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PASQUALE FRANCIOSA Senior Research Fellow at WMG, University of Warwick, Coventry, CV4 7AL, UK

PERSONAL INFORMATION

First Name/Last Name: Pasquale Franciosa

Email: p.franciosa@warwick.ac.uk

Phone: +44 02476 573422

Mobile: +44 07440022523

Office: IMC - room 351 (3rd floor)

BIOGRAPHY

Dr Pasquale Franciosa is a Senior Research Fellow at WMG department of University of Warwick.

His research focus is manufacturing assembly process simulation and process monitoring/control,

machine learning and multi-disciplinary/multi-objective optimization. In 2010, he earned his PhD in

Mechanical Engineering System at the University of Naples Federico II, Italy. In 2009 Visiting

Fellow at MIT (Boston - USA) working on robotics and motion/constraint analysis. In 2007 Visiting

PhD Student at the Institut Supérieur de Mécanique de Paris – SUPMECA (France) working on

variation simulation of compliant assembly systems. He has been contributing on several academic

and industrial projects (founded by Italy MIUR; UK EPSRC; EU FP7) involving: (i) dimensional

management control and innovative tools development to predict stack-up of variations (defects)

propagating in multi-stage assembly systems, (ii) CAD and FEA modelling, (iii) multi-physics

simulation for product/process performance improvement, (iv) remote laser welding process design

and control. He is author and co-author of about 50 papers, published on international peer-reviewed

journals and conferences. His research papers have received ~210 independent citations (Google

Scholar - H-index: 9). Among Top-10 staff with most downloaded articles at WMG (ResearchGate).

RESEARCH DISSEMINATION

IMPACT BY PUBLICATIONS

Citations: The research papers have received ~210 independent citations (H-index: 9) - 199 since

2011 (GoogleScholar). Among Top-10 staff with most downloaded articles at WMG

(ResearchGate).

DEVELOPMENT OF NEW SIMULATON TECHONOLOGY

As part of the FP7-FoF “RLW Navigator” research program, I have intensively contributed to the

implementation and verification and validation of:

Fixture optimizer for compliant assembly: the tool offers the possibility to evaluate and

optimise product performances for given joint layout and to optimise clamp layout for given joint

requirements (i.e., max gap per stitch). Tool’s integration capabilities are: (i) optimised product

design loop to generate a feasible assembly process; (ii) optimum locator/clamp layout; (iii)

joining process parameters’ loop; (iv) work-station optimisation loop with robot simulation and

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path planning. The tool can be used as interactive/collaborative framework among process and

product design engineers. The following benefits have been proved during the process of

designing and optimizing complex door assembly systems (JLR case study): (i) reduced

engineering implementation cost; (ii) reduced fixture design time and engineering design

changes; (iii) reduction of installation, commissioning and launch time; (iv) improved strength

and dimensional quality of assemblies.

In-line Remote Laser Welding (RLW) process monitoring: The first in-line monitoring

system (both hardware and software) developed for COMAU SmartLaser. The tool extends the

state-of-art by developing a novel methodology by linking in-process monitoring signals with

process joint performance. The following benefits have bene proved: (i) estimation of joint

performance (i.e., penetration and s-value) using in-line process monitoring data; (ii) use of

analytical mathematical model automatically linking monitoring data to joint performance; (iii)

facilitate Statistical Process Control and root cause of joint failure; (iv) capability for in-line

closed loop process control and adjustment.

RESEARCH PROJECTS

I have participated to the preparation of the following project proposal:

2015/16 “Closed-Loop In-Process Quality Improvement for Multi-station Assembly System for

Lightweight Structures”. H2020-Factory-of-the-Future 2016 (call on “Zero Defect

Strategies at System Level for Multi-Stage Manufacturing in Production Lines”). Project

coordinator: Prof. D. Ceglarek, co-I: P. Franciosa and Prof. M Williams. Project support

(WMG): 2 PDRA, 20% DC, 50% PF, 5% MW; 20% admin support. Consortium partners:

Hungarian Academy of Science (Institute of Computer Science & Control), University of

Naples Federico II, Fraunhofer Gesellschaft, Centro Ricerche FIAT SCpA, Nikon

Metrology Europe NV, Precitec GmbH & Co. KG, COMAU, Optis, Finmeccanica S.p.A.,

STADCO. Duration: 42 months (January 2017 – June 2021)

€5,999,708 (€2,025,178 for WMG)

2015/16 “EPSRC HUB in Intelligent manufacturing”, expression of interest prepared for “Future

manufacturing HUBs 2016”. Academic Partners: University of Nottingham – Institute of

advanced manufacturing (PI), Oxford – Department of engineering science & computer

science, Sheffield AMRC, WMG, University of Birmingham - School of mechanical

engineering. Duration: 7 years. Project grant: £10 mln. WMG PI Prof. D Ceglarek, co-I

Dr P. Franciosa.

Project outline invited to full proposal submission (15 outlines selected out of 36)

2015 “InNovativE Multi-scale dEsign of joining technologieS for multi-materIals Structures

(NEMESIS)." H2020-Factory-of-the-Future 2015. (WMG PI-Ceglarek, co-I: P. Franciosa

and K. Kodua) Project supports: 2 PDRA, 20% 1 Senior Research Fellow, 10% Assistant

Prof.; 20% admin support, 10% DC. Consortium includes: FORD, Dow Europe GmbH,

SWEREA IVF AB, Muhr und Bender KG, Mubea Centre for Lightweight Design,

EnginSoft SPA, Research Center for Non Destructive Testing (Recendt) GmbH, ALTAIR

Engineering France SARL., KIRCHHOFF Automotive Deutschland GmbH, Electrolux

Italia S.P.A. (Jan 2016 - Dec 31, 2019)

€6,111,500.00 (€1,560,280.00 for WMG)

2014 “Closed-loop Self-Resilient Production System Launch (ResiPros Launch)”. EPSRC-JLR

Programme for Simulation Innovation. (Oct 2013 - Sept, 2018)

£1 mln. Not Funded. To be re-submitted

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Member of the following research projects:

2014-

2018

In-process Quality Improvement - EPSRC grant (EP/K019368/1)

Self-Resilient Reconfigurable Assembly Systems with In-process Quality Improvement

(IPQI)

Member of the research unit of University of Warwick. Leader of the reconfigurable multi-

station assembly system work-package.

5-year project (from 2014 to 2018)

The project is a five year EPSRC funded collaborative project with Universities and

industrial partners. It aims to develop and implement a systematic methodology and toolsets

for modelling, analysis and in-process quality control of a Reconfigurable Assembly System

integrated within a multi-station assembly system with compliant (deformable) parts.

2012-

2014

European Project. FP7 scheme - FoF-ICT-2011.7.4 Digital Factories: Manufacturing Design

and Product Life Cycle Management

RLW Navigator (Remote Laser Welding System Navigator for Eco & Resilient Automotive

Factories)

From 2012 to 2013 member of the research unit of University of Molise. From 2013 to 2014

member of the research unit of University of Warwick. Leader of the process design

optimisation work-package.

3-year project (from 2012 to 2014)

The project aims to develop an innovative Process Navigator to configure, integrate, test

and validate applications of remote laser welding (RLW) in automotive assembly addressing

today’s critical need for frequently changing operating conditions and product-mix

provisions. The RLW Navigator will serve as a crucial enabler for embedding new processes

such as RLW for future energy efficient smart factories. RLW is emerging as a promising

joining technology for sheet metal assembly, with benefits that include reduced processing

time (50-75%), decreased factory floor footprint (50%), reduced environmental impact

through reduced energy consumption (<60% including benefits related to process and

product re-design), and a flexible process base for future model introduction or product

changes.

2007-

2009

PRIN Project. Funded by Italian Ministry of Research and University

PUODARSI: Product User-Oriented Development based on Augmented Reality and

interactive Simulation

Member of the research unit of University of Naples Federico II (school of engineering)

3-year project (from 2007 to 2009)

The project aimed to implement a computer tool to quickly perform multiphysics

simulations (starting from real objects, digitalized by means of reverse engineering

technologies), visualize results in stereoscopic mode, modify the shape of the object

interactively, and, then, update simulation results. This re-design loop is stopped when a

satisfactory solution is reached according to the design requirements.

2009 Cooperation between SAFEWAY srl and University of Naples

Improving comfort of shoe sole through experiments based on CAD-FEM modeling

Member of the research unit of University of Naples Federico II (school of engineering)

1-year project

The project aimed to improve the comfort of occupational footwear by evaluating the

elements that play an important role in the perceived human comfort/discomfort. Physical

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experiments were conducted to get a comfort function that was used to guide the virtual

experimental study aimed to generate the best design of footwear corresponding to the more

comfortable design. Physical experimentation was combined to virtual experimentation to

determine the response surface linking the perceived human comfort to the measured peak

pressure at the footwear sole.

2008 Cooperation between FIAT-ELASIS and University of Naples

Variation Analysis of Compliant Assembly in Automotive Application

Member of the research unit of University of Naples Federico II (school of engineering)

1-year project

The project aimed study and quantify the variation propagation of the bonnet on Lancia

Delta. The resistance spot welding (RSW) assembly process was investigated and simulated.

Correlation studies were conducted to verify and validate simulation results.

LIST OF PUBLICATIONS & PATENTS

PATENTS

2015

1. Das A., Franciosa, P., Ceglarek, D., 2015, Three-Dimensional Shape Error Detection, draft

prepared and reviewed with Patent Attorney (Warwick Venture)

2. Franciosa, P., Das, A., Ceglarek, D., Gerbino, S., 2015, Product Assembly Systems, draft

prepared and reviewed with Patent Attorney (Warwick Venture)

3. Franciosa, P., Prakash PKS, Ceglarek, D., 2015, Joint Quality Evaluation, draft prepared and

reviewed with Patent Attorney (Warwick Venture)

WORKING PAPERS

1. Babu, KM., Franciosa P., Ceglarek D., Generation of Part Geometric Errors for Variation

Simulation Analysis of Deformable Parts at Preliminary Design Phase, May 2016.

2. Ozkat, E., Franciosa P., Ceglarek D., Simulation-driven Closed-loop Quality Control for

Remote Laser Welding, to be submitted to ICALEO Conference, October 2016.

3. Ozkat, E., Franciosa P., Ceglarek D., Process Parameter Interactions in Laser Dimpling Process

of Thin Galvanized Steels for Automotive Applications, to be submitted to Journal of Intelligent

Manufacturing, April 2016.

4. Chen Luo, Franciosa D, Ceglarek D, Zhonghua Ni, Fang Jia, A Novel Geometric Tolerance

Model based on Parametric Envelop Space, to be submitted to IEEE Transactions, June 2016.

5. Kiraci E, Franciosa D, Ceglarek D, Williams M, Inspection Fixture Design and Optimisation by

Integration of Assembly Quality Requirements and Metrology Constraints, December 2016.

6. Franciosa P., Kovács A., Erdős G., Ceglarek D., Váncza J., Fixture Design Synthesis of Robotic

Remote Laser Welding with Compliant Sheet Metal Non-Ideal Parts, to be submitted to

Computer Aided Design, April 2016.

INTERNATIONAL JOURNALS

2015

1. Franciosa, P., Ceglarek, D., 2015, Hierarchical Synthesis of Multi-level Design Parameters in

Assembly System, CIRP Annals (Manufacturing Technology), 64(1), pp 149-152, 2015.

2014

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2. Perrella, M., Franciosa, P., Gerbino, S., 2014, FEM and BEM Analysis of Mandibular Bone

Sorrounding a Dental Implant, accepted to Open Mechanical Engineering Journal.

3. Franciosa P., Gerbino S., Patalano S., A Computer-aided Tool to Quickly Analyse Variabilities

in Flexible Assemblies in Different Design Scenarios, Int. Journal of Product Development,

DOI:10.1504/IJPD.2013.053496, 2013.

2013

4. Franciosa, P., Gerbino S., Patalano, S., A Sequential Constraint Solver to Simulate Assembling

Operations for Tolerance Analysis, Procedia CIRP Volume 10, Page 169-177 (selected paper of

Int. CIRP-CAT, 2012), 2013.

5. Franciosa, P., Gerbino, S., Lanzotti A., Silvestri L., Improving Comfort of Shoe Sole through

Experiments based on CAD-FEM Modeling, Medical Engineering and Physics,

doi:10.1016/j.medengphy.2012.03.007, 2013.

6. Franciosa, P., Gerbino, S., Patalano, S., Automatic Evaluation of Variational Parameters for

Tolerance Analysis of Rigid Parts based on Graphs, Int. Journal on Interactive Design and

Manufacturing, DOI: 10.1007/s12008-012-0178-4, 2013.

2012

7. Ausiello P., Franciosa P., Martorelli M., Watts D. C.: Effects of Thread Features in Osseo-

Integrated Titanium Implants using a Statistics-based Finite Element Method. Dental Materials,

10.1016/j.dental.2012.04.035, 2012.

8. Franciosa, P., Martorelli, M., Stress-based Performance Comparison of Dental Implants by

Finite Element Analysis, Int. Journal on Interactive Design and Manufacturing, DOI:

10.1007/s12008-012-0155-y, 2012.

2011

9. Ausiello P., Franciosa P., Martorelli M., Watts D. C.: Mechanical behaviour of post-restored

upper canine teeth: A 3D FE analysis. Dental Materials, 27(12): 1283-1292,

doi:10.1016/j.dental.2011.09.009, 2011.

10. Ausiello, P., Franciosa, P., Martorelli, M., Watts, D., Numerical 3D-FE Modelling of Indirect

Composite-Restored Posterior Teeth, Dental Materials, 10.1016/j.dental.2010.12.001 2011.

11. Franciosa, P., Gerbino, S., Patalano, S., Simulation of Variational Compliant Assemblies with

Shape Errors based on Morphing Mesh Approach, Int. Journal of Advanced Manufacturing

Technology, Volume 53, Numbers 1-4, pp.47-61, ISSN 0268-3768, DOI: 10.1007/s00170-010-

2839-4, 2011.

2009

12. Franciosa, P., Gerbino, S., Patalano S., Variation Analysis of Compliant Assemblies: A

Comparative Study of a Multi-Station Assembly, Journal Anales de Ingenieria Grafica, N. 21,

pp.45-52, 2010. Selected paper of Int. ADM-INGEGRAF, 2009.

13. Franciosa, P., Gerbino, S., Patalano, S., Variational Modeling and Assembly Constraints in

Tolerance Analysis of Rigid Part Assemblies: Planar and Cylindrical Features, Int. Journal of

Advanced Manufacturing Technology, DOI 10.1007/s00170-009-2400-5, 2009.

14. Di Gironimo, G., Franciosa, P., Gerbino, S., An RE-CAE Methodology for Re-Designing Free

Shape Objects Interactively, Int. Journal on Interactive Design and Manufacturing, DOI

10.1007/s12008-009-0082-8, 2009.

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15. Franciosa, P., Patalano, S., Riviere, A., 3D Tolerance Specification: an Approach for the

Analysis of the Global Consistency based on Graphs, Int. Journal on Interactive Design and

Manufacturing, DOI 10.1007/s12008-009-0067-7, 2009.

16. Franciosa, P., Gerbino, S., Patalano, S., Variation Analysis of Compliant Assemblies: A

Comparative Study of a Single-Station Assembly, Journal Anales de Ingenieria Grafica, N. 20,

pp.57-64, 2009. Selected paper of XX Int. INGEGRAF, 2009.

2008

17. Gerbino, S., Patalano, S., Franciosa, P., Statistical Variation Analysis of Multi-Station

Compliant Assemblies based on Sensitivity Matrix, Int. Journal Computer Applications in

Technology, Vol. 33, No. 1, pp.12–23, 2008.

BOOK'S CHAPTERS

2011

18. Franciosa, P., Gerbino S., Patalano, S., Advanced User-Interaction with GUIs in MatLAB®, in

Engineering Education and Research Using MATLAB, Ed. by: Dr. Ali Assi, InTECH, ISBN

978-953-307-656-0, October 2011.

2010

19. Franciosa, P., Gerbino S., Patalano, S., Modeling and Simulation of Assembly Constraints in

Tolerance Analysis of Rigid Part Assemblies, (selected paper of Int. CIRP-CAT, 2009) in

Geometric Variation within Product Lifecycle Management, edited by M. Giordano, L. Mathieu

and F. Villeneuve, ISBN: 9781848212763, August 2010.

INTERNATIONAL CONFERENCES

2015

20. Gerbino S, Kriechenbauer S, Franciosa P, Das A, Mauermann R, Patalano S, Lanzotti A.,

Understanding whole shape variability of stamped sheet metal parts for root cause analysis. In:

ICAFT2015, Chemnitz (D), Nov. 10-11, 2015.

21. Franciosa P., Gerbino S., Ceglarek D., Fixture Capability Optimization for Early-stage Design

of Assembly System with Compliant Parts Using Nested Polynomial Chaos Expansion,

proceedings of CIRP-CMS 2015.

22. Das A., Franciosa P., Williams D., Ceglarek D., Physics-Driven Shape Variation Modelling at

Early Design Stage, proceedings of CIRP-CMS 2015.

23. Das A., Franciosa P., Ceglarek D., Fixture Design Optimisation Considering Batch of

Compliant Non-Ideal Sheet Metal Parts, Volume 1, 2015, Pages 157–168, 43rd North American

Manufacturing Research Conference, NAMRC 43, 8-12 June 2015, UNC Charlotte, North

Carolina, United States.

2014

24. Gerbino S., Franciosa, P., Patalano, S., Parametric Variational Analysis of Compliant Sheet

Metal Assemblies with Shell Elements, 9th CIRP Conference on Intelligent Computation in

Manufacturing Engineering, Naples, 23-25 July 2014.

25. Franciosa, P., Das, A., Ceglarek, D., Bolognese, L., Marine, C., Mistry, A., Design Synthesis

Methodology for Dimensional Management of Assembly Process with Compliant non-Ideal

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Parts, Joint Conference on Mechanical, Design Engineering & Advanced Manufacturing,

Toulouse, France, June 18th–20th, 2014.

26. Pal, A., Franciosa, P., Ceglarek, D., Root Cause Analysis of Product Service Failures in Design:

A Closed-loop Lifecycle Modelling Approach, 24th CIRP Design Conference, Milan, 14-16 April

2014.

27. Das, A., Franciosa, P., Prakash, PKS, Ceglarek, D., Transfer Function of Assembly Process with

Compliant Non-ideal Parts, 24th CIRP Design Conference, Milan, 14-16 April 2014.

28. Pal, A., Franciosa, P., Ceglarek, D., Corrective Actions of Product Service Failures via

Surrogate Modelling of Dimensional Variations, Industrial and Systems Engineering Research

Conference, Montreal - Canada, May 31-June 3 2014.

2013

29. Shrouti, C., Franciosa, P., Ceglarek, D., Root Cause Analysis of Product Service Failure using

Computer Experimentation Technique, 2nd International Through-Life Engineering Service

Conference, October 5-6, Cranfield University, Milton Keynes, UK, 2013.

2012

30. Franciosa, P., Gerbino, S., Patalano, S., Automatic Evaluation of Variational Parameters for

Tolerance Analysis of Rigid Parts based on Graphs, Int. IMPROVE-ADM Workshop, Capri

(Italy), 2012.

31. Franciosa, P., Gerbino S., Patalano, S., A Sequential Constraint Solver to Simulate Assembling

Operations for Tolerance Analysis, in Proc. of Int. Conference CIRP-CAT 2012, University of

Huddersfield (UK) 18-19 April.

2011

32. Franciosa, P., Gerbino S., Developing self-identifying Planar Markers for Automated Detection

in a Stereo-Vision System, ISBN 978-88-7784-328-9, in Proc. of IMPROVE 2011, Venezia (San

Servolo).

33. Franciosa, P., Martorelli M., Studying the Influence of Thread Features in Osseo-Integrated

Implants, ISBN 978-88-7784-328-9, in Proc. of IMPROVE 2011, Venezia (San Servolo).

34. Franciosa, P., Gerbino, S., Lanzotti, A., Patalano, S., Rufrano, V., Trotta, M., Silvestri, L.,

Frattari, L., Virtual prototype development for comfort assessment of occupational footwear sole,

ISBN 978-88-7784-328-9, in Proc. of IMPROVE 2011, Venezia (San Servolo).

2010

35. Franciosa, P., Gerbino S., From CT Scan to Plantar Pressure Map Distribution of a 3D Anatomic

Human Foot, in Proc. of COMSOL Conference’10, Paris (France), November 17-19, 2010.

36. Franciosa, P., Gerbino S., Patalano, S., Riviere, A., Early Fast Analysis of the Effect of Different

Fixture Configurations in Compliant Assembly Design, Proc. of the Int. Conference IDMME,

Bordeaux (France), October, 20-22, ISBN: 978-2-8178-0168-1, 2010.

37. Franciosa, P., Martorelli M., Marenzi, G., Sammartino, G., Stress Distribution on the Bone

Tissue: a Preliminary Comparative Study of Different Fixture Designs, Proc. of the Int.

Conference IDMME, Bordeaux (France), October, 20-22, ISBN: 978-2-8178-0168-1, 2010.

2009

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38. Franciosa, P., Gerbino S., A CAD-based Methodology for Motion and Constraint Analysis

According to Screw Theory, Proc. of the ASME-IMECE’09, Lake Buena Vista, Florida (USA),

November 13-19, 2009.

39. Franciosa, P., Gerbino S., Handling Tessellated Free Shape Objects with a Morphing Mesh

Procedure in Comsol Multiphysics®, in Proc. of COMSOL Conference’09, Milano (Italy),

October 14-16, 2009.

40. Franciosa, P., Martorelli, M., Ausiello, P., 3D Visualization and Fatigue Simulation in Restored

Human Teeth by Using Micro-CT Data, Proc. of the Int. ADM-INGEGRAF, Lugo (Spain), June

10-12, 2009.

2008

41. Franciosa, P., Gerbino S., A CAD-based Methodology for Planar and Cylindrical Features

Recognition, Proc. of the Int. CIRP-ICME, Naples (Italy), 2008.

42. Franciosa, P., Gerbino S., Lanzotti, A., Patalano S., A Numerical Methodology for Worst-Case

and Statistical Tolerance Analysis of Rigid Part Assemblies, Proc. of the Int. CIRP-ICME,

Naples (Italy), 2008.

CONFERENCE PRESENTATIONS & INVITED TALKS

Linking Manufacturing and Design through Simulation, 12th November 2015, Manufacturing

Technology Centre (MTC), Coventry (invited speech: Simulation-Driven Closed-Loop Quality

Control for Robotic Remote Laser Welding Assembly System)

International Academy for Production Engineering, 65th CIRP General Assembly, 24th – 29th

August 2015, Cape Town – South Africa (speech: Hierarchical Synthesis of Multi-level Design

Parameters in Assembly System)

Design and Development of Jigs and Fixtures: Going Local (Automotive Body Assembly Fixture

Development – a Collaborative Initiative Between Kulim Hi-Tech Park (KHTP) and WMG), 11th

June, Kuala Lumpur (Malaysia) (2 speeches: (i) Demonstration of Fixture Configuration

Simulation, (ii) Hands-on Session on Fixture Configuration and Development)

International Symposium – From design to production: Simulation and optimisation of body in

white joining process, 9th December 2014, Uni. of Warwick (2 speeches: (i) RLW process

optimizer; (ii) RLW process control)

KOREA-EU CSF (Connected Smart Factory) Symposium, Seoul (South Korea), 4th November

2014 (speech: Process design optimisation and process control). The symposium has been

targeted to South Korea’s leading industries, including automotive, shipbuilding and petro-

chemical. More than 300 people have attended the event, including the Vice Minister of Ministry

of Science and Technology

International CAE Conference, Pacengo del Garda - Verona (Italy), 26-27 October 2014 (speech:

Design synthesis of robotic remote laser welding assembly system with compliant non-ideal

parts)

ModeFrontier International user meeting, Trieste (Italy), 12-13 May 2014 (speech:

Understanding real world variations to optimise new generation welding processes)

International 24th CIRP Design Conference, Milan (Italy), 14-16 April 2014 (speech: Transfer

function of assembly process with compliant non-ideal parts)

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International CIRP-CAT Conference, University of Huddersfield (UK), April 2012 (speech: A

Sequential Constraint Solver to Simulate Assembling Operations for Tolerance Analysis)

International conference IMPROVE, San Servolo - Venice (Italy), June 2011 (2 speeches: (i)

Virtual prototype development for comfort assessment of occupational footwear sole; (ii)

Studying the Influence of Thread Features in Osseo-Integrated Implants)

International conference COMSOL Conference, Paris (France), November 2010 (speech: From

CT Scan to Plantar Pressure Map Distribution of a 3D Anatomic Human Foot)

International conference ASME-IMECE 2009, Lake Buena Vista - Orlando (USA), November

2009 (speech: A CAD-based Methodology for Motion and Constraint Analysis According to

Screw Theory)

International conference CIRP-CAT 2009, Annecy (France) 26-27 March 2009 (speech: Modeling

and Simulation of Assembly Constraints in Tolerance Analysis of Rigid Part Assemblies)

International conference CIRP-ICME, Naples (Italy), July 2011 (speech: A Numerical

Methodology for Worst-Case and Statistical Tolerance Analysis of Rigid Part Assemblies)

SELECTED PAPERS AND AWARDS

PUBLISHED PAPERS

1. Best paper award: Franciosa, P., Das, A., Ceglarek, D., Bolognese, L., Marine, C., Mistry, A.,

Design Synthesis Methodology for Dimensional Management of Assembly Process with

Compliant non-Ideal Parts, Joint Conference on Mechanical, Design Engineering & Advanced

Manufacturing, Toulouse, France, June 18th–20th, 2014.

2. Best contribution award: Franciosa P., Gerbino S., Patalano S., (2009), Variation Analysis of

Compliant Assemblies: A Comparative Study of A Multi-Station Assembly, XXI Ingegraf-XVII

ADM, Lugo, Spain. Promoted for publication on the Journal Anales de Ingenieria Grafica

3. Best contribution award: Franciosa P., Gerbino S., Patalano S., (2009), Modelling and

Simulation of Assembly Constraints in Tolerance Analysis of Rigid Part Assemblies, CIRP-

CAT, Annecy, France. Promoted for publication as chapter in: Max Giordano, Luc Mathieu,

Francois Villeneuve. Product Life-Cycle Management Geometric Variations. ISBN:

9781848212763

4. Best contribution award: Franciosa P., Gerbino S., Patalano S., (2008), Variation Analysis of

Compliant Assemblies: A Comparative Study of a Single-Station, XX Ingegraf, Valencia, Spain.

Promoted for publication on the Journal Anales de Ingenieria Grafica

CHAIRED STUDENTS

Gabriele Gattere, MSc student at the Politecnico di Milano in Mechanical Engineering received

2014 “Premio di Laurea Fabio Soavi 2013” Award, established by the Italian Association of

Manufacturing AITeM for the Best Italian MSc thesis in manufacturing during the academic

year 2012-2013 for his MSc thesis titled “Development of an Optical Based Monitoring Device

for Remote Laser Welding of Zinc Coated Steels.” The MSc thesis was conducted in the DLM lab,

WMG at the University of Warwick as a collaborative research work between WMG and

Politecnico di Milano; and the thesis was defended at the Politecnico di Milano, Italy.

(Supervisors: Prof. Barbara Previtali, Prof. Darek Ceglarek and Dr. Pasquale Franciosa). The

award ceremony was held during the AITeM annual meeting in Rimini on 09 September 2014.

More information at: http://www.aitem.org/premio-di-laurea-aitem-2013-f-soavi/

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Luca Ferrarini, MSc student at the Politecnico di Milano in Mechanical Engineering received 2014

"Premio di Laurea UCIMU” Award (in area of Robotics, Automation and ITC: Applications

in Manufacturing) for his MSc thesis titled “Characterization of the laser dimpling process on

galvanized steels for automotive applications.” The MSc thesis was conducted in the DLM lab at

the University of Warwick as a collaborative research work between University of Warwick and

Politecnico di Milano; and the thesis was defended at the Politecnico di Milano, Italy.

(Supervisors: Prof. Barbara Previtali, Prof. Darek Ceglarek and Dr. Pasquale Franciosa). The

award ceremony was held during the 29th BI-MU fair “Metal forming and metal cutting machines,

robots, automation and auxiliary technologies” in Milan on 04 October 2014.

ADMINISTRATION AND MANAGMENT

RLW PILOT STUDY

WORK-PACKAGE leader of the process design optimisation work-package of the EU founded

RLW Navigator project. Cooperating partners: Hungarian Academy of Sciences (Institute for

Computer Science and Control), University of Patras, École Polytechnique Fédérale de Lausanne,

University of Molise, Politecnico of Milano, Jaguar Land Rover, Stadco, Comau, EnginSoft.

Implementation of the RLW demonstration cell in academy facility is a challenging task which

requires systematic planning and identification of risks and sub-sequential mitigations. The

following tasks has been achieved: (i) design and manufacturing of the welding and dimpling

fixture; (ii) installation and calibration of welding and dimpling fixture; (iii) design and

installation of semi-automatic optical scanner (WLS400A) for in-line dimensional quality

assessment (integration of 7-axis ABB robot and Hexagon scanner). I have intensively

contributed to the development of the first optimised RLW assembled door by digital simulation

and optimization. It involves: (i) fixture; (ii) laser parameters; and (iii) off-line generated

trajectory program.

Laser safety manager – I am health and safety of the robotic laser welding cell in the IMC

engineering workshop (WMG).

CONFERENCE ORGANISATION

Multiphysics Simulation with Applications in Manufacturing, September 24, 2015 at WMG,

University of Warwick. 22 people participated to the event. The use of simulation in manufacturing

processes has become an essential component and cost-effective application for the manufacturing

industry as well as academic research. This half day event includes a number of talks showcasing the

research of several members from WMG. One of COMSOL’s simulation specialists will demonstrate

the COMSOL Multiphysics interface along with some case studies related to manufacturing

technologies.

PROGRAMME

09:00 - 09:15 Welcome speeches (Pasquale Franciosa & Darek Ceglarek (WMG)

09:15 - 09:45 Introduction to simulations in COMSOL Multiphysics (Robert Boswell (COMSOL)

09:45 - 10:15 Physics-driven modelling of remote laser joint (Erkan Ozkat (WMG))

10:15 - 10:45 Modelling steel corrosion by a combined thermodynamics transport approach (Michael

Auinger (WMG)

10:45 - 11:30 Live demos with COMSOL Multiphysics (Edmund Dickinson (COMSOL))

11:30 - 12:00 Round table and open discussion

Co-Chair, International Symposium, Remote Laser Welding (RLW) System Navigator: “From Design

to Production: Simulation and Optimisation of the Body in White Joining Process”, December 9,

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2014 at WMG, University of Warwick. 95 people registered for the event, representing 8 countries.

It was a very targeted audience: around half of the attendees were from industry representing

companies such as JLR, Volkswagen, Nissan, Tata Motors, General Motors, Tata Steel, John Deere,

thyssenkrupp, Trumpf, Magna Corporation, Ford, Hexagon, Laser Trader and all industrial partners

(JLR, COMAU, Stadco, Precitec, enginsoft) ; as well as government institutions: UK Innovate UK

(formerly UK Technology Strategy Board), UK HVM Catapult’s Manufacturing Technology Centre,

Advanced Propulsion Centre UK, Fraunhofer Institute (IWU Dresden and Chemnitz) as well as a

number of universities. We had also on-line participants as we offered live streaming of the event,

though it was not possible to record of participants for the live stream portion. The event included

keynote presentations from WMG High Value Manufacturing Catapult (UK initiative), and Trumpf,

the world’s leading laser manufacturer. Several presentations, panel discussions and expos were

organized around RLW Navigator tools. Seven screens simultaneously ran demos of the project’s

software tools. In addition, tours were organized for attendees to show the RLW Navigator’s

demonstrator, specifically RLW cell with L538 door fixture and smartlaser monitoring system

developed by the project. We also conducted survey of participants to understand the impact of the

tools impact and availability on market. We have received a number of interests from attendees

including conducting pilot studies and invitations to present and demonstrate the developed tools to

various companies.

TEACHING ACTIVITY

2015 Applied Engineering Program (AEP) - Advanced Quality Techniques: Closed-Loop

Quality Control: New Trends & R&D Perspectives (module leader: Rinkal Desai)

2015 Applied Engineering Program (AEP) - Advanced Industrial Processes: New Process

Development - Demonstration of Fixture Configuration Capability Simulation (module

leader: Steven Maggs)

2014/15 China Aerospace - Talent Development and Exchange Centre (CAT-DEC): Introduction

to Remote Laser Welding (module leader: Neil Davies)

2014/15 Dimensional Measurement & Management (DMM) - JLR’s Technical Accreditation

Scheme: Statistical quality control and gauge R&R (module leader: Ercihan Kiraci)

2014/15 JLR’s Technical Accreditation Scheme - Automotive Body Joining for Light-Weight

Structures: Remote Laser Welding Process Design and Control (module leader: Darren

Hughes)

2011 Teaching Assistant at University of Molise, School of Engineering, on Computational

Structural Mechanics and Numerical Computing - (Civil Engineering, 1st-year

postgraduate) member of examination board.

The course introduces the fundamental knowledge about numerical computing and Finite

Element Method to solve partial differential equations. Structural mechanics is introduced

and common 2D and 3D finite elements are modelled: bar, beam, shell, solid Hexa and

solid Tetra. Linear static mechanics is demonstrated. The isoparametric formulation is also

explored to offer high flexibility in modelling complex systems. Case studies are

implemented and developed using SCILAB programming code.

2011 Teaching Assistant at University of Naples Federico II (School of Engineering) on

Computer Aided Design & Virtual Prototyping - (Mechanical Engineering, 1st-year

postgraduate) member of examination board.

The course introduces the (i) fundamental knowledge about computer aided design (CAD)

modellers and (ii) methods and approaches to model complex assembly systems. 2D and

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3D parametric modeller are explored and fundamental algorithms are analysed: parametric

sketch, Hermite, Bezier, spline, b-spline, NURBS curve/surface.

Advanced CAD-CAE environments are also presented as a design tool to deal with

complex systems. Case studies are implemented and developed using SolidWorks

package. Industrial applications are pointed-out.

Nominal CAD representation is not sufficient to capture variation propagation occurring

during the manufacturing and the assembly process. Propagation mechanists are then

introduced. The constraint status of the assembly is checked using the screw theory

fundamentals. Case studies are implemented and developed using MATLAB

programming code. Team working is highly recommended.

2010 Teaching Professor at University of Naples Federico II (School of Engineering) on

Mechanical Drawing - (Material Science Engineering, 2nd-year undergraduate) president

of examination board.

The course introduces the fundamental concepts to draw standard mechanical components

(such as screw, bolt, spring, bearing, gear) according to international Standards. Both

manual drawing and computer aided tools (CAD modeller) are explored. Industrial case

studies are illustrated and used as course material.

2009 Teaching Assistant at University of Naples Federico II (School of Engineering) on

Tolerance Design - (Mechanical Engineering, 3-year undergraduate) member of

examination board.

The course introduces the fundamental concepts of GD&T and ISO specification to

deliver high quality product.

SHORT COURSES AND WORKSHOPS

I have been organiser and teacher of the following course/workshops:

2013 Teacher on Digital Pattern Technique. The course focalized on the training of experienced

researchers in computer assisted design and virtual prototyping.

Module A: Virtual Prototyping: Multiphysics Simulation based on Computer

Experimentation.

The course introduces advanced modelling technique to deal with complex systems where

multi-physics are acting simultaneously. Typical applications are: thermo-structure

interaction or thermo-structure-fluid interaction. Numerical techniques, general approaches

and guidelines are presented and highlighted. Case studies are developed using COMSOL

Multiphysics.

Module B: Variation Propagation Analysis in Mechanical Assembly.

Nominal CAD representation is not sufficient to capture variation propagation occurring

during the manufacturing and the assembly process. Propagation mechanists are then

introduced. Functional features are modelled based on 4x4 homogenous transformation

matrices. Kinematic constraints are also modelled considering bilateral (mate joint) and

unilateral constraints (contact joint). The constraint status of the assembly is checked using

the screw theory fundamentals. Case studies are implemented and developed using

MATLAB programming code.

2011 Teacher on Mechanical Drawing at AMS automation (Casalnuovo - ITALY) - professional

training class.

2010 Organizer and Teacher of Seminars events on Computer-aided Design and Reverse

Engineering at University of Molise.

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2010 Teacher on Mechanical Drawing and Graphical Representation at IAROS srl (project

funded by Italian research council).

COMMITTEES CHAIRED

Since 2007 I have been supervisor and co-advisor of about 30 students among MSc Students and PhD

students.

Current PhD Students

Özkat, Erkan Caner: Physics-driven modelling of remote laser welding joint quality for in-line

process control. The research involves the integration of multi-physics models and data mining

approaches to develop a predictive model of the RLW joint with near-to-zero physical experiments.

Manoj K Babu: Variation Simulation Analysis and Synthesis of Multi-Stage Assembly Systems with

Compliant Parts at Early Design Phase. The research involves modelling and simulation of both

single- and multi-stage assembly systems with the final aim of achieving zero-defect assembly

systems. The topic of the PhD fits very well with current trends in manufacturing to achieve zero-

defect strategy (i.e., Industry 4.0, Factory-of-the-Future).

Ercihan Kiraci: Sensor fusion methodology for in-line process control of automotive assembly

systems. The research involves integration of advanced metrology technique and quality control

methods to improve the quality of the assembly process.

Graduated Students

2014

C. Cheng, Strategies for reconfigurable assembly fixture technology (RAFT). Co-chaired with prof.

D. Ceglarek.

2013

C. Shrouti, Root case analysis of product service failure using computer experimentation technique.

Co-chaired with prof. D. Ceglarek.

M. Ansari, Surface-Based Quality Improvement: Effect of Environmental Noise on Stereovision

Measurements for Remote Laser Welding Application. Co-chaired with prof. D. Ceglarek.

D. Osorio, Remote Laser Welding Optimisation using Orthogonal Projection of Process Parameters

into Key Performance Indicator Space. Co-chaired with prof. D. Ceglarek.

2012

S. Yilmazer, Fixture Design Optimization for Sheet Metal Assembly Process with Remote Fiber Laser

Welding. Co-chaired with prof. D. Ceglarek - University of Warwick - WMG.

Visiting Students at University of Warwick

2016

F. Vitolo, Development of Multi-goal Task Sequencing Method for In-line Automatic Measurements

System Using Blue Light Optical Gage, PhD program in Mechanical System Engineering - Co-

chaired with prof. D. Ceglarek (WMG). Thesis defended at University of Naples Federico II (Italy).

2014

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A. Pesce, Simulation of assembly process using compliant non-ideal sheet-metal part in multi-stage

configuration, Master of Science in Mechanical Engineering - Co-chaired with prof. D. Ceglarek and

prof. S. Gerbino (UNIMOL/Uni. of Naples). Thesis defended at Uni. of Naples.

C. Ciancio, Adaptive KPIs prediction for Remote Laser Welding, PhD program in Industrial

Engineering - Co-chaired with prof. D. Ceglarek (WMG). Thesis defended at Università della

Calabria (Italy).

2013

L. Ferrarini, Characterization of the laser dimpling process on galvanized steels for automotive

applications, Master of Science in Mechanical Engineering - Co-chaired with prof. D. Ceglarek

(WMG) and prof. B. Previtali and Dr. D. Colombo (POLIMI). Thesis defended at Politecnico di

Milano.

G. Gattere, Development of an optical monitoring device for remote laser welding of zinc coated

steels, Master of Science in Mechanical Engineering - Co-chaired with prof. D. Ceglarek (WMG) and

prof. B. Previtali and Dr. D. Colombo (POLIMI). Thesis defended at Politecnico di Milano.

2012

Lorenzo Maio, Development and Validation of a Methodology for Clamp Layout Optimization of

Non-ideal Compliant Sheet Metal Assembly in Remote Laser Welding Applications. Master of Science

in Mechanical Engineering - Co-chaired with prof. D. Ceglarek (WMG) and prof. S. Gerbino

(UNIMOL). Thesis defended at University of Naples.

Internship Students at University of Warwick

2016

R. Fisco, Development of Collision-Free Path Planning for In-line Automatic Measurements System

Using Blue Light Optical Gage, Master of Science in Mechanical Engineering - Co-chaired with prof.

D. Ceglarek. Thesis to be defended at Uni. of Naples.

B. Capuozzo, Development of Light Reflectance Model for In-line Automatic Measurements System

Using Blue Light Optical Gage, Master of Science in Mechanical Engineering - Co-chaired with prof.

D. Ceglarek. Thesis to be defended at Uni. of Naples.

2015

P. Rosalia, In-line quality control for remote laser welding joints by high-speed camera, Master of

Science in Mechanical Engineering - Co-chaired with prof. D. Ceglarek and prof. S. Gerbino

(UNIMOL/Uni. of Naples). Thesis defended at Uni. of Naples.

A., Barde, Characterization, Modelling and Analysis of Light Reflectance During In-process Surface

Measurements Using White Light Based 3D Optical Gage, IIT Kharagpur (India) - Co-chaired with

prof. D. Ceglarek.

A., Nandan, Camera-Based Joint Quality Monitoring System for Remote Laser Welding, IIT

Kharagpur (India) - Co-chaired with prof. D. Ceglarek.

2014

M. Ivanov, Physics-based modelling of remote laser welding joint in conduction mode, Department

of Mathematics (University of Warwick) - Co-chaired with prof. D. Ceglarek (WMG).

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A. Awasthi, Fixture design optimisation of non-ideal compliant sheet metal parts based on Variation

Response Method (VRM) & Surrogate Modelling (SM), Design And Manufacturing, B.Tech +

M.Tech, IIT Kharagpur (India) - Co-chaired with prof. D. Ceglarek (WMG).

Graduated Students at University of Naples Federico II, School of Engineering (Italy)

2013

Michele Antoniello, An Innovative Methodology for Variational Shape Analysis of Flexible Parts

Based on High Density Data Oriented to Statistical Quality Control, Master of Science in Mechanical

Engineering.

Andrea Cangiano, A Methodology for Variational Shape Modeling of Compliant Sheet-Metal Parts

Based on Principal Component Analysis, Master of Science in Mechanical Engineering.

Gian Marco Di Vincenzo, A Computer Aided Design Tool to Model Mechanical Assembly based on

TTRS Theory. Master of Science in Industrial Engineering - Co-chaired with prof. JV. Choley,

SUPMECA.

Andrea Amoroso, Comparative Study of CAT Software for Tolerance Analysis and Specification of

Rigid-Part Assembly (in Italian), Master of Science in Mechanical Engineering.

2011

Ferdinando Vitolo, Graph Theory Application to Model Complex Gear Devices (in Italian), Master

of Science in Mechanical Engineering.

Andrea Cappelli, Development of a Sequential Solver to Model Mating Constraints in Mechanical

Assembly (in Italian), Master of Science in Mechanical Engineering.

Dario Di Matteo, Development of a CAD Toolbox to Model Radial Impeller of Turbo-Machinery, (in

Italian), Master of Science in Mechanical Engineering.

Giuseppe Pepe & Giuseppe Severino, Virtual Prototyping and Robust Ergonomic Design of a Boot

Footwear, (in Italian), Master of Science in Mechanical Engineering.

2010

Raffaele Ferrara, Static Analysis and Optimisation of a Wing Stabilizer in Virtual Reality

Environment, (in Italian), Master of Science in Mechanical Engineering.

2009

Mario Tassi, Variation Propagation Analysis of Compliant Assembly: Comparative Analysis of two

CAT Software, (in Italian), Master of Science in Mechanical Engineering.

Marco Moffa, Over-constrained Assembly: Methods and Approaches, (in Italian), Master of Science

in Mechanical Engineering.

2008

Giovanni Tuccillo & Domenico Tuccillo, Modelling and Simulation of Variation Mechanical

Assembly: Application to Planar and Cylindrical Features, (in Italian), Master of Science in

Mechanical Engineering.

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Vito Rufrano, Development of a CAT Software to Simulate 2D Tolerance Chains, (in Italian), Master

of Science in Industrial Engineering.

TECHNICAL SKILLS

CAD-CAE Software SolidWorks, CATIA, Pro-Engineer, SolidEdge, AutoCAD, RhinoCeros

Geomagic, Polyworks

HyperMesh

Simpleware

modeFrontier

Programming Multi-core computing (openMP), C++, Visual Basic

FEM Software COMSOL Multiphysics

Mcs-Patran, Msc-Nastran

Numerical Computing MATLAB/Simulink, SCILAB

I have participated to the following technical training courses:

2015 IOSH Working Safely - Health and Safety Training & Risk Assessment, 2 November 2015,

University of Warwick (UK).

2015 Hexagon WLS400A: dimensional measurement solutions, 7-10 April 2015, University of

Warwick (UK).

2015 ABB IRB 6620-150: robot programming and PLC control, 1-2-3 April 2015, University of

Warwick (UK)

2014 COMAU SmartLaser: C4G use and advanced programming, 3-4-5 March 2014, University

of Warwick (UK)

2014 PRIMES power and focal meter, 28-29 April 2014, University of Warwick (UK)

2013 Laser safety management training course, 13-14 August 2013, University of Warwick (UK)

2012 Using PolyWorks to measure functional gaps for automotive applications, 18-22 June 2012,

University of Warwick (UK)

2012 Cognitens Optigo 200: dimensional measurement solutions, 11-15 June 2012, University

of Warwick (UK).

2010 Nonlinear computational solid and structural mechanics theoretical formulations,

technologies and computations, 12-16 April 2010 IMATI-CNR, Pavia (ITALY)

2010 High Productivity Computing (HPC), 11 March 2010, CILEA (Milano - ITALY)

2009 Scientific visualisation and interactive computer graphics, 15-26 June 2009, CINECA,

Casalecchio di Reno (ITALY).

2008 Laser Scanner VI-9i and Geomagic Studio Intensive Professional Training, 14-18 April

2008, Milano (ITALY)

2008 Using MATLAB & Simulink for video and image processing, 14 February 2008, Roma