Jian Cao

US Patent:

6769280, Aug 3, 2004

Filed:

May 7, 2002

Appl. No.:

10/140916

Inventors:

Jian Cao - Wilmette IL
Junghoon Lee - Wilmette IL
Michael Peshkin - Evanston IL

Assignee:

Northwestern University - Evanston IL

International Classification:

B21D 2222

US Classification:

72 173, 72347, 72350

Abstract:

A method and system for providing real time measurements of draw-in for closed loop control of a metal forming process including an elongated sensor on one of the tools positioned in the proximity of the deformation zone and adjacent to an edge of a sheet metal blank being formed. The sensor includes coils disposed in a signal coupling relationship and during the forming process, a signal applied to one of the coils induces a signal in the coil, producing a response signal that varies linearly as a function of the amount of overlap between the sensor and the sheet metal blank as the sheet metal blank is drawn into the deformation zone. A feedback signal produced from the response signal is used to control a parameter of the forming process as a function of retreat of the edge of the sheet metal blank into the deformation zone.

US Patent:

8408039, Apr 2, 2013

Filed:

Oct 6, 2009

Appl. No.:

12/587408

Inventors:

Jian Cao - Wilmette IL, US
Anthony Swanson - Chicago IL, US
Tiffany Davis - Chicago IL, US

Assignee:

Northwestern University - Evanston IL

International Classification:

B21J 11/00
B21D 5/06
B21B 27/06

US Classification:

72418, 72446, 72455, 723792, 72404, 72414, 72462

Abstract:

Method of forming depressions (e. g. dimples) in a sheet material to form a textured surface thereon involves pressing one or more tool tips into a metallic or non-metallic sheet material while the sheet material is supported by a support layer that is relatively softer (e. g. having a lower Young's modulus) than the sheet material so as to allow plastic deformation and reduce pile-up of raised displaced material of the sheet material at the edges of the depressions.

US Patent:

8545142, Oct 1, 2013

Filed:

Mar 6, 2009

Appl. No.:

12/399703

Inventors:

Kevin Scott Smith - Huntersville NC, US
Bethany A. Woody - Charlotte NC, US
John C. Ziegert - Seneca SC, US
Jian Cao - Wilmette IL, US

Assignee:

University of North Carolina at Charlotte - Charlotte NC
Clemson University - Clemson SC
Northwestern University - Evanston IL

International Classification:

B23C 9/00
B23C 1/16
B21D 22/02
B21D 31/00

US Classification:

409 80, 72 68, 723792

Abstract:

The present invention relates generally to deformation machining systems and methods that combine, in a single machine tool setup, the machining of thin structures and single point incremental forming (SPIF), such that novel part geometries and enhanced material properties may be obtained that are not achievable using conventional machining or forming systems and methods, individually or collectively. Important to many applications, lighter weight parts may be produced at lower cost using a conventional 3-axis computer numerically controlled (CNC) machine tool or the like, instead of the conventional 5-axis CNC machine tool or the like that is typically required.

US Patent:

20110084648, Apr 14, 2011

Filed:

Oct 9, 2009

Appl. No.:

12/576803

Inventors:

Jian Cao - Chicago IL, US
Ali Emadi - Chicago IL, US

International Classification:

H02J 7/00

US Classification:

320103, 320167, 307 91

Abstract:

A hybrid energy storage system for supplying power to an application with a fluctuating load profile, such as, for example, electric vehicles, hybrid electric vehicles, plug-in hybrid electric vehicles, wind energy harvesting equipment and solar energy harvesting equipment. The hybrid energy storage system includes an ultra-capacitor electrically connected to a DC bus and a power source electrically connected to the DC bus via a controlled switch. The hybrid energy storage system further including a DC/DC converter connected between the power source and the ultra-capacitor, the DC/DC converter boosting a voltage of the power source to charge the ultra-capacitor. The DC/DC converter is preferably controlled to maintain a voltage of the ultra-capacitor at a higher value than the voltage of the power source.

US Patent:

20120055217, Mar 8, 2012

Filed:

Aug 30, 2011

Appl. No.:

13/221304

Inventors:

John Roth - Mckean PA, US
Jian Cao - Wilmette IL, US

Assignee:

The Penn State Research Foundation - University Park PA

International Classification:

B21D 26/00

US Classification:

72 54

Abstract:

A process for forming a sheet metal component using an electric current passing through the component is provided. The process can include providing a double side incremental forming machine, the machine operable to perform a plurality of double side incremental deformations on the sheet metal component and also apply an electric direct current to the sheet metal component during at least part of the forming. The direct current can be applied before or after the forming has started and/or be terminated before or after the forming has stopped. The direct current can be applied to any portion of the sheet metal. The electrical assistance can reduce the magnitude of force required to produce a given amount of deformation, increase the amount of deformation exhibited before failure and/or reduce any springback typically exhibited by the sheet metal component.

US Patent:

20120164384, Jun 28, 2012

Filed:

Dec 15, 2011

Appl. No.:

13/374210

Inventors:

Jian Cao - Wilmette IL, US
Rui Zhou - Evanston IL, US
Kornel F. Ehmann - Evanston IL, US

International Classification:

B32B 3/00
B29C 59/02

US Classification:

428141, 425385, 264293

Abstract:

A compact deformation-based micro-texturing apparatus and method employ flexure bearing houses for rotatably supporting opposite ends of each of a first (e.g. upper) roll and a second (e.g. lower) roll to provide a working roll gap between the rolls, wherein at least one of the rolls has one or more micro surface features to plastically deform a surface of a workpiece deformed by rolling action in the roll gap. An electrical current may be passed through the workpiece to assist micro deformation. A roll gap adjusting device is operably associated with the first and second flexure bearing houses for adjusting the roll gap dimension to the final depth of the micro surface features to be imparted to the surface of the workpiece by the rolling action.

US Patent:

20130291613, Nov 7, 2013

Filed:

May 7, 2012

Appl. No.:

13/465587

Inventors:

Zhiyong Cedric Xia - Canton MI, US
Jian Cao - Wilmette IL, US
Qian Wang - Mt. Prospect IL, US
Rajesh Talwar - St. Louis MO, US
Donald J. Grzina - St. Louis MO, US
Tiffany Davis Ling - Plymouth MN, US
Pinzhi Liu - Evanston IL, US

Assignee:

FORD GLOBAL TECHNOLOGIES, LLC - DEARBORN MI

International Classification:

B21D 24/04
G06F 17/50
B21D 22/00

US Classification:

72350, 723792, 703 1

Abstract:

A manufacturing method forms components having a desired shape. A contoured surface is defined for a forming tool for forming a metal blank into the desired shape, wherein respective portions of the metal blank flow over the contoured surface during forming. An intrinsic material flow pattern resulting from the contoured surface is compared to a desired flow in order to identify regions of the contoured surface having an insufficient flow that creates areas in the formed metal blank receiving less than a desired amount of metal. A surface microtexture is applied onto the contoured surface in a pattern selected to increase metal flow along the identified regions by providing a friction in the identified regions that is reduced relative to adjacent regions of the contoured surface.

US Patent:

59411104, Aug 24, 1999

Filed:

May 12, 1997

Appl. No.:

8/854480

Inventors:

Jian Cao - Wilmette IL
Brad L. Kinsey - Clio MI

Assignee:

Northern University - Evanston IL

International Classification:

B21B 3700

US Classification:

72 214

Abstract:

Method and apparatus for TWB forming with adaptive control of movable punch and/or die segments in a manner to maintain a holding force at the weld line by the punch and die segments during at least initial forming of the blank in a manner to control and limit movement of the weld line. A tailor welded metal blank having a weld line is positioned between a punch and a die with the weld line spanning a cavity defined between the punch and the die. One or more individual segments of the punch and of the die are moved in a manner to engage opposite side regions of the weld line to apply a holding force to the weld line. Relative movement of the punch and/or die segments is adaptively controlled during at least initial deformation of the blank by the punch in a manner to maintain the holding force applied to weld line at a selected holding force value to retain the weld line in a plane defined by the punch and die segments, thereby reducing weld line movement. After initial deformation of the blank by movement of the punch to a preset punch location, the punch and die segments can be retracted away from the weld line during subsequent deformation of the blank.