Manufacturing Research at McMaster An Emphasis on Materials and - - PDF document

Manufacturing Research at McMaster

• $65 million invested by Canadian Foundation for I nnovation (CFI ) in research infrastructure
• 48% has gone to projects associated with the Materials and Manufacturing strategic area

31.44 9.825 1.31 6.55 15.72 0.393 0.3275

Materials and Manufacturing Environment and Health Globalization Information technology Molecular biology Work and Society Other

An Emphasis on Materials and Manufacturing

CFI investment at McMaster by Strategic Area

1998: McMaster selected Materials and Manufacturing as a

strategic area for investment.

McMaster Manufacturing Research Institute

MMRI Development

• 1999 - $9.1M CFI/OIT award for 4 labs
• 2000 – 5 year ORDCF funding ($9.9 M)
• $3.3M Ontario
• $3.3M McMaster
• $3.3M Industrial (contracts)
• 2001 – Machine hall opens (1,400m²)
• 2002-2003 – Awarded Additional Infrastructure Funding ($5,716,395)
• $3.7M - CFI/OIT – Micromachining
• $794K - Sheet Forming Technology
• $844K - Grinding / EDM Productivity Innovations

MMRI Student Growth

20 40 60 80 100 120 140 1999 2000 2001 2002 2003 2004 Masters PhD's Post Docs Internships Total

Scope of Research

Micro Machining

• Surface Engineering
• Optics
• Micro Components
• 2 Dimensional Patterns
• 3 Dimensional Objects

Robotics & Automation

• Fixtureless Assembly
• Robotic Deburring, Grinding
• Vision Based Registration
• Fixturing

CAD/CAM

• Geometric Modeling
• 5-Axes Tool Path Planning
• Advanced CMM Systems
• Tool simulation

Metal Forming

• Sheet Metal Forming
• Hydro Forming
• Process Modeling
• Material evaluation

Polymer Processing

• Injection moulding
• Extrusion
• Process Modelling
• Material Characterization
• Advanced part design

Machining

• Intelligent Machining Systems: Sensors, Monitoring,

and Controls

• Predictive Modeling of Machining Processes
• High Speed Machining Technologies
• Machine Tools: Design, Dynamics, Accuracy, and Controls
• Machinability of Difficult-to-Cut Materials
• Process Development and Optimization

Thermal processing

• Design and modeling of thermal

and fluid flow systems

• Combustion engineering
• Boiling heat transfer
• Jet cooling
• Cooling of electronic systems

Areas of Interest:

• Machining Systems
• Machine Tool Design
• Modeling
• Sensors and Controls

Faculty:

• Mo Elbestawi
• Steve Veldhuis
• Phil Koshy

Areas of Interest:

• Polymer Processing
• Rheology
• Physical Property Testing
• Mechanical Property Testing

Faculty

• Andy Hrymak
• John Vlachopolous
• Mike Thompson

• Sheet Metal Forming Processes

Areas of Interest:

• Modeling
• Tube Forming
• Form Strain Measurement

Faculty

• Mukesh Jain

Areas of Interest:

• Robotic Fixtureless Assembly
• Robotic Servo Grippers
• Inspection Using Machine Vision
• Automated Robotic Deburring

Faculty

• Gary Bone

Areas of Interest:

• Modeling of micro cutting
• Surface engineering
• Simulation and optimization
• Micro-Machine Accuracy
• Micro-Machine tool design
• Micro metrology

Faculty

• Steve Veldhuis

• Thermal processing of materials
• Combustion engineering
• Boiling heat transfer
• Jet cooling
• Neural networks modeling
• Cooling of electronic systems

Areas of Interest:

Faculty

• Mohamed Hamed

McMaster Centre for Automotive Research

Scope of the Program

ORDCF is an infrastructure program which funds

primarily people

new faculty positions research technicians students, research associates

support is split (equally) between university,

industry and government (ORDCF)

total support of $9,000,000 over 5 years of which

$3 - 4,000,000 is cash support

ORDCF matches industry and university support

Scope of the Program

Major partners include

Alcan: $2,000,000 in-kind, $75,000 cash over 5 years INCO: $270,000 cash over 2 years General Motors of Canada: $500,00 in cash and in-kind

• ver 3 years

this has supported

3 new faculty appointments

tenure track appointment in physical metallurgy, modeling,

mechanical behaviour

research associates and students centre manager

Overall Program

Two main areas of focus

autobody materials

primarily aluminum some projects on dual-phase and TRIP steels

materials for alternative power sources

battery conducting phase fuel cells Supercapacitors for regenerative braking systems

New investment from General Motors: Centre for Materials and Corrosion

New investment of $2M cash (GM + Ontario

government)

Establish a Chair in Automotive Materials Two new faculty positions New centre will focus on

Metallurgy of lightweight alloys Development of Mg alloy sheet

Strip casting, thermomechanical processing, sheet

formability

Advanced corrosion protection systems

McMaster Innovation Park

Innovation Park Rationale

Manufacturing is a global activity Manufacturing centres can be based on

Abundant, local raw materials Low wages Highly skilled, innovative workforce Supportive environment for innovation

Golden Horseshoe region lacks raw materials

and is wage-disadvantaged

Must compete on basis of innovation

Knowledge-embedded products High productivity

Role of universities

Universities need to

Adopt Economic Development as a Core Mission Grow, Train, Attract and Retain the Best and Brightest Promote Technology Transfer Create Entrepreneurial Ecosystems Build Strong Research Partnerships with Industry

Innovation park provides

A physical place A knowledge based environment Research based economy Infrastructure – physical and intellectual Investment in the future Partnership

McMaster Innovation Park Focus on Manufacturing

Hamilton and surrounds are the manufacturing centre of

Canada

Automotive industry contribute $100B to Ontario economy

McMaster has a strong history of materials and

manufacturing research

College system with solid links to industry / skill training CANMET Materials Technology Laboratory moving to

Hamilton

Strong support at ALL three levels of government

MIP: Long term vision

MIP: Long term development plan

McMaster Innovation Centre at MIP

CANMET - MTL Current Facilities

23,000 sq metres staff of 150

Experimental Casting Laboratory Metal Rolling and Forming Laboratory Extensive Materials Characterization Structural Integrity and Weld assessment Corrosion Research Capability Advanced Materials Production (MMC, ceramics, MPIM) Concrete Production and Testing Non destructive evaluation and testing Technical services - machine shop, carpentry, electrical

MTL specializes in pilot scale facilities

CANMET-MTL’s Academic User Access Facility

CANMET-MTL supports an Academic User Access Facility (AUAF)

• an agreement among NRCan, NSERC and McMaster University
• Under the terms of the agreement, researchers from any Canadian university may apply

for access to the pilot-scale materials processing facilities at CANMET-MTL.

The AUAF provides university researchers with:

1.

the opportunity to prepare pilot-scale quantities of materials requiring specialized or unique equipment

2.

an expert team of operators

3.

the opportunity to conduct research at a reduced cost

4.

safe operating conditions for pilot-scale work not available in universities.

SUMMARY: Materials and Manufacturing at McMaster University

One of five strategic areas at McMaster Area of traditional strength in both training of undergraduate and

graduate students and research

Linked to regional industrial focus on materials processing and

manufacturing (esp. automotive)

Strong links between university and local industry

Strong interdisciplinary tradition that crosses departmental and

faculty boundaries

Excellent suite of research facilities in advanced manufacturing and

materials processing and characterization