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Steven Wallace

Research Engineer

San Jose State University: BS Industrial Technology, Currently with The Boeing Company (since 1990) in Machining Technology Development; Associated with the metalworking industry since 1977; Extensive experience in Machining Dynamics, Sensors, Modal analysis, Titanium, Product Design for Machining....
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experience

Engineer / Scientist  
Boeing, September 1990 to Present

• Machining Technology Development • Titanium machining, Process Modeling, CATIA V5 user • Advanced modal analysis techniques for High Speed Machining • Instructor, “Machining Technology in Aerospace Manufacturing” • Boeing Design Manual custodian for BDM1326 “Machined Parts Design” • Data acquisition, vibration signal analysis, and system simulation of metal removal processes • Vice President, ASME Standardization and Testing (2014) • ASME Board on Standardization and Testing • ASME Vice Chair, Strategic Initiatives, Board on Standards and Certification • Chair, ASME B5 Machine Tools • Management and supervision of the dimensional, design, application, drafting, and performance test codes and miscellaneous standards activities of the Society, The standards developed by groups managed by the board are submitted to the American National Standards Institute to become American National Standards.

Mechanical Engineeer  
Varian Associates, September 1979 to September 1990, Palo Alto, California United States
(Defense Electronics)
Sheet metal Worker, Then Mechanical Technician, then Mechanical Engineer!

Apprentice  
NASA - Ames Research Center, September 1977 to September 1979, Mountain View, California United States
(Air and Space Research)
Sheet metal and welding apprenticeship while working on wind tunnel models and research aircraft.

education

San Jose State University  
Bachelor's degree, Industrial Technology, Jan, 1981 to Jan, 1985


projects

World Land Speed Racing Association  by  Keith Zanghi, Les Holm, Steve Green, Steve Wallace    
January, 2003 - Present
Lead Engineer, developing and testing next land speed record challenger.

Tug Comanche  by  Joe Peterson    
August, 1944 - Present
Electro-Technical Officer for Comanche 202 Foundation, a non-profit founded for the purpose of preserving, restoring and operating the last complete ATA (Navy rescue tugboat) and the first U.S. Coast Guard Medium Endurance Cutter preserved on the west coast. Comanche is frequently open for tours. Comanche is fully operational and makes cruises on the Puget Sound.

patents

Modal Impact Testing Assembly, System and Method  (US 9,134,212, B2)    
Inventors: Steven G. Wallace.  Issued September 15, 2015  in United States

The modal impact testing assembly enables modal impact testing of a test element that is rotating at operational speeds.

Receivers and Methods for Forming such Receivers  (US 10,010,945)    
Inventors: Steven G. Wallace.  Issued July 03, 2018  in United States

In one imbodiment, as implemeted for use on a machining center, this invention prevents a machining cutter, such as an end mill or, more generally, a shank, from “walking out” of its receiver (or collet) when used for heavy machining operations during which large quantities of material are machined away in a single pass. Such “walk-out” of the cutter leads to a loss of machining accuracy, thus significantly increasing manufacturing costs.

Frictional Coupling  (US 9,360,029)    
Inventors: Steven G. Wallace.  Issued June 07, 2016  in United States

An anisotropic non-slip coupling between two parts may include a first part having an anisotropic surface pattern formed thereon, and a second part having a surface shape to receive the first part in an interference fit, wherein the anisotropic surface pattern is oriented to provide directional slippage of the first part relative to the second part in a direction that facilitates engagement of the first and second parts in response to vibration of at least one of the first and second parts, and resists slippage of the first part relative to the second part in an opposite direction.

Methods of Forming Shanks  (US 10,071,438)    
Inventors: Steven G. Wallace.  Issued September 11, 2018  in United States

A machining cutter, such as an end mill or, more generally, a shank, has a tendency to “walk out” of its receiver (or collet) when used for heavy machining operations during which large quantities of material are machined away in a single pass. Prior to introduction of lateral forces between a shank and a receiver during, e.g., a milling operation, an inside wall of the receiver contacts the shank circumferentially and uniformly, maintaining static friction between the shank and the receiver and retaining the shank within the receiver. When lateral forces are introduced, the receiver may locally elastically deform, resulting in a loss of static friction between the shank and the receiver. As a result, slippage of the shank relative to the receiver may occur. Accordingly, apparatuses and methods, intended to address at least the above-identified concerns, would find utility.

Methods of Frictional Coupling  (10,208,775)    
Inventors: Steven G. Wallace.  Issued   in United States

A method of forming a coupling between a first part and a second part is disclosed. The method includes providing a first surface of the first part. The first surface has a first shape and a surface roughness average that is less than or equal to about 500 microinches (13 microns). The method also includes forming a second surface of the second part where the second surface has a second shape and the first shape and the second shape are substantially complementary shapes. Projections form at least a portion of the second surface in a preselected pattern, and are configured to produce a friction fit between the first surface and the second surface when the first surface and the second surface are biased against each other. The projections have an average elastic compressive range substantially equal to the surface roughness average.

publications

Elimination of Vibration Induced Machine Damage through Modal Analysis and Computerized Modeling     
Published by (SAE)
Authors: Steven G. Wallace.  Published October 01, 1996

Increased demand for machining with higher material removal rates necessitates the use of higher rotational speeds and higher side loads during the cutting process. These new machining parameters manifest themselves as chronic degenerative problems with spindles and tool holder taper interfaces. Regenerative vibrations serve to complicate this condition and greatly contribute to the severity of this degenerative process. This paper describes solutions for these recent machining process problems to manufacturing engineers and machine tool builders. An overview of the complicated processes that cause vibration induced damage to machine tools is presented in simple terms. The objective is to give the reader a basic understanding of vibration induced machine damage, and several ways to combat this problem. A fresh look at the problems associated with higher rotational speeds, high side forces, and material removal rates, with knowledge of Finite Element Analysis and Vibration Analysis techniques can solve many machining production problems of recent years.