INCREMENTAL FORMING
Double-Side Incremental Forming (DSIF) is a relatively new concept for flexible sheet forming, in which a sheet blank is clamped around its periphery and gradually deformed to a complex 3D freeform part using two strategically aligned stylus-type tools that follow pre-described toolpaths.
COMPOSITES FORMING
Polymer-based composites are strong candidates for lightweight structures. We aim to develop an integrated computational materials engineering (ICME) approach to take material architecture and process-induced local variations into the modeling of material behavior and part performance.
METAL FORMING
Metal working has long been an intriguing part of our human development. Cao co-authored a metal forming review article [Cao and Banu 2020] in honoring the 100th anniversary of the establishment of the Manufacturing Engineering Division of ASME.
Additive Manufacturing
We’re working on rapid certification and new process development in DED processing for tool path generation and parameter control for desired microstructure and component geometry. Modeling efforts and in-situ monitoring for temperature and defects allow for controlled processing.
Other Ongoing Work
Our research objectives are to increase energy utilization efficiency and to empower individual’s creativity through innovative manufacturing processes and systems, and through a better understanding of material behavior and process mechanics.
Research Instrument
We specialize in advanced materials processing at both the macro- and micro-scales. As a result, we have developed our own systems and equipment that range in application from microscale laser machining to large, industry-scale sheet metal stamping.