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- In-process Quality Improvement - EPSRC grant (EP/K019368/1)
2018
Self-Resilient Reconfigurable Assembly Systems with In-process Quality Improvement
(IPQI)
Member of the research unit of University of Warwick. Leader of the reconfigurable multistation 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.
20122014
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.
20072009
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.
2.
3.
Das A., Franciosa, P., Ceglarek, D., 2015, Three-Dimensional Shape Error Detection, draft
prepared and reviewed with Patent Attorney (Warwick Venture)
Franciosa, P., Das, A., Ceglarek, D., Gerbino, S., 2015, Product Assembly Systems, draft
prepared and reviewed with Patent Attorney (Warwick Venture)
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.
3.
Perrella, M., Franciosa, P., Gerbino, S., 2014, FEM and BEM Analysis of Mandibular Bone
Sorrounding a Dental Implant, accepted to Open Mechanical Engineering Journal.
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.
5.
6.
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.
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.
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.
8.
Ausiello P., Franciosa P., Martorelli M., Watts D. C.: Effects of Thread Features in OsseoIntegrated Titanium Implants using a Statistics-based Finite Element Method. Dental Materials,
10.1016/j.dental.2012.04.035, 2012.
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/s00170-0102839-4, 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 petrochemical. 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.
2.
3.
4.
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.
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
Best contribution award: Franciosa P., Gerbino S., Patalano S., (2009), Modelling and
Simulation of Assembly Constraints in Tolerance Analysis of Rigid Part Assemblies, CIRPCAT, Annecy, France. Promoted for publication as chapter in: Max Giordano, Luc Mathieu,
Francois Villeneuve. Product Life-Cycle Management Geometric Variations. ISBN:
9781848212763
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 zerodefect 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 - Cochaired 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).
Laser Scanner VI-9i and Geomagic Studio Intensive Professional Training, 14-18 April
2008, Milano (ITALY)
Using MATLAB & Simulink for video and image processing, 14 February 2008, Roma
2008
2008
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