner Radius and Edge Radius on Tool Flank Wear, Journal of Manuf. Proc., 4, 89-96, 2002
- Schimmel, R. J., Endres, W. J., and Stevenson, R., The Application of an Internally Consistent Material Model to Determine the Effect of Tool Edge Geometry in Orthogonal Machining, ASME Journal of Manufacturing Science and Engineering, 124, 536-543, 2002
- Endres, W. J., and Ozdoganlar, O. B., Existence and Effects of Overlap Factors Greater than Unity and Less than Zero, Journal of Manuf. Proc., 4, 67-76, 2002
- Manjunathaiah, J., Beecherl, P. M., Szuba, P. S., and Endres, W. J., Model-Based Design of Rotating Insert Tools for Metal Cutting Applications, Trans. of NAMRI/SME, 29, 351-358, 2001
- Chiu, W.-C., Endres, W. J., and Thouless, M. D., An Analysis of Surface Cracking during Orthogonal Machining of Glass, Journal of Mach. Sci. and Tech., 5, 195-215, 2001
- Manjunathaiah, J., and Endres, W. J., A Study of Apparent Negative Rake Angle and its Effects on Shear Angle During Orthogonal Cutting with Edge-Radiused Tools, Trans. of NAMRI/SME, 28, 197-202, 2000
- Schimmel, R. J., Manjunathaiah, J., and Endres, W. J., Edge Radius Variability and Force Measurement Considerations, ASME Journal of Manufacturing Science and Engineering, 122, 590-593, 2000
- Manjunathaiah, J., and Endres, W. J., A New Model and Analysis of Orthogonal Machining with an Edge-Radiused Tool, ASME Journal of Manufacturing Science and Engineering, 122, 384-390, 2000
- Schimmel, R. J., Endres, W. J., and Stevenson, R., The Application of an Internally Consistent Material Model to Determine the Effect of Zero Clearance in Orthogonal Machining, Journal of Mach. Sci. and Tech., 4, 101-125, 2000
- Chiu, W.-C., Endres, W. J., and Thouless, M. D., An Experimental Study of Chip Formation and Surface Formation during Orthogonal Machining of Homogeneous Brittle Materials, Journal of Mach. Sci. and Tech., 4, 253-275, 2000
- Ozdoganlar, O. B., and Endres, W. J., An Analytical Representation of Chip Area for Corner-Radiused Tools Under Depth-of-Cut and Feed Variations, ASME Journal of Manufacturing Science and Engineering, 122, 660-665, 2000
- Chiu, W.-C., Thouless, M. D., and Endres, W. J., An Analysis of Chipping in Brittle Materials, Journal of Fracture, 90, 287-298, 1998
- Melkote, S. N., and Endres, W. J., The Importance of Considering Size Effect when Modeling Slot End Milling, ASME Journal of Manufacturing Science and Engineering, 120, 68-75, 1998
- Endres, W. J., A Quantitative Energy-Based Method for Predicting Stability Limit as a Direct Function of Spindle Speed for High-Speed Machining, Trans. of NAMRI/SME, 24, 27-32, 1996
- Endres, W. J., DeVor, R. E., and Kapoor, S. G., A Dual-Mechanism Approach to the Prediction of Machining Forces: Part 2 – Calibration and Validation, ASME J. Engg. for Industry (now ASME J. Manuf. Sci. Engg.), 117, 534-541, 1995
- Endres, W. J., DeVor, R. E., and Kapoor, S. G., A Dual-Mechanism Approach to the Prediction of Machining Forces: Part 1 – Model Development, ASME J. Engg. for Industry (now ASME J. Manuf. Sci. Engg.), 117, 526-533, 1995
- Endres, W. J., and Waldorf, D. J., The Importance of Size Effect Variation Along the Cutting Edge in Predicting the Effective Lead Angle in Turning, Trans. of NAMRI/SME, 22, 65-72, 1994
- Radulescu, R., Kapoor, S. G., Endres, W. J., and DeVor, R. E., An Investigation of the Vibration of the Face Milling Process During High-Speed Machining, Trans. of NAMRI/SME, 21, 237-246, 1993
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