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

Manufacturing Research at McMaster

An Emphasis on Materials and Manufacturing 1998: McMaster selected Materials and Manufacturing as a strategic area for investment. • $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 CFI investment at McMaster by Strategic Area Materials and Manufacturing 31.44 Environment 0.3275 and Health 0.393 Globalization Information technology 15.72 Molecular biology Work and Society 9.825 6.55 1.31 Other

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 140 120 100 80 60 40 20 0 1999 2000 2001 2002 2003 2004 Masters PhD's Post Docs Internships Total

Scope of Research Machining Metal Forming • Intelligent Machining Systems: Sensors, Monitoring, • Sheet Metal Forming and Controls • Hydro Forming • Predictive Modeling of Machining Processes • Process Modeling • High Speed Machining Technologies • Material evaluation • Machine Tools: Design, Dynamics, Accuracy, and Controls • Machinability of Difficult-to-Cut Materials • Process Development and Optimization Robotics & Automation Micro Machining CAD/CAM • Fixtureless Assembly • Surface Engineering • Geometric Modeling • Robotic Deburring, Grinding • Optics • 5-Axes Tool Path Planning • Vision Based Registration • Micro Components • Advanced CMM Systems • Fixturing • 2 Dimensional Patterns • Tool simulation • 3 Dimensional Objects Polymer Processing Thermal processing • Injection moulding • Design and modeling of thermal • Extrusion and fluid flow systems • Process Modelling •Combustion engineering • Material Characterization •Boiling heat transfer • Advanced part design •Jet cooling •Cooling of electronic systems

Areas of Interest: Faculty: •Machining Systems • Mo Elbestawi •Machine Tool Design • Steve Veldhuis •Modeling •Sensors and Controls • Phil Koshy

Areas of Interest: Faculty •Polymer Processing • Andy Hrymak •Rheology •Physical Property Testing • John Vlachopolous •Mechanical Property Testing • Mike Thompson

Areas of Interest: Faculty •Sheet Metal Forming Processes • Mukesh Jain •Tube Forming •Modeling •Form Strain Measurement

Areas of Interest: Faculty •Automated Robotic Deburring • Gary Bone •Inspection Using Machine Vision •Robotic Servo Grippers •Robotic Fixtureless Assembly

Areas of Interest: •Modeling of micro cutting Faculty •Surface engineering • Steve Veldhuis •Simulation and optimization •Micro-Machine Accuracy •Micro-Machine tool design •Micro metrology

Areas of Interest: •Thermal processing of materials Faculty •Combustion engineering •Boiling heat transfer • Mohamed Hamed •Jet cooling •Neural networks modeling •Cooling of electronic systems

Automotive Research McMaster Centre for

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 over 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 : the opportunity to prepare pilot-scale quantities of materials requiring specialized or 1. unique equipment an expert team of operators 2. the opportunity to conduct research at a reduced cost 3. safe operating conditions for pilot-scale work not available in universities. 4.

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