Professor Prasad Yarlagadda

Biography

Broad Area of Research: Smart Systems

Main Areas of Research Professor Prasad Yarlagadda and his research team have defined seven main research areas:

• Rapid Prototype Manufacturing and Rapid Tooling
• Permanent Scaffolds for Tissue Engineering
• Control Systems for Weld Process Automation
• Solar Energy and Its Impact for Manufacturing Applications
• Product Data Modelling and Engineering Knowledge Management
• Antibacterial Impact Assessment of Nano-pillar Surfaces on Titanium Implants
• Improving Productivity and Efficiency of Australian Airports - A Real Time Analytics and Statistical Approach
• Investigation of the Atherosclerotic Plaque Progression and Rupture using Image based Bio-mechanical Modelling and Simulation
• Fault Diagnosis/Prognosis - A Distributed Model-Based Approach for Safety-Critical Reactive Systems

Rapid Prototype Manufacturing and Rapid Tooling In order to survive in today's competitive environment, companies need to constantly seek technologies to shorten product development cycle, reducing design & manufacturing lead-time and improving time to market. As industries press for faster development, the ability to have a full-functioning working assembly in hand in a short time frame is more and more important. Computer Aided Design (CAD), and Rapid Prototyping and Tooling (RP&T) are a combination of tools and latest manufacturing technologies which are required to keep up with this time-sensitive pace and help to develop new products faster than before. Technological advancements in communications, automation, and computers continue to fuel the growth of Rapid Prototyping (RP) since it came to the forefront in 1986. RP and its derivative Rapid Tooling (RT) have become an integral part of the design and manufacturing processes. RT has the potential to dramatically improve the speed and cost of tool development. Using CAD, electronic data transfer, process simulation, and RP&T technologies, tooling cost and development times can be reduced, especially when tools geometry (part complexity or specific geometry features) make traditional / conventional machining difficult. By reducing tooling costs, RP&T enable high volume process, such as press metal forming tool, to be competitive at lower production volumes. Prof. Yarlagadda worked with a number of both Australian and international manufacturing industries in reducing lead time in new product development by adopting combination of both traditional and rapid prototype manufacturing techniques. CAD/CAM Applications in Sheet Forming Computer Aided Design and Computer Aided manufacturing (CAD/CAM) applications for tool and die making is becoming increasingly attractive to traditional / conventional machining. Rapid prototyping also called free form fabrication, uses additive process to create a physical geometry directly from a CAD file, replacing conventional methods that remove materials. Rapid tooling typically requires several steps to create the tools. In an indirect method, a master model (pattern) is created by RP and used other techniques or processes to form the tool. On the other hand, a direct method produces the tool directly from RP model. RP&T along with press metal forming tool have combined to offer an alternative to conventional machining processes. This comes at a time when more and more emphasis is being placed on minimizing the inherent time and cost associated with the development of a product. RP&T have found a role by bridging the design and manufacturing entities by hastening the time to market a product from conception. The future of these technologies appears to be bright. This is supported by the intensive research efforts being conducted at universities, research institutions, and industries. Prof. Prasad and his team worked extensively with a number SMEs, and tooling industry in developing quick tools for various sheet metal applications. Permanent Scaffolds for Tissue Engineering Titanium and its alloys are widely used in orthopedic surgeries. This is because of their outstanding biocompatibility and mechanical properties. Their interactions with cells depend mostly on surface properties. The tissue integration of a biomaterial is a critical factor in determining how well the implant material commonly used in bone surgery or reconstruction is incorporated into the human body. The biocompatibility of a biomaterial is highly related to the behavior of the cells in contact and in particular the cell adhesion to its surface. A bio-scaffold can be broadly termed as a structure used to substitute an organ either permanently or temporarily to restore functionality. The material that can be used varies with the application intended. Tissue Engineering is one such application demanding certain requirements to be met before it is applied. One of the applications in tissue engineering is the tissue scaffold, which provides either a permanent or temporary support to the dam aged tissues/organ until the functionalities are restored. A biomaterial can exhibit specific interactions with cells that will lead to stereotyped responses. The use of a particular material and morphology depends on various factors such as Osteoinduction, Osteoconduction, angiogenesis, growth rates of cells and degradation rate of the material in case of temporary scaffolds etc. Prof. Yarlagadda and his team consists of Prof. Ross Crawford, Prof. Kunle Oloyele, Prof. Sreejith, Assoc. Prof. Yin Xiao and others are working on number of issues related to permanent scaffolds by using Titanium and its alloys for various tissue engineering applications. Prof. Prasad Yarlagadda has extensive collaboration with a number of researchers from various international institutes such as Singapore Institute of Manufacturing Technology, Singapore Government Hospital, Bio Scaffold Pty. Ltd in development permanent scaffolds for tissue engineering. Control Systems for Weld Process Automation Recent developments in materials and material joining have increased the scope and extent of their areas of application. However, stern market demand for the improved weld quality necessitates the need for automation of the welding processes. As a result, improvements in the process parameter feedback, sensing and control, are necessary to successfully develop the automated control technology for the welding processes. Hence, several aspects of the GMAW-P process have been investigated in this study in order to improve its control techniques. This investigation explores the effects of different process parameters on welding process. Prof. Yarlagadda, Dr. Praveen Posinasetti and their team have extensive international collaboration in this area with various world famous researchers and institutes such as Prof. Sehun Rhee from HanYang University, Korea, Dr. B.Y. Kang, Dr. M.J. Kang from Korean Institute of Industrial Technology, Prof. Ill-Soo Kim from Mokpo National University, Korea. Microwave Energy Applications in Manufacturing Microwave technology is one of the alternative high energy technologies used for number of manufacturing related applications. Microwave offers the possibility of uniform curing of the materials by generating instantly heat in the entire part independently of its shape complexity and dimensions. Materials for microwave heating need to be electrically non-conductive and should have dipole structure. The dipoles are polarised at microwave frequency. When the frequency is high, such as at microwaves, the dipole can not follow with the reorientation of the electric field and at this point microwave energy is converted into heat. Effective microwave heating is achieved, when the rate of microwave power absorption is greater than the rate of heat dissipation through convection or conduction During microwave applications the environment is filled with electromagnetic waves at all times. Light, X-irradiation, TV, AM and FM radio waves, ultraviolet, infra-red and microwaves are some of the manifestations of these waves. Microwaves occupy the part of the spectrum from 300 MHz to 300 GHz. Most applications of microwave technology make use of frequencies in the range of 1 to 40 GHz. Of particular importance to this study is the manner in which microwaves interact with the materials. When microwave impinges upon a material, the material preferentially absorbs the waves. The frequencies that are absorbed called the resonant frequencies of the material, and are dependent upon its molecular composition. Microwaves travel in the same manner as light waves and they can be reflected by metallic objects, absorbed by some dielectric materials, transmitted without significant absorption through other dielectric materials. Prof. Yarlagadda and his team did extensive study of microwave energy applications for various manufacturing processes and product developments. Solar Energy and Its Impact for Manufacturing Applications Solar radiation has served as an energy source since the beginning of life and, the living creatures illuminated by the terrestrially available sunlight have been using it in many different ways. A variety of solar energy technologies are being developed to harness the available solar radiation but its utilization is still an expanding field of human endeavour. Researchers continue to discover new ways to utilize this “free delivered” power and apply it to different energy consuming processes. Beam solar radiation that intercepts the earth is fairly uniform with a broader spectral range and relatively low intensity compared to other modern sources of electromagnetic radiation. Therefore, when high temperatures are desired, concentration of the incident solar radiation becomes necessary. Solar concentration technologies have made considerable progress over the years and recent achievements have contributed to further increasing the recognition of solar power as a potentially viable source of renewable energy. Radiation processing of materials using ionizing electromagnetic energy has had practical application for many years. Prof. Prasad, Dr. Loubmir and his other colleagues developed a Solar Energy Concentration system and used for manufacturing applications such as joining and other studies as ageing of polymers ar among others. Product Data Modelling and Engineering Knowledge Management Manufacturing, particularly tooling companies, which are typical small and medium-sized enterprises (SMEs), usually operate in a make-to-order fashion. They have to rapidly respond to customers to gain business opportunities in a contracting market. These tooling companies should be flexible and innovative, taking into consider the size and structure. However, they are still faced with the challenge of frequently changing customer requirements. As the product market lifecycle is becoming short, tooling industry also have to shorten their business cycle to rapidly respond to these demands. To survive in such a competitive market, many manufacturing companies are seeking solutions to improve their overall business performance by integrating critical business processes, i.e. design, planning and production. At present, most of tooling companies are faced with an inefficient computing environment that lacks of integration and is not capable of effective supporting information sharing and exchange. As a result, the overall business performance is not improved as expected though the efficiency of ndividual activities is increased by individual software systems. Prof. Yarlagadda, Mr. Ni and other team members attempted to design and develop of a PDM-based system for the integration of critical business process, which are design, planning and production, to achieve higher business performance. Firstly, the PDM frame is extended to manage non-engineering data and support business activities of planning and production. Then, the integration-supported models, including design model, routing planning model and task model, are discussed from the perspectives of information association and process automation. The integration of workflow management to streamline business processes is also investigated. Grants Professor Prasad Yarlagadda has received over $3 M in research funding since 1998. Successful Grant Applications as Principal Investigator

• Development of an accurate model of calculation of springback for plane-strain bending by using FEA - QUT NRG scheme ($6,208)
• Development of a solar energy concentrator system for joining of translucent thermoplastics and for fast curing of adhesively - BEE Faculty and Local Industry ($26,907)
• Development of rapid tooling for electronic discharge machining using electroforming and spray metal deposition techniques - ARC-SPIRIT and Macro Engg ($123,540)
• Evaluation of Nickel electroformed and Stereolithography tooling for production of aluminium components - Rover Movers and QMI ($16,500)
• Rapid prototyping of EDM electrodes by Stereolithography and electroforming techniques - QUT-Ind. Collab. and Marky Industries ($20,473)
• Solar Energy for Joining of Translucent Thermoplastics and Fast Curing of Epoxy Base Adhesive Joints - MMME Seed Grant ($12,000)
• An Innovative Technique for Rapid Product Development by Using Stereolithography Process and Microwave Radiation - QUT and QMI Scholarship ($60,000)
• Procurement of Zinc Die Casting Machine - Emro Products Pty. Ltd. ($26,000)
• Development of a tracking device for sustainable solar energy application for joining - BEE Faculty Staff Initiative Grant ($5,000)
• Enhancement and Optimisation of a newly developed Mcirowave-Based Toxic Waste Disposal System - BEE Faculty Staff Initiative Grant ($4,875)
• A 50 KeV Ion Implanter for Wear Resistant and Electrically Active Coatings - BEE Faculty Staff Initiative Grant ($4,814)
• Development of Infomechatronics Laboratory for ME 40 – B.Eng. (Infomechatronics Engineering) course - BEE Faculty and QUT Central Initiative ($700,000)
• Development of an Intelligent System for Optimisation of the Robotic Arc Welding Process in Fillet Welds - ARC-Linkage ($63,195)
• Development of Intelligent Welding System - QUT-Visit Fellow ($6,100)
• Development of an Innovative Rapid Prototyping Technique using Microwave Curing of Thin Epoxy Layers with Metallic Particles - EGR Plastics and QUT Strategic Links ($45,000)
• Development of an Internet-based Distributive Product Design System - QUT-PDF Support ($110,000)
• Studies on the weld characteristics and weldability of welded joints with alternate supply of shielding gases in welding - ARC-Linkage ($74,711)
• Preliminary Experimental Studies to Develop Alternative Mould Materials by using Microwave Curing - KNR Systems South Korea ($10,000)
• Development of Permanent Titanium Tissue Engineering Scaffolds - A-STAR, Singapore ($172,800)
• Development of Knowledge Based Process Planning System for Non-Symmetrical Sheet Metal Forming Processes - ARC-Linkage ($81,000)
• Development of High Formability Mg-Al Alloy and Sheet Forming Process - KITECH, Korea ($48,000)
• Design and Development of C-ARM based Navigation System - QUT-Visiting Fellow ($16,000)
• Modeling of Pulse Current Parameters and Design of Fuzzy Logic Controller for Uniform Metal Transfer in Pulsed Gas Metal Arc Welding of Aluminium Alloy - ARC-Linkage ($105,202)
• Evaluation of the Surface Deflection in Pressed Automobile Outer Panels (Under agreement between QUT and POSCO) - POSCO, Korea ($110,000)

Successful Grant Applications as an Associate Investigator

• Development of interdisciplinary teamwork skills for engineering and information technology students - CUTSD, Canberra and Faculty of IT, QUT ($49,060)
• Development of information systems for small flexible manufacturing environment - OZ Electronics Mfg and AUS Ind. GBT Scheme ($265,000)
• Selective laser sintering instrumentation for free form fabrication - ARC-UQ-QUT_RIF ($460,000)
• Analysis and modelling of failure dependency and interaction of multi-component - QUT Early Career Researcher Grant ($7,500)
• Development of models for optimising inspection schedules and maintenance plans for high volume infrastructure - QUT Early Career Researcher Grant ($9,000)

Selected List of Consultancy Projects Professor Prasad K. D. V. Yarlagadda and his research team has been granted funds to conduct following research projects:

• Stress Analysis of Drive Side Mill Base Frame, Bundaberg Foundry Engineers, Limited, Australia.
• Design and Metallurgical Analysis of Geometry of the Rack and Pinion, Ecofab, Australia.
• Design and Manufacture of Multi-Cavity Soap Dies, Colgate-Palmolive (PNG), Pty, Ltd.
• Public course to several industries located in U.A.E. in collaboration with PROMIS, Project Management and Engineering Systems, Dubai and two in-house training courses, Saudi ARMCO (biggest Oil Refinery) and Salene.
• Walter Conversion Corporation, Saudi Arabia. The cooperative training courses are in the areas of Non Destructive Testing and Inspection, and also coordinated other courses in the Process Control of Manufacturing Systems and other related areas.

Awards and Recognition

• Recipient of 2000 Outstanding Scholars of the 20th Century Award in honour of his outstanding contribution in the field of manufacturing engineering, Cambridge, UK, 2000
• Recipient of 2001 QUT Outstanding Academic Contribution Award in Research and Scholarship, for his contribution in support of university mission and goals in research and scholarship, 2001
• Recipient of 2001 QUT Equity Award for his outstanding efforts in support of QUT’s equity objectives and promotion of good practice and innovation in implementing equity within the university, 2001
• Recipient of 2002 Innovation in BEE Education award, as recognition to his contribution in Teaching Innovation, 2002. One award each year is made to a member of staff from B.E.E. Faculty (Across all disciplines of Built Environment and Engineering)
• Recipient of 2004 Global Research Award (GCMM) as recognition to his contribution to Manufacturing Engineering Discipline. One award once in two years is made to an outstanding researcher in the manufacturing engineering discipline
• In 2007 Professor Prasad Yarlagadda received Fryderyk Staub Golden Owl Award from World Academy of Manufacturing and Materials, Poland for his outstanding contribution to the discipline of materials and manufacturing engineering in the international arena.

Career History

Aug 2005 - Current: Director Smart Systems Research and Professor, School of Engineering Systems, Queensland University of Technology (QUT) Jul 2004 - Dec 2004: Associate Director, (Centre for Built Environment & Engineering Research) and Assistant Dean (Research), Faculty of Built Environment and Engineering, QUT Aug 2003 - Jul 2005: Associate Professor, School of Mechanical, Manufacturing and Medical Engineering (MMME) and Program Leader: Product Design & Manufactuirng

Mar 2003 - Oct 2003: Senior Research Scientist, SIMTECH, Singapore (sabbatical Leave) Aug 1998 - Jul 2003: Director, Manufacturing Systems Engineering Research Concentration Senior Lecturer, School of MMME, QUT

Jan 1996 - Jul 1998: Lecturer, School of MMME, QUT Mar 1995 - Dec 1995: Lecturer II, Department of Mechanical Engineering, PNG University of Technology, Papua New Guinea

Oct 1994 - Feb 1995: SRA and Visiting Lecturer, Department of Manufacturing Engineering, City University of Hong Kong, Hong Kong

Dec 1992 - Sep 1994: RA and Visiting Lecturer, Department of Manufacturing Engineering, City University of Hong Kong, Hong Kong

Jan 1988 - Nov 1992: Research Scholar, Department of Mechanical Engineering, Indian Institute of technology, Bombay, India

Dec 1985 - Jul 1992: Lecturer, Mechanical Engineering Department, V.R.S Engineering College, India