Danny Hoang

Danny Hoang, Anandkumar Patel, Ruimen Chen et al.

Smart manufacturing can significantly improve efficiency and reduce energy consumption, yet the energy demands of AI models may offset these gains. This study utilizes in-situ sensing-based prediction of geometric quality in smart machining to compare the energy consumption, accuracy, and speed of common AI models. HyperDimensional Computing (HDC) is introduced as an alternative, achieving accuracy comparable to conventional models while drastically reducing energy consumption, 200$\times$ for training and 175 to 1000$\times$ for inference. Furthermore, HDC reduces training times by 200$\times$ and inference times by 300 to 600$\times$, showcasing its potential for energy-efficient smart manufacturing.

Danny Hoang, Ryan Matthiessen, Christopher Miller et al.

High-precision CNC machining of free-form aerospace components requires bounded compensations informed by inspection, simulation, and process knowledge. Off-the-shelf large language model (LLM) assistants can generate text, but they do not reliably execute risk-constrained multi-step numerical workflows or provide auditable provenance for high-stakes decisions. We present multi-agent knowledge analysis (MAKA), a human-in-the-loop decision-support architecture that separates intent routing, tools-only quantitative analysis, knowledge graph retrieval, and critic-based verification that enforces physical plausibility, safety bounds, and provenance completeness before recommendations are surfaced for human approval. MAKA is instantiated on a Ti-6Al-4V rotor blade machining testbed by fusing virtual-machining path-tracking error fields, cutting-force and deflection simulations, and scan-based 3D inspection deviation maps from 16 blades. The analysis decomposes deviation into an evidence-linked pathing component, a drift-based wear proxy capturing systematic evolution across parts, a residual systematic compliance term, and a variability proxy for instability-aware escalation. In a three-level tool-orchestration benchmark (single-step through $\geq$3-step stateful sequences), MAKA improves successful tool execution by up to 87.5 percentage points relative to an unstructured single-model interaction pattern with identical tool access. Digital twin what-if studies show MAKA can coordinate traceable compensation candidates that reduce predicted surface deviation from order $10^{-2}$in to approximately $\pm 10^{-3}$in over most of the blade within the simulation environment, providing a pre-deployment verification signal for risk-aware human decision-making.

Danny Hoang, David Gorsich, Matthew P. Castanier et al.

Precision process planning in Computer Numerical Control (CNC) machining demands rapid, context-aware decisions on tool selection, feed-speed pairs, and multi-axis routing, placing immense cognitive and procedural burdens on engineers from design specification through final part inspection. Conventional rule-based computer-aided process planning and knowledge-engineering shells freeze domain know-how into static tables, which become limited when dealing with unseen topologies, novel material states, shifting cost-quality-sustainability weightings, or shop-floor constraints such as tool unavailability and energy caps. Large language models (LLMs) promise flexible, instruction-driven reasoning for tasks but they routinely hallucinate numeric values and provide no provenance. We present Augmented Retrieval Knowledge Network Enhanced Search & Synthesis (ARKNESS), the end-to-end framework that fuses zero-shot Knowledge Graph (KG) construction with retrieval-augmented generation to deliver verifiable, numerically exact answers for CNC process planning. ARKNESS (1) automatically distills heterogeneous machining documents, G-code annotations, and vendor datasheets into augmented triple, multi-relational graphs without manual labeling, and (2) couples any on-prem LLM with a retriever that injects the minimal, evidence-linked subgraph needed to answer a query. Benchmarked on 155 industry-curated questions spanning tool sizing and feed-speed optimization, a lightweight 3B-parameter Llama-3 augmented by ARKNESS matches GPT-4o accuracy while achieving a +25 percentage point gain in multiple-choice accuracy, +22.4 pp in F1, and 8.1x ROUGE-L on open-ended responses.