The lab was established in 2015 by Dr. Jami Shah, Honda Professor of Engineering Design for Manufacturing, when he moved from Arizona State University to OSU. DDML is housed in Scott Lab Building West Wing (W285) within Mechanical & Aerospace Engineering Department. The Lab aspires to educate 21st Century workforce in rapidly evolving computational techniques to support advanced product design and manufacturing.
DDML focuses on teaching and applied research related to:
- Structural design, FE analysis and optimization
- Crashworthiness of automotive body frames
- Driving Topology Optimization towards manufacturable designs
- Data Science and Machine Learning Algorithms for engineering applications
- AI/Knowledge Based Systems to support product design
- Non-traditional and hybrid joining methods for dissimilar thin walled structures
- Advanced mathematical models for 3D tolerance analysis and dimensional metrology
- Tolerance analysis of flexible assemblies
DDML has established close collaboration with Honda companies in Ohio, Honda Research Institute in Germany, Digital Manufacturing & Design Innovation Institute, Chicago (now called MxD), Arnold Fastening Systems (Michigan), Center for Design & Manufacturing Excellence (CDME), OSU SIMCenter, Integrated Systems Engineering (ISE) Depratment at OSU and Arizona State University.
DDML sponsors include National Science Foundation, Honda, DMDII, RollsRoyce, Siemens PLM.
DDML is first and foremost an Engineering Software Development and Simulation Lab. We develop advanced software tools in C++ and Python. We use software libraries and toolkits, such as ACIS, StarLab, MeshLab. We train our students in the use of various workbenches in CATIA, ANSYS, DYNA.
DDML is always looking for graduate students and undergrad interns to work on R&D projects. We are primarily interested in motivated students who enjoy coding and simulation and have a background in mechanical design and stress analysis.
To learn more about different aspects of DDML, please visit the following pages:
Dr. Jami Shah
Automotive Body in White (BIW): Honda/Acura
Thanks to the generosity of Honda Research & Development Americas, Inc. (HRA), the Department of Mechanical and Aerospace Engineering has received a customized 2014 Acura TLX frame to be used in teaching and research.
The HRA facility in Raymond, OH, a close partner of the department, used a production TLX to create a one-off display in order to expose core body frame components made suitable for design education. Design specifications were created by HRA engineers, who contracted with the university’s Center for Design and Manufacturing Excellence for final preparation of the display.
DDML houses the vehicle frame, which is color-coded to indicate its different materials. Under the direction of Jami Shah, Honda Professor of Engineering Design, it will be used to inform research aimed at improving vehicle structures.
“The TLX frame will be a great educational resource for teaching and research in structural design, topology optimization, materials and joining technology for lightweight structures,” said Shah. “It will allow students to get a detailed and up-close look at automotive frame structures, one of my lab’s research areas.”
Since being designated as the Honda Professor of Engineering Design three years ago, Shah has spent one day per week at HRA in the Strategic Research Area. There, he’s able to collaborate with engineers, access CAD files and develop research projects of mutual interest.
The relationship has also been instrumental in developing new mechanical engineering courses taught by Shah, which will utilize the vehicle frame donation.
“HRA engineers have been a big part of helping me with the development of new courses in advanced CAD and finite element analysis,” said Shah, who teaches both undergraduate and graduate students. “The TLX will benefit students enrolled in these classes, helping them conceptualize key elements of vehicle structures.”
Division Director of Strategic Research Operations and Chief Engineer at HRA Duane Detwiler (BS AE, MS AE) described the significance of the donation. “Honda values practical hands on education, and our collaboration with Professor Shah continues to be extremely successful in producing students that are sought-after as recruits by many Honda Engineering Divisions.”
Coordinate Measuring Machine (CMM)
The FARO Design ScanArm is a portable lightweight 3D scanning solution. It is developed for so you can reverse engineer legacy parts to design changes or replacement, create digital libraries to decrease inventory and warehouse costs, design aesthetically pleasing free form surfaces or leverage the power of rapid prototyping. It can also be used fro inspection and metrology of manufactured parts.
Below is the list of uses for this machine:
- Capture and digitize objects and props in full realistic detail for digital visualization
- Manufacture parts without existing CAD models
- Develop aftermarket products that need to fit tightly with existing products
- Digital archiving and historical preservations
- Reverse engineer legacy parts for design changes or replacement
- Create digital libraries to decrease inventory and warehouse costs
- Design aesthetically pleasing, freeform surfaces
- Leverage the power of rapid prototyping
SLA printer: Form2 by formlabs
The Form 2 delivers high-resolution parts that can be printed with 20 different materials. DDML has four different materials, including flexible and dental materials. Stereolithography (SLA) 3D printing uses a laser to cure solid isotropic parts from a liquid photopolymer resin.
FDM printer: Lulzbot Taz2
Fused Deposition Modeling (FDM), is a 3D printing process that uses a continuous filament of a thermoplastic material.
|1.||NAFEMS workbook of Examples|
|2.||Benchmark Tests for Finite Element Modelling of Contact, Gapping and Sliding|
|3.||Three Dimensional Test Cases in Linear Elastic Fracture Mechanics|
|4.||Introduction to Nonlinear Finite Element Analysis|
|How to- Perform Linear Dynamics Analysis|
|6.||How to- Use Beam, Plate and Shell Elements|
|Why to- Manufacturing Simulations|
|8.||Why to- Discrete Element Analysis|
|9.||Understanding Non-Linear Finite Element Analysis Through Illustrative Benchmarks|
|10.||How to Anlayse the static and Dynamic Response of Viscoelastic Components|
|11.||An Introduction to Modelling Buckling and Collapse|
|12.||How to Undertake a Contract & Fraction Analysis|
|13.||An Explicit Finite Element Primer|
|14.||The NAFEMS Benchmark Challenge - Volume1|
|15.||How to Manage Finite Element Analysis in the Design Process|
|16.||Why do Multi-Body System Simulation|
|17.||NAFEMS Computational Fluid Dynamic Benchmarks - Volume 1|
|18.||Robust Design Optimization in Virtual Product Development|
|19.||High value Manufacturing Modelling and Simulation Best Practices|
|20.||Tutorials for the Simulation of Forging processes|
|21.||How to Analyse Composites|
|22.||Why do a Multi-Physics Analysis|
|23.||A Designer's Guide to Simulation with Finite Element Analysis|
|24.||How to Undertake Fracture Mechanics Analysis with Finite Elements|
|25.||Tips and Workaround- for CAD -Generated Models|
|26.||A Finite element primer|
|27.||Introduction to non-linear Finite element analysis|
|28.||How to - Undertake a contact and friction analysis|
|29.||A review of contact and friction in FEA|
|30.||Advanced workbook of examples and case studies V2|
DDML has a collection of classic and modern automotive transmissions, both manual and automatic.
Three generations of design faculty have collected mechanical components that have failed by various modes: ductile, brittle, fatigue, fretting, brinelling, wear, stress corrosion, etc.
Honda releases Big Data Set generated by Ohio State
Title: OSU-Honda automobile hood data set (CarHoods10k)
The CarHoods10k data set comprises a set of over 10,000 3D mesh geometries for variants of car hood frames, generated through an automated, industry-grade Computer-Aided Design (CAD) workflow. The data set provides realistic designs validated by experts in terms of realism, manufacturability, variability, and performance. Variations in geometries were generated by a feature-based approach that varies parameter values describing design features on parameterized base geometries ('skins'). Geometries are represented as surface meshes (STL files) and are provided with the corresponding design parameter values and performance metrics from structural mechanics, generated through finite element analysis (FEA). The data set provides realistic and validated designs for the evaluation and development of methods such as optimization approaches or machine learning for metamodeling or performance prediction. CarHoods10k thus enables the evaluation of data-driven approaches for application in the engineering design domain.
Join the Lab
DDML is constantly looking for highly motivated and creative research scholars and graduate students, who are interested in learning new computational tools and development of automated systems for Design, and Manufacturing in mechanical and structural design.
If interested in joining the lab, contact Dr. Jami Shah.
Undergraduate Interns: Open
Motivated computer savvy OSU undergraduate students interested in gaining experience in design and manufacturing or to get ready for graduate school can also contact Dr. Shah for internship positions.
We regret that DDML does not offer internships to undergraduate students at foreign universities.