Northwestern University Robert R. McCormick School of Engineering and Applied Science

Advanced Manufacturing Processes Laboratory

Refereed Journal Articles

Additive Manufacturing

  1. Webster, S., Giovannini, M., Shi, Y., Martinez-Prieto, N., Fezzaa, K., Sun, T., Ehmann, K., and Cao, J. (2022) “High-throughput, In-situ Imaging of Multi-layer Powder-blown Directed Energy Deposition with Angled Nozzle”, Review of Scientific Instruments, Vol.93(2), https://doi.org/10.1063/5.0077140

  2. Liao, S., Webster, S., Huang, D., Council, R., Ehmann, K. and Cao, J. (2022) “Simulation-guided Variable Laser Power Design for Melt Pool Depth Control in Directed Energy Deposition”, Additive Manufacturing, https://doi.org/10.1016/j.addma.2022.102912.

  3. Fang, L., Cheng, L., Glerum, J., Bennett, J., Dunand, D., Cao, J. and Wagner, G. (2022) “Data-driven analysis of process, structure, and properties of additively manufactured Inconel 718 thin walls”, npj Computational Materials, Vol. 8:126, https://doi.org/10.1038/s41524-022-00808-5.

  4. Bennett, J., Webster, S., Byers, J., Johnson, O., Wolff, S., Ehmann, K. and Cao, J. (2022) “Powder-borne porosity in directed energy deposition”, Manufacturing Processes, Vol. 80, pp. 69-74, https://doi.org/10.1016/j.jmapro.2022.04.036.

  5. Kozjek, D., Carter, F., Porter, C., Mogonye, J.E., Ehmann, K. and Cao, J. (2022), “Data-driven prediction of next-layer melt pool temperatures in laser powder bed fusion based on co-axial high-resolution Planck thermometry measurements”, Manufacturing Processes, Vol. 79, pp.81-90, https://doi.org/10.1016/j.jmapro.2022.04.033.

  6. Lindenmeyer, S. Webster, M. F. Zaeh, K. F. Ehmann, and J. Cao, “Template-bayesian approach for the evaluation of melt pool shape and dimension of a DED-process from in-situ X-ray images,” CIRP Ann., vol. 70, no. 1, pp. 183–186, 2021, doi: 10.1016/j.cirp.2021.03.011

  7. Xie, X., Bennett, J., Saha, S., Lu, Y., Cao, J., Liu, W.K. and Gan, Z. (2021) “Mechanistic Data-driven Prediction of as-built Mechanical Properties in Metal Additive Manufacturing”, npj Computational Materials, Vol. 7, 86, https://doi.org/10.1038/s41524-021-00555-z.

  8. Bennett, J., Glerum, J. and Cao, J. (2021) “Relating additively manufactured part tensile properties to thermal metrics”, CIRP Annals, Vol. 70(1), pp. 187-190, https://doi.org/10.1016/j.cirp.2021.04.053.

  9. Bennett, J., Liao, H.G., Buergel, T., Hyatt, G., Ehmann, K. and Cao, J. (2021) “Towards Bi-metallic Injection Molds by Directed Energy Deposition”, Letters, Vol. 27, Pages 78-81. https://doi.org/10.1016/j.mfglet.2021.01.001.

  10. Webster, S., Lin, H., Carter, F., Ehmann, K. and Cao, J. (2021) “Physical Mechanisms in Hybrid Additive Manufacturing: A Process Design Framework”, Materials Processing Technology, Vol. 291, 117048. https://doi.org/10.1016/j.jmatprotec.2021.117048.

  11. Glerum, J., Bennett, J., Ehmann, K. and Cao, J. (2021) “Mechanical Properties of Hybrid Additively Manufactured Inconel 718 Parts Created via Thermal Control after Secondary Treatment Processes”, Materials Processing Technology, Vol. 291, 117047. https://doi.org/10.1016/j.jmatprotec.2021.117047.

  12. Mozaffar, M., Liao, S., Lin, H., Ehmann, K., & Cao, J. (2021). Geometry-Agnostic Data-Driven Thermal Modeling of Additive Manufacturing Processes using Graph Neural Networks. Additive Manufacturing, 102449.

  13. Webster, S. Wolff, N. D. Parab, B. Aronson, B. Gould, A. Greco, T. Sun, “In-situ Observations of Directed Energy Deposition Additive Manufacturing Using High-Speed X-ray Imaging,” JOM, no. In Situ Synchrotron and Neutron Characterization of Additively Manufactured Alloys, Nov. 2020, doi: 10.1007/s11837-020-04469-x.

  14. Cheng, P., Liu, W. K., Ehmann, K. and Cao, J. (2020) “Enumeration of Additive Manufacturing Toolpaths Using Hamiltonian Paths”, Letters, Vol. 26, 29-32, https://doi.org/10.1016/j.mfglet.2020.09.008.

  15. Bennett, J., Garcia, D., Kendrick, M., Hartman, T., Hyatt, G., Ehmann, K.F., You, F., Cao, J. (2019) “Repairing Automotive Dies with Directed Energy Deposition: Industrial Application and Life Cycle Analysis”, ASME Journal of Manufacturing Science and Engineering, 141(2),021019, https://doi.org/10.1115/1.4042078.

  16. Gan, Z., Li, H., Woff, S.J., Bennett, J.L., Hyatt, G., Wagner, G.J., Cao, J., Liu, W.K. (2019) “Data-Driven Microstructure and Microhardness Design in Additive Manufacturing Using a Self-Organizing Map,” Engineering, https://doi.org/10.1016/j.eng.2019.03.014

  17. Wolff, S.J., Gan, Z., Lin, S., Bennett, J.L., Yan, W., Hyatt, G., Ehmann, K.F., Wagner, G.J., Liu, W.K., Cao, J., (2019) “Experimentally validated predictions of thermal history and microhardness in laser-deposited Inconel 718 on carbon steel,” Additive Manufacturing, Vol. 27, p.540-551, https://doi.org/10.1016/j.addma.2019.03.019.

  18. Mozaffar, M., Ndip-Agbor, E., Lin, S., Wagner, G., Ehmann, K., Cao, J. (2019) “Acceleration strategies for explicit finite element analysis of metal powder‑based additive manufacturing processes using graphical processing units”, Computational Mechanics, Vol. 64, pp. 879-894, https://doi.org/10.1007/s00466-019-01685-4.

  19. Wolff, S., Wu, H., Parab, N., Zhao, C., Ehmann, K, Sun, T. and Cao, J. (2019) “In-situ high-speed X-ray imaging of piezo-driven directed energy deposition additive manufacturing”, Scientific Reports, 9:962, DOI:10.1038/s41598-018-36678-5.

  20. Garcia, D.J., Mozaffar, M., Ren, H., Correa, J. E., Ehmann, K., Cao, J. and You, F. (2019) “Sustainable Manufacturing with Cyber-Physical Discrete Manufacturing Networks: Overview and Modeling Framework”, ASME J. of Manufacturing Science and Engineering, Vol. 141(2), 021013, 10.1115/1.4041833.

  21. Mozaffar, M., Paul, A., Al-Bahrani, R., Wolff, S., Choudhary, A., Agrawal, A., Ehmann, K. and Cao, J. (2018) “Data-Driven Prediction of the High-Dimensional Thermal History in Directed Energy Deposition Processes via Recurrent Neural Networks”, Manufacturing Letter, Vol. 18, pp.35-39, https:// doi.org/10.1016/j.mfglet.2018.10.002.

  22. Pritchet, D., Moser, N., Ehmann, K., Cao, J. and Huang, J. (2018) “Quantifying discretization errors in electrophoretically-guided micro additive manufacturing”, Micromachines, Vol. 9, pp. 447, doi:10.3390/mi9090447.

  23. Martinez-Prieto, N., Fratta, G., Cao, J. and Ehmann, K. F. (2018) “Deposition of variable bead diameter arrays by self-focusing electrohydrodynamic jets," ASME Journal of Micro and Nano-Manufacturing, Vol. 6(3), 031003 (11 pages), doi:10.1115/1.4040450.

  24. Yan, W.T., Lin, S., Kafka, O.L., Lian, Y.P., Yu, C., Liu, Z.L., Yan, J.H., Wolff, S., Wu, H., Ndip-Agbor, E., Mozaffar, M., Ehmann, K., Cao, J., Wagner, G., Liu, W.K. (2018) “Data-driven multi-scale multi-physics models to derive process-structure-property relationships for additive manufacturing”, Computational Mechanics, https://doi.org/10.1007/s00466-018-1539-z

  25. Yan, W., Lin, S., Kafica, O.L., Yu, C., Liu, Z., Lian, Y., Wolff, S., Cao, J., Wagner, G.J., Liu, W.K. (2018) “Modeling process-structure-property relationships for additive manufacturing”, Frontiers of Mechanical Engineering, February 12, 2018, pp. 1-11

  26. Wolff, S. J., Lin, S., Faierson, E. J., Liu, W. K., Wagner, G. L., & Cao, J. (2017). A framework to link localized cooling and properties of directed energy deposition (DED)-Processed Ti-6Al-4V. Acta Materialia. https://doi.org/10.1016/j.actamat.2017.04.027

  27. Bennett, J.L.*, Wolff, S.J.*, Hyatt, G., Ehmann, K., and J. Cao, (2017) “Thermal effect on clad dimension for laser deposited Inconel 718”, Journal of Manufacturing Processes, Vol. 28(3), pp. 550-557, https://doi.org/10.1016/j.jmapro.2017.04.024.

  28. Wolff, S., Lee, T., Faierson, E., Ehmann, K. and Cao, J. (2016) “Anisotropic Properties of Directed Energy Deposition (DED)-Processed Ti-6Al-4V”, Journal of Manufacturing Processes, Vol. 24(2), pp.397-405, http://dx.doi.org/10.1016/j.jmapro.2016.06.020.

  29. Smith, J., Cao, J., Liu, W.K. (2016) "Computational Challenges and Future Research Directions in Additive Manufacturing,” IACM Expression, 38, 2-5.

  30. Smith, J., Xiong, W., Yan, W., Lin, S., Cheng, P., Kafka, O.L., Wagner, G.J., Cao, J., Liu, W.K. (2016) Linking process, structure, property, and performance for metal-based additive manufacturing: computational approaches with experimental support”, Computational Mechanics, DOI:10.1007/s00466-015-1240-4.

  31. Smith, J., Xiong, W., Cao, J. and Liu, W.K. (2016) "Thermodynamically Consistent Microstructure Prediction of Additively Manufactured Materials”, Computational mechanics, DOI:10.1007/s00466-015-1243-1, ISSN 0178-7675.

  32. Martinez-Prieto, N., Abecassis, M., Xu J., Guo, P., Cao, J., Ehmann, K. (2015) "Design of a Near-Field Electrospinning Setup for Precise Deposition of Nanofibers", ASME. J. Micro Nano-Manuf. 2015; doi:10.1115/1.4031491. 

  33. Martinez-Prieto N, Abecassis M, Xu J, Guo P, Cao J, Ehmann K. (2015) "Feasibility of Fiber-Deposition Control by Secondary Electric Fields in Near-Field Electrospinning" ASME. J. Micro and Nano-Manuf, Vol. 4(1), doi:10.1115/1.4031491 [link]

Composite Sheet Forming

  1. Rout, S., Bisram, M. and Cao, J. (2022) ‘Methods for Numerical Simulation of Knit Based Morphable Structures: KnitMorphs”, Scientific Reports, 12:6630, https://doi.org/10.1038/s41598-022-09422-3.

  2. Bruschi, S., Cao, J., Merklein, M. and Yanagimoto, J. (2021) “Forming of Metal-based Composites Parts”, CIRP Annals, Vol. 70(2), https://doi.org/10.1016/j.cirp.2021.05.009.

  3. Liang, B., Zhang, W.Z., Fenner, J.S., Gao, J.Y., Shi, Y., Zeng, D., Su, X.M., Liu, W.K., Cao, J. (2019) “Multi-scale modeling of mechanical behavior of cured woven textile composites accounting for the influence of yarn angle variation”, Composites Part A, Vol. 124, 105460, 10.1016/j.compositesa.2019.05.028.

  4. Zhang, W.*, Bostanabad, R.*, Liang, B., Su, X., Zeng, D., Bessa, M.A., Wang, Y., Chen, W., and Cao, J. (2019) “A Numerical Bayesian-Calibrated Characterization Method for Multiscale Prepreg Preforming Simulations with Tension-Shear Coupling”, Composites Science and Technology, Vol. 170, pp. 15-24, https://doi.org/10.1016/j.compscitech.2018.11.019.

  5. Bostanabad, R. Liang, B., Gao, J., Liu, W. K., Cao, J. Zeng, D., Su, X., Xu, H., Li, Y. and Chen, W. (2018) “Uncertainty quantification in multiscale simulation of woven fiber composites”, Computer Methods in Applied Mechanics and Engineering, Vol. 338 (15), pp. 506-532, https://doi.org/10.1016/j.cma.2018.04.024.

  6. Zhang W, Ma X, Lu J, Zhang Z, Wang Q, Su X, Zeng D, Mirdamadi M, Cao J, (2018) Experimental Characterization and Numerical Modeling of the Interaction Between Carbon Fiber Composite Prepregs During a Preforming Process. ASME. J. Manuf. Sci. Eng. 2018; doi:10.1115/1.4039979.

  7. Zhang, W., Ren, H., Liang, B., Zeng, D., Su, X., Dahl, J., and Cao, J. (2017). A non-orthogonal material model of woven composites in the preforming process. CIRP Annals - Manufacturing TechnologyDOI: 10.1016/j.cirp.2017.04.112

  8. Lee, W., Um, M.K., Boisse, P. and Cao, J. (2010) “Numerical study on thermo-stamping of woven fabric composites based on double-dome stretch forming”, International Journal of Material Forming, Vol. 3(2), 1217-1227. [link]

  9. Sargent, J., Chen, J., Sherwood, J., Cao, J., Boisse, P., Willem, A., Vanclooster, K.,  Lomov, S.V., Khan, M., Mabrouki, T., Fetfatsidis, K., Jauffrès, D. (2010) “Benchmark study on finite element models for simulating the thermostamping of woven-fabric reinforced composites”, International Journal of Material Forming, Vol. 3(1), 683-686, [link]

  10. Lee, W., Um, M.K., Boisse, P. and Cao, J. (2009) “Numerical study on thermo-stamping of woven fabric composites based on double-dome stretch forming”, International Journal of Material Forming, Vol 3(2), pp. 1217-1227, DOI: 10.1007/s12289-009-0668-5.[link]

  11. Cao, J., Akkerman, R., Boisse, P., Chen, J.,Cheng, H.S., de Graaf, e.F., Gorczyca, J.L., Hivet, G., Launay, J., Lee, W., Liu, L., Lomov, S.V., de Luycker, E., Morestin, F., Padvoiskis, J., Peng, J. Sherwood, X.Q., Stoilova, T., Tao, X.M., Verpoest, I., Willems, A., Yu, T.X., and Zhu, B. (2008) “Characterization of Mechanical Behavior of Woven Fabrics: Experimental Methods and Benchmark Results”, Composites: Part A, pp.1037-1053. [link]

  12. Boisse, P., Hamila, N., Helenon, F., Hagege, B. and Cao, J. (2008) “Different Approaches for Woven Composite Reinforcement Forming Simulation”, International Journal of Material Forming, Vol.1, pp.21-29. [link]

  13. Hang Shawn Cheng, Jian Cao, Numpon Mahayotsanun (2006) “Experimental Study on Behavior of Woven Composites in Thermo-stamping under Nonlinear Temperature Trajectories”, International Journal of Forming Processes, Vol.8, pp.1-12.

  14. Xue, P., Cao, J. and Chen, J. (2005) “Integrated micro/macro mechanical model of woven fabric composites under large deformation”, Composite Structures, Vol. 70, pp.69-80. [link]

  15. Peng, X.Q. and Cao, J. (2005) “A continuum mechanics based non-orthogonal constitutive model for woven composites”, Composites: Part A Applied Science and Manufacturing, Vol. 36(6), pp. 859-874. [link]

  16. Peng, X.Q., Cao, J., Chen, J., Xue, P., Luisser, D.S. and. Liu, L. (2004) “Experimental and numerical analysis on normalization of picture frame tests for composite materials”, Composites Science and Technology, Vol. 64, pp.11-21. [link]

  17. Cao, J., Xue, P., Peng, X.Q. and Krishnan, N (2003) “An approach in modeling the temperature effect in thermo-forming of woven composites”, Composite Structures, Vol. 61(4), pp.413-420. [link]

  18. Xue, P., Peng, X.Q. and Cao, J. (2003) “A non-orthogonal constitutive model for characterizing woven composites11:19 AM 3/18/2010”, Composites: Part A, Vol 34/2, pp. 183-193. [link]

  19. Peng, X.Q. and Cao, J (2002) "A dual homogenization and Finite Element approach for material characterization of textile composites ", Composites Part B, Vol. 33 (1),pp 45-56. [link]

  20. Chen, J., Lussier, D.S., Cao, J. and Peng, X.Q. (2001) "The relationship between materials characterization methods and material models for stamping of woven fabric/thermoplastic composites", International Journal of Forming Processes, Vol. 4(3), pp. 269-294.

Incremental Forming

  1. Leem, D., Liao, S., Bhandari, S., Wang, Z., Ehmann, K. and Cao, J. (2022) “A toolpath strategy for double-sided incremental forming of corrugated structures”, Materials Processing Technology, https://doi.org/10.1016/j.jmatprotec.2022.117727

  2. Jiang, Z.L., Liao, S., Slocum, A.H., Leem, D., Ehmann, K.F. and Cao, J. (2022) “Toolpath planning for manufacturing of complex parts through incremental sheet forming”, ASME Open Journal of Engineering

  3. Jiang, Z.L., Ehmann, K. and Cao, J. (2022) “Prediction of forming temperature in electrically-assisted double-sided incremental forming using a neural network”, Materials Processing Technology, https://doi.org/10.1016/j.jmatprotec.2021.117486

  4. Moser, Newell, et al. "A high-fidelity simulation of double-sided incremental forming: Improving the accuracy by incorporating the effects of machine compliance." Journal of Materials Processing Technology 295 (2021): 117152. https://www.sciencedirect.com/science/article/pii/S0924013621001126

  5. Moser, N., Leem, D., Ehmann, K and Cao, J (2021) “A High-Fidelity Finite Element Model for Quantifying the Stress Triaxiality and Lode Angle Parameter in Double-Sided Incremental Forming”, Materials Processing Technology, Vol. 295, 117152, https://doi.org/10.1016/j.jmatprotec.2021.117152

  6. Shi, Y. Zhang, W.Z., Cao, J. and Ehmann, K. F. (2019) “Experimental study of water jet incremental micro-forming with supporting dies”, J. Materials Processing Technology, Vol. 268, pp. 117-131, https://doi.org/10.1016/j.jmatprotec.2019.01.012

  7. Shi, Y., Zhang, W., Cao, J., Ehmann, K.F. (2019) “An Experimental and Numerical Study of Dieless Water Jet Incremental Microforming”, ASME Journal of Manufacturing Science and Engineering, 141(4),041008, https://doi.org/10.1115/1.4042790.

  8. Zhang, H., Ren, H., Chen, J. and Cao, J. (2019) “Global-cumulative incremental hole-flanging by tools with complementary-shape cross section”, Int. J. Materials Forming, vol. 12, pp.899-906, https://doi.org/10.1007/s12289-018-01460-5

  9. Ren, H., Xie, J., Liao, S., Leem, D., Ehmann, K. and Cao, J. (2019) “In-situ springback compensation in incremental sheet forming”, CIRP Annals, Vol. 68(1), pp. 317-320, https://doi.org/10.1016/j.cirp.2019.04.042

  10. Ndip-Agbor, E. E., Cheng, P., Moser, N., Ehmann, K. and Cao, J. (2019) “Prediction of Rigid Body Motion in Multi-Pass Single Point Incremental Forming”, Journal of Materials Processing Technology, Vol. 269, pp. 117-127, doi.org/10.1016/j.jmatprotec.2019.02.007

  11. Zhang, X., He, T., Miwa, H., Nanbu, T., Murakami, R., Liu, S., Cao, J. and Wang, Q. J. (2019) “A new approach for analyzing the temperature rise and heat partition at the interface of coated tool tip-sheet incremental forming systems”, Int. J. of Heat and Mass Transfer, Vol. 129, 1172–1183, https://doi.org/10.1016/j.ijheatmasstransfer.2018.10.056.

  12. Ren, H., Li, F., Moser, N., Leem, D., Li, T., Ehmann, K. and Cao, J. (2018) “General contact force control algorithm in double-sided incremental forming”, CIRP Annals, Vol. 67(1), pp. 381-384, https://doi.org/10.1016/j.cirp.2018.04.057

  13. Zhang, H., Zhang, Z.X., Ren, H.Q., Cao, J. and Chen J. (2018) “Deformation mechanics and failure mode in stretch and shrink flanging by double-sided incremental forming”, Int. J. Mechanical Sciences, Vol. 144, 216-222, https://doi.org/10.1016/j.ijmecsci.2018.06.002

  14. Duflou, J.R., Habraken A.M., Cao, J., Malhotra, R., Bambach M., Adams D., Vanhove, H., Mohammadi A. and Jeswiet J. (2018) “Single point of incremental forming: state-of-the-art and prospects”, Int. J. of Material Forming, Vol. 11(6), pp. 743-773, https://doi.org/10.1007/s12289-017-1387-y.

  15. Ndip-Agbor, E. E., Ehmann, K. and Cao, J. (2018) “Automated flexible forming strategy for geometries with multiple features in double-sided incremental forming”, ASME J. of Manufacturing Science and Engineering, Vol. 140(3), 0310041, DOI: 10.1115/1.4038511.

  16. Cao, T., Lu, B., Cao, J. and Chen, J. (2017) “Experimental investigations on the forming mechanism of a new incremental stretch-flanging strategy with a featured tool”, Int. J. Advanced Manufacturing Technology, Vol. 92(5-8), pp.2953-2964, http://dx.doi.org/10.1007/s00170-017-0355-5

  17. Valoppi, B., Egea, A.J.S., Zhang, Z.X., Rojas, H.A.G., Ghiotti, A., Bruschi, S. and Cao, J. (2016) A Hybrid Mixed Double-Sided Incremental Forming Method for Forming Ti6Al4V Alloy”, CIRP Annals, Vol. 66 (1), 10.1016/j.cirp.2016.04.135

  18. Xu, D.K., Lu, B., Cao, T.T., Zhang, H., Chen, J., Long, H. and Cao, J. (2016) “Enhancement of Process Capabilities in Electrically-assisted Double Sided Incremental Forming”, Materials and Design, Vol. 92, pp. 268-280, http://dx.doi.org/10.1016/j.matdes.2015.12.009

  19. Davarpanah, M.A., Zhang, Z.X., Bansal, S., Cao, J. and Malhotra, R. (2016) “Preliminary Investigations on Double Sided Incremental Forming of Thermoplastics”, Manufacturing Letters, Vol. 8, pp.21-26, http://dx.doi.org/10.1016/j.mfglet.2016.05.003

  20. Moser, N., Pritchet, D., Ren, H.Q., Ehmann, K.F. and Cao, J. (2016) “An efficient and general finite element model for double-sided incremental forming”, ASME J. of Manufacturing Science and Engineering, Vol. 138, September, 091007 (10 pages), doi:10.1115/1.4033483

  21. Zeng, Q., Ehmann, K.F. and Cao, J. (2016) Design of General Kinematrotropic Mechanisms”, Robotics and Computer-Integrated Manufacturing, Vol. 38, pp.67-81, http://dx.doi.org/10.1016/j.rcim.2015.10.005.

  22. Moser, N., Zhang, Z.X., Ren, H., Zhang, H., Shi, Y., Ndip-Agbor, E. E., Lu, B., Chen, J., Ehmann, K. and Cao, J. (2016) Effective Forming Strategy for Double-Sided Incremental Forming Considering In-plane Curvature and Tool Direction”, CIRP Annals, Vol. 66 (1), 10.1016/j.cirp.2016.04.131.

  23. Zeng, Q., Ehmann, K.F. and Cao, J. (2016) “Design of General Kinematrotropic Mechanisms”, Robotics and Computer-Integrated Manufacturing, Vol. 38, pp.67-81, http://dx.doi.org/10.1016/j.rcim.2015.10.005.

  24. Zeng, Q., Ehmann, K.F. and Cao, J. (2016) “Tri-pyramid Robot: Stiffness Modeling of a 3-DOF Translational Parallel Manipulator”, Robotica, DOI: 10.1017/S0263574714001520, Vol. 34(2), pp. 383-402.

  25. Zhang, Z., Ren, H., Xu, R., Moser, N., Smith, J., Ndip-Agbor, E., Malhotra, R., Xia, Z.C., Ehmann, K.F. and Cao, J. (2015) A Mixed Double-Sided Incremental Forming Toolpath Strategy for Improved Geometric Accuracy”, ASME Journal of Manufacturing Science and Engineering, Vol.137(5), 051007 (7 pages), doi: 10.1115/1.4031092.

  26. Cao, T.T., Lu, B., Xu, D.K., Zhang, H., Chen, J., Long, H. and Cao, J. (2015) An efficient method for thickness prediction in multi-pass incremental sheet forming”, Int. J. Advanced Manufacturing Technology, Vol. 77(1-4), pp. 469-483., DOI 10.1007/s00170-014-6489-9.

  27. Lu, B., Fang, Y., Xu, D.K., Chen, J., Ai, S., Long, H., Ou, H. and Cao, J (2015) Investigation of material deformation mechanism in double side incremental sheet forming”, Int. J. Machine Tools and Manufacture, Vol.93, pp.37-48, doi:10.1016/j.ijmachtools.2015.03.007.

  28. Ndip-Agbor, E.E., Smith, J., Ren H., Jiang, Z., Moser, N., Chen, W. Xia, Z.C. and Cao, J. (2015) Optimization of Relative Tool Position in Accumulative Double Sided Incremental Forming using Finite Element Analysis and Model Bias Correction”, Int. J. Material Forming, DOI:10.1007/s12289-014-1209-4.

  29. Moser, N., Ndip-agbor, E., Ren, H., Zhang, Z., Ehmann, K., & Cao, J. (2015). Challenges and Process Strategies Concerning Multi-Pass Double Sided Incremental Forming. Key Engineering Materials, 651-653, 1122–1127. doi:10.4028/www.scientific.net/KEM.651-653.1127. 

  30. Lu, B., Chen, J., Ou, H. and Cao, J. (2013) “Feature-Based Tool Path Generation Approach for Incremental Sheet Forming Process”, Journal of Materials Processing Technology, Vol. 213(7), pp. 1221-1233, DOI:10.1016/j.bbr.2011.03.023. [link]

  31. Smith, J. L., Malhotra, R., Liu, W.K. and Cao, J. (2013) “Deformation Mechanics in Single Point and Accumulative Double-Sided Incremental Forming”, International Journal of Advanced Manufacturing Technology, Vol. 69 (5-8), pp 1185-1201, DOI: 10.1007/s00170-013-5053-3. [link]

  32. Xu, D.K; Wu, W.C., Malhotra, R., Chen, J., Lu, B. and Cao, J. (2013) “Mechanism Investigation for the Influence of Tool Rotation and Laser Surface Texturing (LST) on Formability in Single Point Incremental Forming”, International Journal of Machine Tools and Manufacture, Vol. 73, pp. 37-46, DOI: 10.1016/j.ijmachtools.2013.06.007. [link]

  33. Beltran, M., Malhotra, R., Nelson, A.J., Bhattacharya, A., Reddy, N.V., and Cao, J. (2013) "Experimental study of failure modes and scaling effects in micro-incremental forming", ASME Journal of Micro- and Nano-manufacturing, Vol 1(3) DOI: 10.1115/1.4025098. [link]

  34. Xu, R., Shi, X.T., Xu, D.K, Malhotra, R. and Cao, J. (2013) “A preliminary study on the fatigue behavior of sheet metal parts formed with accumulative-double-sided incremental forming”, Manufacturing Letters, Vol. 2(1), pp. 8-11, DOI: 10.1016/j.mfglet.2013.10.009. [link]

  35. Agrawal, A., Ziegert, J., Smith, S., Woody, B. and Cao, J. (2012) “Study of Dimensional Repeatability and Fatigue Life for Deformation Machining Bending Mode”, ASME Journal of Manufacturing Science and Engineering, Vol 134(6), DOI:10.1115/1.4007716. [link]

  36. Xu, D.K., Malhotra, R., Cao, J., Reddy, N.V. and Chen, J. (2012) “Analytical Prediction of Stepped Feature Generation in Multi-pass Single Point Incremental Forming”, Journal of Manufacturing Processes, Vol.14(4), pp.487-494, DOI:10.1016/j.jmapro.2012.08.003. [link]

  37. Dittrich, M.A., Gutowski, T.G., Cao. J, Roth, J.T., Xia, Z.C., Kiridena, V., Ren, F., Henning, F. (2012) “Exergy Analysis of Incremental Sheet Forming”, Production Engineering Research & Development, Vol. 6, pp. 69–177. [link]

  38. Malhotra, R., Xue, L, Belytschko, T., Cao, J. (2012) “Prediction and Analysis of Fracture in Single Point Incremental Forming using a Damage based Material Model”, Journal of Materials Processing Technology, Vol. 212, pp. 1573-1590. [link]

  39. Malhotra, R., Cao, J., Beltran, M., Xu, D., Magargee, J., Kiridena, V., Xia, Z.C. (2012) “Accumulative-DSIF Strategy for Enhancing Process Capabilities in Incremental Forming”, CIRP Annals, Vol.61/1. [link]

  40. Malhotra, R., Cao, J., Ren, F., Kiridena, V., Xia, Z.Cedric. and Reddy, N.V. (2011) ”Improvement of geometric accuracy in Incremental Forming by using a Squeezing Toolpath With Two Forming Tools”,  ASME Journal of Manufacturing Science and Engineering, Vol. 133(6), 061019, [link]

  41. Bhattacharya, A., Maneesh, K., Reddy, N.V. and Cao, J. (2011) “Formability and surface finish studies in single point incremental forming”, ASME Journal of Manufacturing Science and Engineering, Vol. 133(6), 061020, [link]

  42. Malhotra, R., Bhattacharya, A., Kumar, A., Reddy, N.V. and Cao, J. (2011) “A New Methodology for Multi-Pass Single Point Incremental Forming with Mixed Toolpaths”, CIRP Annals, Vol.60/1. [link]

  43. Malhotra, R., Reddy, N.V. and Cao, J. (2010) “Automatic Spiral Toolpath Generation for Single Point Incremental Forming”, ASME Journal of Manufacturing and Science Engineering, Vol. 132(6), 061003, [link].

Machining

  1. Zhang, Y., Bhandari, S., Xie, J., Zhang, G., Zhang, Z., & Ehmann, K. (2021) "Investigation of the Capabilities of Transverse Magnetic Field Controlled Laser-Induced Plasma Micro-Machining", ASME. J. Manuf. Sci. Eng., 143(6): 061002. https://doi.org/10.1115/1.4049091

  2. Bhandari, S., Martinez-Prieto, N., Cao, J., & Ehmann, K. (2020). "Surface Morphology and Wall Angle Comparison of Microchannels Fabricated in Titanium Alloy Using Laser-Based Processes", ASME. J. Micro Nano-Manuf., 8(2): 021001. https://doi.org/10.1115/1.4046283

  3. Zhang, Y., Liu, Y., Bhandari, S., Zhang, G., Deng, J., Zhang, Z., & Ehmann, K. (2020) "Investigation of the Capabilities of Transverse Magnetic Field Controlled Laser-Induced Plasma Micro-Machining", ASME. J. Manuf. Sci. Eng., 143(6): 061002. https://doi.org/10.1115/1.4049091

  4. Xie, J., Ehmann, K. and Cao, J. (2020) “Simulation of Ultrashort Laser Pulse Absorption at the Water-Metal Interface in Laser-Induced Plasma Micro-Machining (LIPMM)”, ASME of Micro- and Nano-Manufacturing, https://doi.org/10.1115/1.4049360

  5. Giovannini, M., Cao, J., Ehmann, K. (2019) “Design and models of helical needle geometries for core biopsies”, Journal of the Mechanical Behavior of Biomedical Materials, Vol. 90, pp. 113-124, https://doi.org/10.1016/j.jmbbm.2018.09.036.

  6. Yuan, Y., Zhang, D., Jing, X., Zhu, H., Zhu, W.L., Cao, J., Ehmann, K.F. (2019) “Fabrication of hierarchical freeform surfaces by 2D compliant vibration-assisted cutting”, Int. J. Mechanical Sciences, 152, pp. 454-464, https://doi.org/10.1016/j.ijmecsci.2018.12.051.

  7. Giovannini, M., Ren, H., Cao, J. and Ehmann, K. F. (2018) “Study on design and cutting parameters of rotating needles for core biopsy”, J. of the Mechanical Behavior of Biomedical Materials, Vol. 86, pp. 43-54, https://doi.org/10.1016/j.jmbbm.2018.06.013

  8. He, Y., Zhou, P., Zhu, Z., Zhu, W.-L., Yang, X., Cao, J and Ehmann, K.F. (2018) “Design and application of a flexure-based oscillation mechanism”, J. Manufacturing Processes, Vol. 32, pp. 298-306, DOI: 10.1016/j.jmapro.2018.02.017. 

  9. Yuan, Y., Jing, X., Ehmann, K.F., Cao, J., Li, H., Zhang, D. (2018) “Modeling of cutting forces in micro end-milling”, J. Manufacturing Processes, Vol. 31, pp. 844-858. DOI: 10.1016/j.jmapro.2018.01.012.

  10. Zhu, Zhiwei, To, Suet, Ehmann, Kornel, and Xiao, Gaobo, (2015) A novel diamond micro-/nano-machining process for the generation of hierarchical micro-/nano-structures , Journal of Micromechanics and Microengineering

  11. Che, D, Zhu, W., and Ehmann, K., (2015) Chipping and crushing mechanisms in orthogonal rock cutting . J. Rock Mechanics and Rock Engineering.

  12. Zhang, X., Ehmann, K., Yu, T., Wang, W., (2015) Cutting Forces in Micro-End-Milling Processes , International Journal of Machine Tools & Manufacture

  13. Zhu, W. -L., He, Y, Ehmann, K., and Ju, B. -F., (2015) Modeling of the Effect of Machining Parameters on Cutting Performance in 2D Inclined Elliptical Vibration Cutting , International Journal of Machine Tools & Manufacture

  14. Zhu, Zhiwei, To, Suet, Xiao, Gaobo, Ehmann, Kornel, and Guoqing Zhang, (2015) Rotary spatial vibration -assisted diamond cutting of brittle materials , Precision Engineering

  15. Zhu, W. -L., He, Y, Ehmann, K., Antonio J. Sánchez Egea, Wang X., and Ju, B. -F., (2015) Theoretical and experimental investigation on Inclined Ultrasonic Elliptical Vibration Cutting of Alumina ceramics , Journal of Manufacturing Science and Engineering

  16. Zhang, X.,Yu, T., Ehmann, K., Wang, W., (2015) Three-dimensional Process Stability Prediction in Milling of Thin-walled Workpiece , Machining Science and Technology

  17. Che, D., Ehmann, K., and Cao, J., “Analytical modeling of heat transfer in polycrystalline diamond compact cutters in rock turning processes”, Journal of Manufacturing Science and Engineering, 137(3), p. 031005 (2015).

  18. Saxena, I., and Ehmann. K., "Multi-material Capability of Laser Induced Plasma Micromachining." Journal of Micro and Nano-Manufacturing (2014).

  19. Pallav, K., Saxena, I., and Ehmann. K., "Comparative Assessment of the Laser Induced Plasma Micro-machining (LIP-MM) and the Ultra-short Pulsed Laser Ablation Processes." Journal of Micro and Nano-Manufacturing (2014).

  20. Pallav, K., Saxena, I., and Ehmann. K.,"Laser Induced Plasma Micro-machining Process-Principles and Performance." International Journal of Machine Tools and Manufacture (2014).

  21. Wolff, S., and I. Saxena. "A preliminary study on the effect of external magnetic fields on Laser-Induced Plasma Micromachining (LIPMM)." Manufacturing Letters (2014).

  22. Pallav, K., Han, P., Ramkumar, J. and Ehmann, K. F., "Comparative Assessment of the Laser Induced Plasma Micromachining and the Micro-EDM Processes." Journal of Manufacturing Science and Engineering (2014).

  23. Che, D., and Ehmann, K., “Experimental study of force responses in polycrystalline diamond face turning of rock”, International Journal of Rock Mechanics and Mining Sciences, 72, pp. 80-91 (2014).

  24. Pallav, K. "Laser Induced Plasma Micro-machining Process (LIP-MM)." Mechanical Engineering(2013).

  25. Li, L., Li, B., Ehmann, K.F., Li, X., "A thermo-mechanical model of dry orthogonal cutting and its experimental validation through embedded micro-scale thin film thermocouple arrays in PCBN tooling," International Journal of Machine Tools & Manufacture, 70 (2013) 70–87

  26. Werschmoeller, D., Li, X., and Ehmann, K., 2012, "Measurement of transient tool-internal temperature fields during hard turning by insert-embedded thin film sensors," Journal of Manufacturing Science and Engineering, 134(6), p. 061004.

  27. Pallav, K., and Ehmann. K., "Feasibility of Laser Induced Plasma Micro-machining (LIP-MM)." Precision Assembly Technologies and Systems (2010).

Material Characterization

  1. Gao, J., Mojumder, S., Zhang, W., Li, H., Suarez, D., He, C., Cao, J. and Liu, W.K. (2022) “Concurrent n-scale modeling for non-orthogonal woven composite”, Computational Mechanics, https://doi.org/10.1007/s00466-022-02199-2.

  2. Gorji, M. B., Mozaffar, M., Heidenreich, J. N., Cao, J., & Mohr, D. (2020). On the potential of recurrent neural networks for modeling path dependent plasticity. Journal of the Mechanics and Physics of Solids, 143, 103972.

  3. Mozaffar, M., Bostanabad, R., Chen, W., Ehmann, K., Cao, J., and Bessa, M.A. (2019) “Deep learning predicts path-dependent plasticity”, PNAS (Proceedings of the National Academy of Sciences of the United States of America), December 16, 2019, https://www.pnas.org/content/early/2019/12/11/1911815116.

  4. Jiang, Z., Zeng, Q., Anderoglu, O., Maloy, S., Odette, G.R., Ehmann, K.F. and Cao, J. (2019) “Characterization of 14YWT Oxide Dispersion Strengthened Structural Materials under electrically-assisted tension”, Materials Science & Engineering A, Vol. 745, pp. 484-494, https://doi.org/10.1016/j.msea.2018.12.122.

  5. Wang, X, Sánchez Egea, A.J., Xu, J., Meng, X., Wang, Z., Shan, D., Guo, B., Cao, J. (2019) “Current-induced ductility enhancement of a magnesium alloy AZ31 in uniaxial micro-tension below 373 K”, Materials, Vol. 12(1), 111, https://doi.org/10.3390/ma12010111.

  6. Moradi, M., Ng., M.-K., Lee, T., Cao, J. and Picard, Y.N. (2017) “Interface characterization of Al-Cu microlaminates fabricated by electrically assisted roll bonding”, J. Micro and Nano-Manufacturing, Vol. 5(3), 031001, DOI: 10.1115/1.4036149.

  7. Wang, X.W., Xu, J., Shan, De.B., Guo, B. and Cao, J. (2017) “Effects of specimen and grain size on electrically-induced softening behavior in uniaxial micro-tension of AZ31 magnesium alloy: Experiment and modeling”, Materials and Design, Vol. 217, pp.134-132, http://dx.doi.org/10.1016/j.matdes.2017.04.064.

  8. Sánchez Egea, A.J., González Rojas, H.A., Celentano, D.J., Perió, J.J. and Cao, J. (2017) “Thermomechanical analysis of an electrically assisted wire drawing process”, ASME J. of Manufacturing Science and Engineering, Vol. 139(11),No. 111017, http://dx.doi.org/10.1115/1.4037798.

  9. Wang, X.W., Xu, J., Shan, D. Guo, B. and Cao, J. (2016) “Modeling of thermal and mechanical behavior of a magnesium alloy AZ31 during electrically-assisted micro-tension”, Int. J. Plasticity, Vol. 85, pp.230-257, http://dx.doi.org/10.1016/j.ijplas.2016.07.008.

  10. Wang, X.W., Xu, J., Jiang, Z.L., Zhu, W.L., Shan, D.B., Guo, B. and Cao, J. (2016) Size Effects on Flow Stress Behavior during Electrically-assisted Micro-tension in a Magnesium Alloy AZ31”, Materials Science and Engineering: A, Vol. 659, pp. 215-224, 10.1016/j.msea.2016.02.064.

  11. Huang, J., Yuan, Y., Liu, H. and Cao, J. (2016) “Mechanical Behavior Characterization of Magnesium Alloy Sheets at Warm Temperature”, J. Mechanics, Vol. 32(4), pp.391-399, doi.org/10.1017/jmech.2015.101.

  12. Jacob Smith, John A. Moore, Jian Cao, Wing Kam Liu, A General Anisotropic Yield Criterion for Damage-Prone Materials with Sensitivity to Shear Loading”, Journal of the Mechanics and Physics of Solids

  13. Jacob Smith, Wing Kam Liu and Jian Cao, A General Anisotropic Yield Criterion for Pressure-Dependent Materials”, International Journal of Plasticity, doi:10.1016/j.ijplas.2015.08.009 (2015)

  14. Wang, X., Yao, Y., Ulmer, M., Vaynman, S., Graham, M. E., Liu, T., Cao, J., (2015) Characterization of deformation of magnetostrictive coating on glass substrates, Smart materials and structures

  15. Yao, Y., Wang, X., Cao, J. and Ulmer, M. (2015) Stress manipulated coating for fabricating light weight X-ray telescope mirrors”, Optics Express, 23(22), 28605-18. doi: 10.1364/OE.23.028605

  16. Li, Z.F., Ding, W., Cao, J., Ye, L.Y. and Chen, J. (2015) In Situ TEM Observation on Martensitic Transformation during Tensile Deformation of SUS304 Metastable Austenitic Stainless Steel”, Acta Metall. Sin. (Engl. Lett.), Vol. 28(3), pp.302-306, DOI:10.1007/s40195-014-0197-1.

  17. X. Wang, M. Giovannini, Y. Xing, M. Kang, K. Ehmann, “Fabrication and tribological behaviors of corner-cube-like dimple arrays produced by laser surface texturing on medical needles”, Tribology International, submitted (2015).

  18. Xiao, Y.Z., Chen, J., Zhu, X.H. and Cao, J. (2013) “Modified Maximum Mechanical Dissipation Principle for Rate-Independent Metal Plasticity”, ASME Journal of Applied Mechanics, Vol.80(6), DOI: 10.1115/1.4023685. [link]

  19. Fan, R., Magargee, J., Hu, P. and Cao, J. (2013) “Influence of Grain Size and Grain Boundaries on the Thermal and Mechanical Behavior of 70/30 Brass under Electrically-Assisted Deformation”, Materials Science & Engineering A, Vol.574(1), pp.218-225, DOI: 10.1016/j.msea.2013.02.066. [link]

  20. Magargee, J., Morestin, F., and Cao, J. (2013) “Characterization of Flow Stress for Commercially Pure Titanium Subjected to Electrically-Assisted Deformation”, ASME Journal of Engineering Materials and Technologies, Vol.135(4), DOI:10.1115/1.4024394. [link]

Mechanics, Process Design and Control of Forming Process

  1. Jiang, Z.L., Liao, S., Slocum, A.H., Leem, D., Ehmann, K.F. and Cao, J. (2022) “Toolpath planning for manufacturing of complex parts through incremental sheet forming”, ASME Open Journal of Engineering

  2. Li, F., Zeng, Q., Cao, J., Ehmann, K.F., Li, T. (2019) “A calibration method for overconstrained spatial translational parallel manipulators”, Robotics and Computer-Integrated Manufacturing, Vol. 57, 241-254, https://doi.org/10.1016/j.rcim.2018.12.002.

  3. H. Kitano, K. Dohda, M. Kalin, K. F., Ehmann, Galling growth analysis in metal forming, Manufacturing letters, 16, pp. 32-35 (2018). 

  4. T. Aizawa, A. K. Saleh H, N. Takatsuji, K. Dohda,Metal forming simulation by ALE finite element analysis, Research Report, SIT 60(2), pp. 1-10 (2017). 

  5. K. Dohda, N. Mahayotosanun, T. Funazuka, Lubrication & Wear in Sheet Forming, ASM Handbook, Vol. 18. 6D5, pp. 808-816 (2017). 

  6. Wang, X., You, Y., Liu, T.C., Liu, C., Ulmer, M. and Cao, J. (2016) “Deformation of rectangular thin glass plate coated with magnetostrictive material”, Smart Materials and Structures, Vol. 25(8), 085038, http://dx.doi.org/10.1088/0964-1726/25/8/085038

  7. Smith, J., Liu, W. K., Cao, J.  (2015) "A General Anisotropic Yield Criterion for Pressure-Dependent Materials," International Journal of Plasticity, DOI:10.1016/j.ijplas.2015.08.009 [link]

  8. Wang, Z.J, Jin, X.Q., Liu, S.B., Keer, L.M., Cao, J. and Wang, Q. (2013) “A New Fast Method for Solving Contact Plasticity and Its Application in Analyzing Elasto-plastic Partial Slip”, Mechanics of Materials, 60 (2013) pp. 18–35, DOI: 10.1016/j.mechmat.2013.01.001 [link]

  9. Xiao, Y., Chen, J. and Cao, J. (2012) “A Generalized Thermodynamic Approach for Modeling Nonlinear Hardening Behaviors”, International Journal of Plasticity, Vol.38, pp.102-122, DOI: 10.1016/j.ijplas.2012.05.004 [link]

  10. Xu, D.K., Chen, J., Tang, Y.C., Cao, J. (2012) “Topology Optimization of Die Weight Reduction for High-Strength Sheet Metal Stamping”, International Journal of Mechanical Sciences, Vol. 59(1), pp. 73–82, [link]

  11. Yang, Mei, Dong, X.H., Zhou, R. and Cao, J. (2010) "Crystal plasticity-based forming limit prediction for FCC materials under non-proportional strain-path", Materials Science & Engineering A, Vol. 527, 6607–6613. [link]

  12. Zhou, R., Cao, J., Xia, Z.C., Wang, Q. and Alali, I. (2009) “Experimental Analysis of Die Wear in Sheet Metal Forming”, SAE International Journal of Materials and Manufacturing, Vol.2(1), pp. 465-471.

  13. Cao, J., Zhou, R, Wang, Q., Xia, Z.C. (2009) “Strip-on-cylinder test apparatus for die wear characterization”, CIRP Annals, Vol.58/1. [link]

  14. Cao, J., Lee, W. Cheng, H.S., Wang, H. and Chung, K. (2009) “Experimental and Numerical Investigation of Combined Isotropic-kinematic Hardening Behavior”, International Journal of Plasticity. Vol. 25, pp. 942-972.[link]

  15. Chen, W.W., Wang, Q., Wang, F., Keer, L.M., and Cao, J. (2008) "Three-Dimensional Repeated Elasto-Plastic Point Contact, Rolling and Siding," ASME Journal of Applied Mechanics, March, Vol.75. (previously No.2 on Page 2).

  16. Chen, W.W., Liu, Y., Chen, W., Cao, J., Xia, C., and Wang, Q., (2007) "Analysis of Elasto-Plastic Contact with Nominally Flat Surfaces: Average Gap, Contact Area Ratio and Plastic Volume", Tribology Letters, Vol. 28 (1), pp. 27-38.

  17. Buranathiti, T., Cao, J., Chen, W., Xia, Z.C. (2006) “A Weighted Three-Point-Based Methodology for Variance Estimation”, Engineering Optimization, Vol. 38(5), 557 - 576. [link]

  18. Buranathiti, T., Cao, J., Baghdasaryan, L, Chen, W., Xia, Z.C. (2006) “Approaches for model validation in simulating sheet metal flanging processes”, ASME Journal of Manufacturing Science and Engineering, Vol. 128, 588-597.

  19. Shangwu X., Liu, W.K., Cao, J., Li, C.S., Rodrigues, J.M.C. and Martins, P.A.F. (2005) “Simulation of bulk metal forming processes using the Reproducing Kernel Particle Method”, Computers & Structures, Vol. 83, pp. 574-587. [link]

  20. Chen, W., Baghdasaryan, L, Buranathiti, T., Cao, J. (2004) “Model validation via uncertainty propagation and data transformations”, AIAA, Vol. 42(7), pp.1406-1415.

  21. Krishnan, N. and Cao, J. (2003) “Estimation of optimal blank holder force trajectories in segmented binders using an ARMA model”, ASME Journal of Manufacturing Science and Engineering, Vol. 125(4), 763-771. [link]

  22. Shangwu, X., Liu, W.K., Cao, J., Rodrigues J.M.C. and Martins, P.A.F. (2003) “On the utilisation of the reproducing kernel particle method for the numerical simulation of plane strain rolling”, International Journal of Machine Tools and Manufacture, Vol. 43(1), pp.89-102. [link]

  23. Kinsey, B. and Cao, J. (2001) "Enhancement of sheet metal formability via local adaptive controllers", Transactions of the North American Manufacturing Research Institution of SME, Vol. XXIX, pp. 81-88.

  24. Cao, J., Kinsey, B.L., Yao, H., Viswanathan V. and Song, N. (2001) "Next generation stamping dies - flexibility and controllability”, Robotics and Computer-Integrated Manufacturing, Vol.17/1-2, pp.49-56. [link]

  25. Cao, J. and Boyce, M. (1997), “A predictive tool for delaying wrinkling and tearing failure in cup forming”, ASME Journal of Engineering Materials and Technology, Vol. 119, October, pp.354-365. [link]

  26. Sunseri, M., Cao, J, Karafillis, A.P. and Boyce, M. (1996), “Accommodation of springback error in channel forming using active binder force control: Numerical simulation and experiments”, ASME Journal of Engineering Materials and Technology.  Vol.118, July, pp.426-435. [link]

  27. Jalkh, P., Cao, J., Hardt, D. and Boyce, M. C. (1993), “Optimal forming of Al 2008-T4 conical cups using force trajectory control”, Journal of Materials & Manufacturing, Vol.102, Sec. 5, pp.416-427.

  28. Cao, J. and Boyce, M. (1993), “Draw bead penetration as a control element of material flow”, Journal of Materials & Manufacturing, Vol. 102, Sec 5, pp.694-702.

Micro-Forming

  1. T. Funazuka, K. Dohda, T. Shiratori, R. Hiramiya, I. Watanabe, Effect of Punch Surface Grooves on Microformability of AA6063 Backward Microextrusion, Micromachines, 12, , 1299 (2021). 

  2. S. Sucharitpwatskul, N. Mahayotsanun, S. Bureerat, K. Dohda, Effects of Tool Coatings on Energy Consumption in Micro-Extrusion of Aluminum Alloy 6063, Coatings, 10(4), 381 (2020). 

  3. P. Koowattanasuchat, N. Mahayotsanun, S. Sucharitpwatskul, S. Mahabunphachai, K. Dohda, Heat Transfer Enhancement by Shot Peening of Stainless Steel, Coatings, 10(6), 584 (2020). 

  4. P. Preedawiphat, N. Mahayotsanun, S. Sucharitpwatskul, T. Funazuka, N. Takatsuji, S. Bureerat, K. Dohda, Finite Element Analysis of Grain Size Effects on Curvature in Micro-Extrusion, Appl. Sci., 10 (4767), pp. 1-18 (2020). 

  5. T. Funazuka, N. Takatsuji, K. Dohda, Y. Watanabe, Suppression of pick-up defects in hot extrusion of 6063 aluminum alloy by using PVD coating die (in Japanese), Journal of JIML, Vol. 70, No. 11, pp. 510-516 (2020). 

  6. K. Dohda, M. Yamamoto, C. Hu, L. Dubar, K. F. Ehmann,Galling phenomena in metal forming,  Friction, pp. 1-21 (2020). 

  7. Shi, Y. Zhang, W.Z., Cao, J. and Ehmann, K. F. (2019) “Experimental study of water jet incremental micro-forming with supporting dies”, J. Materials Processing Technology, Vol. 268, pp. 117-131, https://doi.org/10.1016/j.jmatprotec.2019.01.012.

  8. T. Shiratori, T. Aizawa, Y. Saito, K. Dohda, Fabrication of Micro-Punch Array by Plasma Printing for Micro-Embossing into Copper Substrates, Materials, 12(16), 2640, pp. 1-12 (2019). 

  9. E. Katsuta, T. Aizawa, K. Dohda, S. Yoshihara, Fabrication of Lower Temperature Plasma-Nitrided Die and Development of Zero Clearance Piercing of Electromagnetic Steel Sheets (in Japanese), Journal of JSTP, Vol. 60, No. 698, pp. 70-74 (2019). 

  10. Shi, Y., Cao, J. and Ehmann, K. F. (2018) “Response of high-pressure micro water jets to static and dynamic nonuniform electric fields”, J. Micro and Nano-Manufacturing, Vol.6(2), p.021006, DOI: 10.1115/1.4039507.

  11. T. Funazuka, N. Takatsuji, K. Dohda, T. Aizawa, Effect of Grain Size on Formability in Micro Extrusion -Research on Micro Forward-Backward Extrusion of Aluminum Alloy 1st report- (in Japanese), Journal of JSTP, Vol. 59, No. 684, pp. 8-13 (2018). 

  12. T. Funazuka, N. Takatsuji, K. Dohda, N. Mahayotosanun, Effect of Die Angle and Friction Condition on Formability in Micro Extrusion - Research on Micro Forward-Backward Extrusion of Aluminum Alloy 2nd Report- (in Japanese), Journal of JSTP, Vol. .59, No. 689, pp. 7-12 (2018). 

  13. Lee, T.Y., Magargee, J., Ng, M.K. and Cao, J. (2017) “Constitutive analysis of electrically-assisted tensile deformation of CP-Ti based on non-uniform thermal expansion, plastic softening and dynamic strain aging”, Int. J. Plasticity, Vol. 94, pp.44-56, http://dx.doi.org/10.1016/j.ijplas.2017.02.012.

  14. Moradi, M., Ng, M.K., Cao, J. and Picard, Y.N., (2017) Interface Characterization of Al/Cu micro-laminates Fabricated Electrically-assisted Roll Bonding , Journal of Micro and Nano-Manufacturing, Journal of Micro and Nano-Manufacturing, , 5(3), 031001

  15. Effects of Friction Models, Geometry and Position of Tool on Curving Tendency of Micro-Extrusion 6063 Aluminum Alloy Pins, (S. Sucharitpwatskul, N. Mahayotsanun, S. Mahabunphachai, T. Funazuka, N. Takatsuji, K. Dohda), In Key Engineering Materials, Vol. 739, pp. 35-142 (2017)

  16. Ng, M.K., Li, L.Y., Fan, Z.Y., Gao, R.X., Smith, E.S. III, Ehmann, K.F. and Cao, J. (2015) “Joining sheet metals by electrically-assisted roll bonding”, CIRP Annals, Vol. 65(1), pp. 273-276, doi:10.1016/j.cirp.2015.04.131.

  17. Zhou, R., Cao, J, Ehmann, K., Xu, C., (2011), "An investigation on deformation-based micro surface texturing", ASME Journal of Manufacturing Science and Engineering, Vol. 133(6), [link]

  18. Li, H., Dong X., Shen, Y., Zhou, R., Diehl, A., Hagenah, H., Engel, U., Merklein, M., Cao, J. (2011) "Analysis of Microbending of CuZn37 Brass Foils Based on Strain Gradient Hardening Model", Journal of Materials Processing Technology, 212, 653–661. [link]

  19. Magargee, J., Cao, J., Zhou, R., McHugh, M. and Brink, D. (2011) "Characterization of Tensile and Compressive Behavior of Microscale Sheet Metals Using a Transparent Micro-wedge Device", ASME Journal of Manufacturing Science and Engineering, Vol. 133(6), [link]

  20. Parasiz, S. A., Kinsey, B., Mahayotsanun, N. and Cao, J. (2011) "Effect of Specimen Size and Grain Size on Deformation in Microextrusion", accept for publication SME Journal of Manufacturing Processes, Vol. 13, pp.153-159, [link].

  21. Cao, J., Dohda, K., Zhou, R., Makino, T., Futamura, M., (2010) "An Investigation on Bump Formation in Forming of Micro Dimples", Steel Research International, 81, No. 9:1160-1165, 81: n/a. [link].

  22. Zhang, H., Makino, T., Dohda, K. and Cao, J. (2009) "Production of Small Pin by Micro/Meso-Scale Rotary Forming", Materials Science Forum, Vol. 614, pp. 105-110. [link]

  23. Parasiz, S., Kinsey, B., Krishnan, N., Cao, J. and Li, M. (2007) “Investigation of Deformation Size Effects during Microextrusion”, ASME Journal Manufacturing Science and Engineering, Vol. 129, Issue 4, pp. 690-697.[link]

  24. Mori, L., Krishnan, N., Cao, J. and Espinosa, H. (2007) “Study of the Size Effects and Friction Conditions in Micro-extrusion: Part II—Size Effect in Dynamic Friction for Brass-steel Pairs”, ASME Journal of Manufacturing Science and Engineering, Vol. 129, Issue 4, pp. 677-689. [link]

  25. Onyancha, R., Kinsey, B.L., Krishnan, N., and Cao, J. (2007) “Development of an Accurate Process Model for Microscale Forward Extrusion”, Transaction of the North American Manufacturing Research Institution of SME, Vol. 35, pp. 121-128.

  26. Krishnan, N., Cao, J. and Dohda K. (2007) “Study of the Size Effect on Friction Conditions in Micro-extrusion: Part 1 – Micro-Extrusion Experiments and Analysis”, ASME Journal of Manufacturing Science and Engineering, Vol. 129, Issue 4, pp. 669-676. [link]

Sensing Metrology

  1. Liao, S., Webster, S., Huang, D., Council, R., Ehmann, K. and Cao, J. (2022) “Simulation-guided Variable Laser Power Design for Melt Pool Depth Control in Directed Energy Deposition”, Additive Manufacturing, https://doi.org/10.1016/j.addma.2022.102912.

  2. Fang, L., Cheng, L., Glerum, J., Bennett, J., Dunand, D., Cao, J. and Wagner, G. (2022) “Data-driven analysis of process, structure, and properties of additively manufactured Inconel 718 thin walls”, npj Computational Materials, Vol. 8:126, https://doi.org/10.1038/s41524-022-00808-5.

  3. T. Sasaki, Y. Fujiwara, K. Tachikawa, K. Terabayashi, K. Dohda, Hydraulic Micro Device with Force Sensing for Measurement of Mechanical Characteristics, International Journal of Automation Technology, 14(4), pp. 625-632 (2020). 

  4. Sah, S., Mahayotsanun, N., Peshkin, M., Cao, J. and Gao, R.X. (2016) “Pressure and Draw-in Maps for Stamping Process Monitoring”, ASME J. Manufacturing Science and Engineering, Vol. 138(9), 091005 (15 pages), doi: 10.1115/1.4033039

  5. Zou, X., Fan, Z., Gao, R.X., Ng, M.K. and Cao, J. (2015) "An Integrative Approach to Spatial Mapping of Pressure Distribution in Microrolling”, CIRP J. Manufacturing Science and Technology, Vol. 9, pp. 107-115, doi:10.1016/j.cirpj.2014.12.002.

  6. Fan, Z., Zou, X., Gao, R.X., Ng, M.K., Cao, J. and Smith, E.F. (2015) Embedded Capacitive Pressure Sensing for Electrically Assisted Microrolling”, IEEE/ASME Transactions on Mechatronics, Focused Section on Mechatronics for Intelligent Manufacturing, Vol. 20, No. 3, pp.1005-1014. DOI: 10.1109/TMECH.2014.2365512.

  7. Fan, Z., Ng, M.K., Gao, R.X., Cao, J. and Smith, E.F. III (2012) "Real-Time Monitoring of Pressure Distribution in Microrolling through Embedded Capacitive Sensing", CIRP Annals, Vol.61/1, 367–370, [link]

  8. Mahayotsanun, N., Sahb, S., Cao, J., Peshkin, M., Gao, R. X. and Wang, C.T. (2009) "Tooling-integrated sensing systems for stamping process monitoring”, International Journal of Machine Tools and Manufacture, Vol. 49, pp. 634–644.[link]

Soft-Coil Analysis

  1. Li, S.P. and Cao, J. (2004) “A hybrid approach for quantifying the winding process and material effects on sheet coil deformation”, ASME Journal of Materials Engineering and Technology, Vol. 126(3), pp.303-313. [link]

  2. Li, S.P. and Cao, J. (2002) “A study on the stress distribution in coil wrapping and its effect on the final coil deformation”, Transaction of the North American Manufacturing Research Institution of SME, Vol. 30, pp.95-102.

Springback Prediction Control

  1. Ren, H., Xie, J., Liao, S., Leem, D., Ehmann, K. and Cao, J. (2019) “In-situ springback compensation in incremental sheet forming”, CIRP Annals, Vol. 68(1), pp. 317-320, https://doi.org/10.1016/j.cirp.2019.04.042.

  2. Huang, Y., Mahayotsanun, N., Cao, J., Lee, W., Wang, H.P. and Xu, S. (2010) “A Framework for Predicting Subtle Surface Distortion in Sheet Metal Flanging”, Transaction of the North American Manufacturing Research Institution of SME, Vol. 38. [link]

  3. Cheng, H.S., Cao, J. and Xia, Z.C. (2007) “An Accelerated Springback Compensation Method”, International Journal of Mechanical Sciences, Vol. 49, pp.267-279. [link]

  4. Buranathiti, T., Cao, J. (2004) “An Effective Analytical Model for Springback Prediction in Straight Flanging Processes”, International Journal of Materials & Product Technology, Vol. 21 (1/2/3), pp.137 – 153. [link]

  5. Viswanathan, V., Kinsey, B.L., and Cao, J., (2003) "Experimental implementation of neural network springback control for sheet metal forming", ASME Journal of Engineering Materials and Technology, Vol. 125 (2), April, pp.141-147. [link]

  6. Liu, G., Lin, Z.Q., Cao, J. and Bao, Y.X. (2002) "Eliminating springback error in U-shaped part forming by variable blankholder force", Journal of Materials Engineering and Performance, v 11, n 1, February, 2002, p 64-70. [link]

  7. Song, N., Qian, D., Cao, J., Liu, W., Viswanathan, V. and Li, S.F. (2001) "Effective models for prediction of springback in flanging", ASME Journal of Engineering Materials and Technology, Vol.123, pp.456-461, October. [link]

  8. Cao, J., Kinsey, B. and Solla, S. (2000) “Consistent and minimal springback using a stepped binder force trajectory and neural network control”, ASME Journal of Engineering Materials and Technology, Vol.122, pp.113-118. [link]

  9. Ruffini, R. and Cao, J. (1998) "Using neural network for springback minimization in a channel forming process", Journal of Materials & Manufacturing, Vol. 107, Section 5, pp. 65-73.

  10. Taylor, L., Cao, J., Karafillis, A.P., and Boyce, M.C. (1995) “Numerical simulations of sheet metal forming”, Journal of Materials Processing Technology, Vol. 50, pp. 168-179.

Surface Texturing

  1. Bhandari, S., Kang, P., Jeong, J., Cao, J. and Ehmann, K. (2022) “Cavitation bubble removal by surfactants in Laser-Induced Plasma Micromachining”, Manufacturing Letters, Vol. 32, pp. 96-99, https://doi.org/10.1016/j.mfglet.2022.04.004.

  2. Shi, Y., Jiang, Z., Cao, J., & Ehmann, K. F. (2020). “Texturing of Metallic Surfaces for Superhydrophobicity by Water Jet Guided Laser Micro-Machining,” Applied Surface Science, Vol.500, 144286, https://doi.org/10.1016/j.apsusc.2019.144286.

  3. Yuan, Y., Zhang, D., Jing, X., Cao, J. and Ehmann, K.F. (2019) “Micro texture fabrication by a non-resonant vibration generator”, J. Manufacturing Processes, Vol. 45, pp.732-745, https://doi.org/10.1016/j.jmapro.2019.08.010.

  4. Wang, X.W., Xu, J., Wang, C., Sanchez Egea, A. J., Li, J., Liu, C. Wang, Z., Zhang, T., Guo, B. and Cao, J. (2020) “Bio-inspired Functional Surface Fabricated by Electrially Assisted Micro-Embossing of AZ31 Magnesium Alloy”, Materials, Vol. 13, pp.412, doi:10.3390/ma13020412, https://www.mdpi.com/1996-1944/13/2/412/pdf.

  5. Xing, Y.Q., Deng, J.X., Wang, X.S., Ehmann, K. and Cao, J. (2016) “Experimental Assessment of Laser Textured Cutting Tools in Dry Cutting of Aluminum Alloys,” ASME J. Manufacturing Science and Engineering, 138(7):071006-071006-10, doi: 10.1115/1.4032263.

  6. Saxena, I., Liu, J., Ehmann, K., Cao, J. (2015) Periodic Surface Pattern Fabrication via Biprism Interference Micro-machining , Journal of Surface Topography: Metrology and Properties, Oct. 27, 2015, 045006, doi:10.1088/2051-672X/3/4/045006.

  7. Zhu, W. -L., Xing, Y., Ehmann, K., Ju, B. -F., (2015) Ultrasonic Elliptical Vibration Texturing of the Rake Face of Carbide Cutting Tools for Adhesion Reduction , International Journal of Advanced Manufacturing Technology

  8. Saxena, I., Wolff, S. and Cao, J. (2015) Unidirectional magnetic field assisted Laser Induced Plasma Micro-Machining”, Manufacturing Letters, Vol. 3, pp.1-4.

  9. Saxena, I., Wolff, S. and Cao, J. (2015) Unidirectional magnetic field assisted Laser Induced Plasma Micro-Machining”, Manufacturing Letters, Vol. 3, pp.1-4.

  10. Ng, M.K., Saxena, I., Ehmann, K.F. and Cao, J. (2016) “Improving Surface Hydrophobicity by Microrolling-Based Texturing”, J. of Micro- and Nano-manufacturing, Vol. 4, 031001 (8 pages), DOI: 10.1115/1.4033680

  11. Ishan Saxena, Kornel Ehmann, ‘High-speed Fabrication of Micro-channels using Line-based Laser Induced Plasma Micro-machining (L-LIPMM)’, Journal of Micro and Nano-Manufacturing, 2015 (accepted)

  12. Ishan Saxena, Kornel Ehmann, ‘High-speed Fabrication of Micro-channels using Line-based Laser Induced Plasma Micro-machining (L-LIPMM)’, Journal of Micro and Nano-Manufacturing, 2015 (accepted)

  13. Saxena, I., Ehmann, K. and Cao, J. (2015) “High Throughput Microfabrication using Laser Induced Plasma in Saline Aqueous Medium”, J. Materials Processing Technology, Vol. 217, March, pp. 77–87, doi:10.1016/j.jmatprotec.2014.10.018.

  14. Dongkai Xu, Man-Kwan Ng, Rong Fan, Rui Zhou, Hui-Ping Wang, Jun Chen, Jian Cao, ‘Enhancement of Adhesion Strength by Micro-rolling Based Surface Texturing’, The International Journal of Advanced Manufacturing Technology, 2015, DOI 10.1007/s00170-014-6736-0.

  15. Ng, M.K., Fan, Z., Gao, R.X., Smith, E.F.III and Cao, J., "Characterization of electrically-assisted micro-rolling for surface texturing using embedded sensor", CIRP Annals - Manufacturing Technology, 2014.

  16. P. Guo, Y. Lu, P. Pei, and K.F. Ehmann, "Fast Generation of Micro-Channels on Cylindrical Surfaces by Elliptical Vibration Texturing," Journal of Manufacturing Science and Engineering. 2014, 136(4), p. 041008.

  17. P. Guo, Y. Lu, K.F. Ehmann, and J. Cao, "Generation of Hierarchical Micro-Structures for Anisotropic Wetting by Elliptical Vibration Cutting," CIRP Annals - Manufacturing Technology. 2014, 63(1), p. 553-556.

  18. Y. Lu, P. Guo, P. Pei, and K. Ehmann, "Experimental Studies of Wettability Control on Cylindrical Surfaces by Elliptical Vibration Texturing," The International Journal of Advanced Manufacturing Technology. 2014, p. 1-11.

  19. Malhotra, R., Saxena, I., Ehmann, K.F. and Cao, J. (2013) “Laser-induced Plasma Micro-machining (LIPMM) for Enhanced Productivity and Flexibility in Laser-based Micro-machining Processes”, CIRP Annals, Vol.62(1), pp. 211-214, DOI: 10.1016/j.cirp.2013.03.036. [link]

  20. P. Guo and K.F. Ehmann, "Development of a Tertiary Motion Generator for Elliptical Vibration Texturing," Precision Engineering. 2013, 37(2), p. 364-371.

  21. Ling, T.D., Liu, P., Xiong, S., Grzina, D., Cao, J., Wang, Q. J., Xia, Z. C. and Talwar, R. (2013) “Surface Texturing of Drill Bits for Adhesion Reduction and Tool Life Enhancement”, Tribology Letters, Vol. 52(1), pp.113-122, DOI: 10.1007/s11249-013-0198-7. [link]

  22. Cui, Y., Yuan, W. and Cao, J. (2013) “The effect of surface texturing on microalgal cell attachment to solid carriers”, International Journal of Agricultural and Biological Engineering, Vol. 6(4), pp.44-54. [link]

  23. Peidong Han, K. Ehmann, "Study of the effect of cannula rotation on tissue cutting for needle biopsy", Med Eng Phys, 35 (2013) 1584-1590.

  24. P. Guo and K.F. Ehmann, "An Analysis of the Surface Generation Mechanics of the Elliptical Vibration Texturing Process," International Journal of Machine Tools and Manufacture. 2013, 64, p. 85-95.

  25. Fan, Z., Ng, M.K., Gao, R.X., Cao, J. and Smith, E.F. III., "Real-Time Monitoring of Pressure Distribution in Microrolling through Embedded Capacitive Sensing", CIRP Annals - Manufacturing Technology, Vol.61/1, 367–370, 2012.

  26. Zhaoyan Fan, Man-Kwan Ng, Robert X. Gao, Jian Cao and Edward F. Smith III, ‘Real-Time Monitoring of Pressure Distribution in Microrolling through Embedded Capacitive Sensing’, CIRP Annals – Manufacturing Technology, Vol.61/1, 367–370, 2012.

  27. Zhou, R., Cao, J, Ehmann, K., Xu, C., (2011), “An investigation on deformation-based micro surface texturing”, ASME Journal of Manufacturing Science and Engineering, Vol. 133(6), [link]

  28. Zhou, R., Cao, J., Xu, C. and Ehmann, K. (2011) “An Investigation on Multi-pass Deformation-based Surface Texturing”, Steel Research International, pp. 171.

  29. Zhou, R., Cao, J., Wang, Q. J., Meng, F., Zimowski, K., Xia, C. Z., (2011) “Effect of EDT Surface Texturing on Tribological Behavior of Aluminum Sheet”, Journal of Materials Processing Technology, Vol. 211(10), pp. 1643-1649, [link]

  30. Davis, T. and Cao, J (2010) “Effect of Laser Pulse Overlap on Machined Depth”, Transaction of the North American Manufacturing Research Institution of SME, Vol. 38. [link]

  31. Meng, F., Zhou, R., Davis, T., Cao, J., Wang, Q., Hua, D., Liu, J., (2010) "Study on effect of dimples on friction of parallel surfaces under different sliding conditions", Applied Surface Science, V. 256, no. 9: pp. 2863-2875. [link]

  32. Cao, J., Yuan, W., Pei, Z.J., Davis, T., Cui, Y. and Beltran, M. (2009) “A preliminary study of the effect of surface texture on algae cell attachment for a mechanical-biological energy manufacturing system”, ASME Journal of Manufacturing Science and Engineering, Vol. 131(6). [link]

  33. Greco, A., Raphaelson, S., Ehmann, K., Wang, Q. J., & Lin, C. (2009). Surface texturing of tribological interfaces using the vibromechanical texturing method. Journal of manufacturing science and engineering131(6), 061005.

  34. Chung, K., Schumacher, J., Sampson, E., Burne, R., Antonelli, P., and A. Brennan, "Impact of engineered surface microtopography on biofilm formation of Staphylococcus aureus" Biointerphases, 2(2), 2007.

Tearing Prediction

  1. S. Ngernbamrung, T. Funazuka, N. Takatsuji, S. Murakami, K. Dohda, Tearing mechanism of high-strength 7000 series aluminum alloy in hot extrusion (in Japanese), Journal of JIML, Vol. 68, No. 12 pp. 660-666 (2018). 

  2. Kinsey, B., Krishnan, N., and Cao, J. (2004) “A Methodology to Reduce and Quantify Wrinkling in Tailor Welded Blank Forming”, International Journal of Materials and Product Technology, Vol. 21 (1/2/3), pp. 154 -168. [link]

  3. Kinsey, B.L. and Cao, J (2003) "An analytical model for Tailor Welded Blank forming", ASME Journal of Manufacturing Science and Engineering, May, Vol. 125(2), pp.344-351. [link]

  4. Yao, H. and Cao, J. (2002) "Prediction of forming limit curves using an anisotropic yield function with prestrain induced backstress", International Journal of Plasticity, Vol.18/8, pp.1013-1038. [link]

  5. Yao, H and Cao, J. (2001) "Assessment of corner failure depths in the deep drawing of 3D panels using simplified 2D numerical and analytical model", ASME Journal of Manufacturing Science and Engineering, Vol.123 (2), pp.248-257. [link]

  6. Kinsey, B.L., Viswanathan, V., and Cao, J. (2001) "Forming of aluminum tailor welded blanks", Journal of Materials & Manufacturing, Vol. 110, Section 5, pp. 673-679.

  7. Cao, J., Yao, H., Karafillis, A. and Boyce, M.C. (2000) "Prediction of localized thinning in sheet metal using a general anisotropic yield criterion", International Journal of Plasticity, Vol. 16/9, pp.1105-1129. [link]

  8. Yao, H., Kinsey, B. and Cao, J. (1999) “Rapid design of corner restraining force in deep drawn rectangular parts”, International Journal of Machine Tools and Manufacture, Vol. 40, No.1, pp.113-131. [link]

  9. Yao, H., Kinsey, B. and Cao, J. (1999) “A simplified 2-D model for predicting 3-D corner failure in a square part”, Journal of Materials & Manufacturing, Vol. 108, Section 5, pp. 958-966.

Tooling Design of Metal Forming

  1. Cao, J., Brinksmeier, E., Fu, M.W., Gao, R.X., Liang, B., Merklein, M., Schmidt, M., Yanagimoto, J. (2019) “Manufacturing of advanced smart tooling for metal forming”, CIRP Annals, Vol. 68(2), pp.605-628, https://doi.org/10.1016/j.cirp.2019.05.001.

  2. M. Okada, M. Shinke, M. Otsu, T. Miura, K. Dohda, Influence of various conditions on quality of burnished surface in developed roller burnishing with active rotary tool, International Journal of Automation Technology, 12(6), pp. 921-929 (2018). 

  3. Aktürk, D.Z., Liu, P., Cao, J., Wang, Q.J., Xia, Z.C., Talwar, R., Grzina, D., and Merklein, M. (2015) Friction Anisotropy of Aluminum 6111-T4 Sheet with Flat and Laser-Textured D2 Tooling”, Tribology International, Vol. 81, pp. 333-340, DOI: 10.1016/j.triboint.2014.09.001.

  4. Huang, Y., Cao, J., Smith, S., Woody, B., Ziegert, J. and Li, M. (2008) “Experimental and Numerical Investigation of Forming Limits in Incremental Forming of a Conical Cup”, Transaction of the North American Manufacturing Research Institution of SME, Vol. 38, pp. 389-396.

  5. Cao, J., Cheng, S.H., Wang, H.P., and Wang, C.T. (2007) “Buckling of Sheet Metals in Contact with Tool Surfaces ", CIRP Annals, Vol. 56/1. [link]

  6. Cao, J., Krishnan, N., Wang, Z., Lu, H., Liu, W.K., Swanson, A. (2004) “Microforming –Experimental investigation of the extrusion process for micropins and its numerical simulation using RKEM”, ASME Journal of Manufacturing Science and Engineering, Vol. 126, pp. 642-652. [link]

  7. Cao, J., Li, Shunping, Xia, Z.C. and Tang, S.C. (2001) "Analysis of an axisymmetric deep drawn part forming using less forming steps", Journal of Materials Processing Technology, Vol. 117/1-2, pp 193-200.

  8. Lee, C.H. and Cao, J. (2001) "Shell element formulation of multi-step inverse analysis for the design of axisymmetric deep drawing process", International Journal of Numerical Methods in Engineering, Vol.50, pp.681-706. [link]

  9. Kinsey, B. Liu, Z.H. and Cao, J. (2000) “A novel forming technology for tailor welded blanks”, Journal of Materials Processing Technology, Vol. 99, pp.145-153. [link]

  10. Kinsey, B., Liu, Zhihong, and Cao, J. (1999) “New apparatus and method for forming tailor welded blanks”, Journal of Materials & Manufacturing, Vol. 108, Section 5, pp. 653-660.

Wrinkling Predition

  1. Lu, H., Cheng, H.S., Cao, J. and Liu, W.K. (2005) “Adaptive enrichment meshfree simulation and experiment on buckling and post-buckling analysis in sheet metal forming,” Computer Methods in Applied Mechanics and Engineering, Vol. 194, pp.2569-2590. [link]

  2. Cheng, H., Cao, J., Yao, H., Liu, S.D., and Kinsey, B.L. (2004) “Wrinkling Behavior of Laminated Steel Sheets”, Journal of Materials Processing Technology, Vol.151/1-3 pp. 133-140. [link]

  3. Lu, H., Li, S. Simkins, D.C., Liu, W.K. and Cao, J. (2004) “Reproducing Kernel Element Method, Part III: Generalized Enrichment and Applications”, Computer Methods in Applied Mechanics and Engineering, Vol. 193, pp.989 – 1011. [link]

  4. Liu, W. K., Han, W., Lu, H., Li, S., and Cao, J. (2004) “Reproducing Kernel Element Method, Part I Theoretical Formulation”, Computer Methods in Applied Mechanics and Engineering, Vol. 193, pp.933 - 951.  [link]

  5. Cao, J., Wang, X., and Mills, F. A. (2002) "Characterization of sheet buckling phenomenon subjected to controlled boundary constraints", ASME Journal of Manufacturing Science and Engineering, August, 2002, Vol. 124, pp.493-501. [link]

  6. Wang, X. and Cao, J. (2001) "Wrinkling limit in tube bending", ASME Journal of Engineering Materials and Technology, Vol.123, pp.430 – 435. [link]

  7. Wang, X., Cao, J. and Li, M. (2001) "Wrinkling analysis in shrink flanging", ASME Journal of Manufacturing Science and Engineering, Vol. 123, pp.426-432. [link]

  8. Wang, X. and Cao, J. (2000) “On the prediction of side-wall wrinkling in sheet metal forming processes”, International Journal of Mechanical Science, Vol. 42/12, pp.2369-2394. [link]

  9. Wang, X. and Cao, J. (2000) "An analytical model for predicting flange wrinkling in deep drawing", Journal of Manufacturing Processes, Vol. 2/2, pp.100-107. Also appeared in Transaction of the North American Manufacturing Research Institution of SME, Vol.26, 1998, pp.25-30.

  10. Cao, J. (1999) “Prediction of plastic wrinkling using energy method”, ASME Journal of Applied Mechanics, Vol.66, pp.646-652. [link]

  11. Wang, X. and Cao, J. (1999) "Stress-based prediction for the straight side-wall wrinkling in deep drawing processes", Transaction of the North American Manufacturing Research Institution of SME, Vol.27, pp.55-60.

  12. Cao, J. and Wang, X. (1999) “An analytical model for plate wrinkling under tri-axial loading and its application”, International Journal of Mechanical Science, Vol. 42, No. 3, pp.617-633. [link]

  13. Cao, J. and Boyce, M. (1997) “Wrinkling behavior of rectangular plates under lateral constraints”, International Journal of Solids and Structures. Vol. 34 (2), Section 5, pp.153-176.  [link]

General Review and Vision Articles

  1. Mozaffar, M., Liao, S.H., Xie, X.Y., Saha, S., Park, C., Cao, J. Liu, W.K. and Gan, Z. (2022) “Mechanistic Artificial Intelligence (Mechanistic-AI) for Modeling, Design, and Control of Advanced Manufacturing Processes: Current State and Perspectives”, Materials Processing Technology, Vol. 302, https://doi.org/10.1016/j.jmatprotec.2021.117485.

  2. Cao, J., Brinksmeier, E., Fu, M.W., Gao, R.X., Liang, B., Merklein, M., Schmidt, M., Yanagimoto, J. (2019) “Manufacturing of advanced smart tooling for metal forming”, CIRP Annals, Vol. 68(2), pp.605-628, https://doi.org/10.1016/j.cirp.2019.05.001.

  3. Ndip-Agbor, E. E., Cao, J. and Ehmann, K. (2018) “Towards smart manufacturing process selection in Cyber-Physical Systems”, Manufacturing Letters, Vol. 17, pp. 1-5, https://doi.org/10.1016/j.mfglet.2018.03.002.

  4. Yang, D.Y., Bambach, M., Cao, J., Duflou, J.R., Groche, P., Kuboki, T., Sterzing, A., Tekkaya, A.E., Lee, C.W. (2018) “Flexibility in metal forming”, CIRP Annals, Vol. 67(2), https://doi.org/10.1016/j.cirp.2018.05.004

  5. Duflou, J.R., Habraken A.M., Cao, J., Malhotra, R., Bambach M., Adams D., Vanhove, H., Mohammadi A. and Jeswiet J. (2017) “Single point of incremental forming: state-of-the-art and prospects”, Int. J. of Material Forming, https://doi.org/10.1007/s12289-017-1387-y

  6. Allwood, J. M., Duncan, S. R., Cao, J., Groche, P., Hirt, G., Kinsey, B., Kuboki, T., Liewald, M., Sterzing, A. and Tekkaya, A.E. (2016) “Closed-loop control of product properties in metal forming”, CIRP Annals, Vol. 66 (2), pp.573-596, dx.doi.org/10.1016/j.cirp.2016.06.002.

  7. Tekkaya, A.E., Allwood, J.M., Bariani, P.F., Bruschi, S., Cao, J., Gramlich S., Groche P., Hirt, G., Ishikawa, T., Merklein, M., Misiolek, W., Pietrzyk, M., Shivpuri, R. and Yanagimoto, J. (2015) Metal Forming Beyond Shaping: Predicting and Setting Product Properties”, CIRP Annals, Vol. 64(2), 629–653.

  8. Mitsuishi, M., Cao, J., Bártolo, P., Friedrich, D., Shih, A., Rajurkar, K., Sugita, N. and Harada, K. (2013) “Biomanufacturing”, CIRP Annals, Vol.62/2, pp.585-606, DOI: 10.1016/j.cirp.2011.05.001. [link]

  9. Che, D., Han, P., Guo, P., and Ehmann, K., 2012, "Issues in polycrystalline diamond compact cutter-rock interaction from a metal machining point of view - part I: temperature, stresses, and forces," Journal of Manufacturing Science and Engineering, 134(6), p. 064001.

  10. Che, D., Han, P., Guo, P., and Ehmann, K., 2012, "Issues in polycrystalline diamond compact cutter-rock interaction from a metal machining point of view - part II: bit performance and rock cutting mechanics," Journal of Manufacturing Science and Engineering, 134(6), p. 064002.

  11. DeVor, R.E., Kapoor, S.G., Ehmann, K.F. and Cao, J. (2012) “Transforming the Landscape of Manufacturing:  Distributed Manufacturing based on Desktop Manufacturing (DM)2”, ASME Journal of Manufacturing Science and Engineering, Vol. 134(4), 041004. [link]

  12. Chung, Y.W., Wang, J. Q., Ajayi, O., Biresaw, G., Cao, J., Hua, D., Lapatovich, W., Liu, W.K., Majumdar, A., Qureshi, F. and Zhu, D. (2011) “Transformative research issues and opportunities in energy efficiency”, Current Opinion in Solid State & Materials Science, Vol. 15(1), pp.16-19. [link]

Public Media

  1. Cao, J. (2017) Machinery investment, not trade agreements, are the problem with Asia, The Hill, http://thehill.com/opinion/international/360877-machinery-investment-not-trade-agreements-are-the-problem-with-asia

  2. Cao, J. (2018) – Manufacturing is an Integration Platform – and a Candy Store, a radio interview at Women and Manufacturing, http://womenandmfg.com/candy-store/?fl_builder