Manufacturing Completed Research

Manufacturing the Tweel for Passenger Vehicles

This area focuses on the prototyping, manufacturing, metrology and reliability in producing commercial Tweel assemblies. (Read more)

Micro-Feature Mold Development and Testing

The objective of the project is to produce sample molded parts built in mold plates to be supplied by sponsor.  (Read more)

Deformation Machining: A New Hybrid Manufacturing Process 

Deformation machining is a unique new manufacturing process that will enable the creation of features that are monolithic, less expensive and more accurate. The project’s goal is to establish the scientific bases for this new process, to create an efficient numerical simulation modeling and simulation method, and to integrate the experimental and modeling approach with in-process control strategies. (Read more)

Gauging of Large Bearing Rings Using a Rotary Encoder-Based Instrument

The goal of this project is to design and test a novel instrument to be used for measuring the diameter and taper of large bearing rings without the need for a master. (Read more)

Predictive Molding of Precision Glass Optics

As the need for smaller optic lenses rises, so does the need to have a molding process capable of predicting the optic’s final form given a shape and set of processing parameters. This change could be a great improvement for lenses used in cell phone cameras. (Read more)

Failure Mode and Effects Analysis of Adhesively Bonded Structures

This activity aims at conducting an FMEA study to analyze the different impacts and effects on the quality of adhesively bonded structures for automotive sub-assemblies. The study implements experimental and modeling efforts to capture the effect of each process (operational window) on the final quality of bonds. Additionally full analyses e.g. thermo-gravimetric, viscosity are done for the adhesive material to evaluate its sensitivity to environmental conditions (humidity) and curing profiles.  (Read more)

Non-Contact Stress Measurements Using Thermo-Elasticity Analyses

This project aims at developing a non-contact stress-strain measurements of small bearing cages under operation. the project utilizes the thermo-elasticity principles to correlate the temperature maps under cyclic loadings with the stress behavior of the heat affected zone of bearing cages. (Read more)

Thermographic Nondestructive Testing and Evaluation of Pipes

This projects aims at developing a non-intrusive system capable of quantifying the thickness and cracks within power plants piping systems, with one side access.  (Read more)

Engine Line Value Stream Mapping and Layout Optimization

This project aims at optimizing the current engine assembly line layout and processes. A value stream mapping analyses are conducted to characterize the processes sequence, value added, and resource allocation.  (Read more)

Thermal Imaging of Vehicular Subsystems

This project aims at analyzing the thermal signature of vehicular sub-systems. The analyses are done using a dual band thermographic systems to acquire the actual temperature readings spatially and temporally. Additionally, a simulation model runs a finite differencing subroutine to test proposed designs and optimizations.  (Read more)

Thermographic Investigation of Adhesive Bonded Joints

This projects aims at investigating the different modalities of thermographic inspection methods (passive, active, selective, global) for the non-contact, real-time testing of adhesive bonded structures. New stimulation methods are developed and used in addition to new optical systems. (Read more)

Stamping Quality Control Through Thermal Imagery

This project aims at developing novel imaging systems to analyze the formability of sheet metals while under press operations. The developed system utilizes the thermo-plasticity principles to correlate the temperature fields with the stretching characteristics of sheet metals. This is done in real-time and in non-intrusive mode. (Read more)

Automotive Production Control Using Thermal Vision Systems

This work presents new generation of online inspection systems, developed and deployed in automotive assembly plants, to provide 100%, online evaluation of automotive processes and sub-assemblies. The presented systems are thermal-vision-based, with capability to provide two-dimensional, spatial and temporal temperature acquisitions, and are equipped with novel processing routines for data collection, conditioning and processing.  (Read more)