CURRICULUM VITAE
1. NAME IN FULL
:
K.P. KARUNAKARA POOPATHI
2. ADDRESS
:
K.P. Karunakaran
Assistant Professor, Dept. of Mechanical Engineering
Co-ordinator, Computer Graphics Laboratory (CGLab) and
Rapid Prototyping Cell (RP Cell)
Indian Institute of Technology Bombay
Powai, Mumbai 400076, INDIA
Phone :
+91 22 5767530 (Off), +91 22 5768530 (Res)
Fax
:
+91 22 5783480 E-mail: [email protected]
3. DATE OF BIRTH
:
April 9, 1962
4. EDUCATIONAL QUALIFICATION
Period
Examination
Institution
From
To
Marks
Class
Remarks
Ph.D. in
Mechanical Engg.
IIT Kanpur
Dec.
1988
Jan.
1994
8.32
CGPA
I Class
-
M.Tech. in
Aircraft Prod. Engg.
IIT Madras
July
1984
Dec.
1987
9.15
CGPA
I Class
-
B.E. Honours in
Mechanical Engg.
College of Engg., Anna
University, Madras
July
1979
May
1984
77%
Honours
-
5. DETAILS OF EXPERIENCE
Period
Sl.
Organization
No.
From
To
Designation
Department
1. HAL, Bangalore
16.07.84 01.12.85 Mgt. Trainee
HAL Staff College, B'lore
2. HAL, Kanpur
02.12.85 14.04.87 Engineer
Machine Shop
3. HAL, Kanpur
15.04.87 29.09.89 Engineer
NC Machine Shop
4. HAL, Kanpur
30.09.89 10.07.91 Deputy Manager
NC Machine Shop
5. HAL, Kanpur
11.07.91 29.02.92 Deputy Manager
Methods Engg. Dept.
6. HAL, Nasik
01.03.92 02.11.92 Deputy Manager
Sub-contract Cell
7. IIT, Kanpur
05.11.92 25.07.94 Sr. Project Engineer CAD Project
8. IIT, Bombay
27.07.94 till date
Assistant Professor Coordinator, CGLab
9. DaimlerChrysler AG, 01.06.00 31.07.00 Consultant
Sindelfingen, Germany
6. DETAILS OF TRAINING
Sl
Name of Training
No
EP/QFM (Body Shop) of
Mercedes-Benz Technology Center
Place of Training
Duration
1. Training as Management Trainee
HAL Staff College, Bangalore 16.07.84 to
01.12.85
2. Introduction to CNC Machines and Manual Part
Programming
Central Machine Tools Institute, 10.11.86 to
Bangalore
21.11.86
3. Programming and operation of Waldrich Siegen
3-spindle 5-axis CNC machine
Waldrich Siegen, Germany
27.06.88 to
10.07.88
4. Training on Low-Cost Automation – sponsored by
Thailand Productivity Institute, 24.11.97 to
Asian Productivity Organization (APO), Tokyo, Japan Bangkok, Thailand
04.12.97
Curriculum Vitae of K.P. Karunakaran
5. Computer-Integrated Manufacturing Systems sponsored by Asian Productivity Organization (APO),
Tokyo, Japan
7. TEACHING
Sl.
Course
No.
No.
2
Korea Productivity Institute,
Seoul, Korea
Course Name
18.10.99 to
23.10.99
Class
Category
Under Graduate / Dual Degree Courses
1.
ME 116
Engineering Drawing II
UG
Core (Lab.)
2.
ME 211
Machine Drawing
UG
Core (Lab.)
3.
ME 327
Production Engineering I
UG
Core
4.
ME 328
Production Engineering II
UG
Core
5.
ME 336
Introduction to CAD/CAM
DD
Core
6.
ME 435
Computer Numerical Control
UG
Elective
7.
ME 454
Advanced Product Modeling
DD
Elective
Post-Graduate Courses
1.
ME 625
Material Removal Processes
PG
Elective
2.
ME 632
Assembly Engineering & Automation
PG
Elective
3.
ME 637
Manufacturing Automation
PG
Elective
4.
ME 643
Manufacturing Processes Laboratory
PG
Core
5.
ME 712
CNC Programming
DD/PG
Core/ Elective
6.
ME 714
Computer Integrated Manufacturing
PG
Elective
7.
ME 735
Interactive Computer Graphics
PG
Elective
8. RESEARCH
Areas of Interest:
 CNC & Automation
 Computer Graphics
 Rapid Prototyping & Tooling
Supervision of student projects:
Category
Ph. D. Dissertations
M.Tech. Dissertations
B.Tech. Projects
Completed
16
09
On-going
03
02
02
Current Research Activities:
(a) A Volumetric NC Simulation and Verification System
Presently, NC programs that control the CNC machines are created from CAM packages. The limited
graphic display of cutter path performed by the existing CAM packages is not adequate to visualize the
errors such as collision, gouging, improper feed rate etc. at the time of CNC program generation. Therefore,
the correctness of these programs can be ascertained only after machining and inspecting the component to
assess its conformance to design requirements and safety. This conventional method of verification is costly
both in terms of time and money.
The volumetric NC simulation system under development will act as a virtual CNC machine. The solid
model of the blank will be machined by the solid model of the cutter to obtain the solid model of the
machined component. This virtual machined part can be realistically displayed as shaded color rendering on
the screen at various orientations for visual inspection. Apart from the visual verification, the conformance
to tolerance specifications and collisions can be automatically assessed using this software by comparing the
machined model with the desired component model. For this purpose, a suitable tolerance representation
Curriculum Vitae of K.P. Karunakaran
3
scheme is being incorporated. Once the verification of conformance and safety is ascertained, the cutting
parameters, viz., spindle speed and feed rate will be optimized by a mechanistic modeling module of this
package.
Conventional modelers such as B-Rep. are not suitable for NC simulation owing to the large number of
Boolean operations and the resulting surface patches owing to the large number of NC blocks. Therefore,
we use Octree solid modeling for this work. This is being developed using Parasolid graphic kernel under
Visual Studio programming environment.
This work is being supported by DST funding of Rs. 9.6 lakhs.
(b) A Hybrid Layered Manufacturing Process for Metallic Dies Using MIG-MAG Welding and
CNC Machining
In mass production, the major part of investment goes to the fabrication of the production tools. Products
such as automobiles and other engineering products have hundreds of die cast aluminium parts, formed
sheet metal parts, extruded sections and plastic parts. The manufacture of these parts require die casting
dies, forming dies, extrusion dies and injection molding dies which are made out of very hard steel
(hardness of the order of 45-60 HRC). Presently, these dies are rough-machined in annealed condition and
the final shape is obtained after hardening using EDM process. An alternate way is to machine these dies to
final shape in single set up in hardened condition using a CNC milling machine with carbide cutters. Great
strides made in the cutting tools and the resulting availability of solid carbide cutters with TiN (golden
color) or ceramic coatings with Al2O3 or [Al+Ti]N off the shelf have made this possible. However, the
CNC machining is yet to become economically viable, the major bottleneck being the inability of CAM
software to create collision free tool paths with optimal cutting parameters. Therefore, the existing method
of rough machining in annealed condition and finishing it by EDM after hardening has to continue. Since
EDM is a slow and costly process, the cost and time incurred in the manufacture of the tools can not be
justified for small and medium batch production.
In this project, we present a process to manufacture the metallic tools faster and cheaper by building
them in layers. Even as several Layered Manufacturing (LM) processes, also known by the terms Rapid
Prototyping (RP) and Solid Freeform Fabrication (SFF), are emerging that can build metallic and ceramic
tools directly from slices, this new manufacturing concept continues to suffer from high cost and poor
accuracy primarily due to uniform slicing and staircase effect. The LM process proposed here surmounts
these difficulties by making use of adaptive slicing with 1st order approximation of the edges. Each layer is
built in two stages: in the first stage, a ‘near-net’ layer is obtained by weld deposition which is followed by
machining with an end mill under 5 axis control in order to obtain the desired layer edges to the required
accuracy. In this method, adaptive slicing (where thickness of the layers is not constant but varies to suit the
local geometry such as curvature) is used which results in very fast building without any sacrifice on
accuracy. As a whole, this two-level process using adaptive slicing will be faster than the existing methods
for tool making. Apart from helping reduce the cost and time involved in making tools for mass production,
it will help bring down the break-even point so that the hard tools can be justified even for small volume
production.
This work is being carried out in two phases supported by DoE funding of Rs. 39.192 lakhs for Phase I
and Rs. 93.173 lakhs for Phase II.
(c) Layered Manufacturing Process for Polystyrene Patterns Used in Evaporative Pattern
Casting (EPC)
Layered Manufacturing (LM) is any automatic process to produce physical prototypes of 3D objects from
their CAD models in a layer by layer manner. Laminated Object Manufacturing (LOM) is a LM process in
which sheets of uniform thickness cut to the desired shape are stacked and glued together to get the physical
prototype. The process proposed here for making polystyrene prototypes is a modified version of the
existing LOM process with certain improvements as follows:
i.
The raw material is input as a block unlike a sheet roll of constant thickness in the existing LOM
process.
ii. Adaptive slicing with 1st order edge approximation is employed. This results in accurate patterns and
parts. For the same accuracy, the number of layers will be considerably less when this type of slicing is
employed. In conventional LOM, adaptive slicing is not possible as it uses sheet roll.
iii. The accuracy requirements of foam objects and the force experienced in cutting them are very less
compared to conventional machining. Therefore, this RP machine needs to have only low accuracy (of
the order of 0.2 mm) and rigidity. However, generally these foam objects are huge. Therefore, it is
Curriculum Vitae of K.P. Karunakaran
4
proposed to build LM machine with optimal rigidity and accuracy. This will be achieved by employing
simple tubular structures, use of ordinary lead screws or wire-pulley drives instead of ball lead screws,
open loop control using stepper motors instead of servo-motors in closed loop, PC-based control
electronics etc. Due to this approach, even a large machine will cost much less than a CNC machine of
similar size.
iv. The adhesive used in the conventional EPC pattern making is of non-uniform thickness and hence it can
become inclusions due to incomplete burning. This process will use very little adhesive of uniform
thickness since it is applied on horizontal planar surfaces. Subsequently, methods to join the layers
without adhesive would be developed using localised heating. We shall also explore other adhesiveless
joining processes such as use of ultrasonic energy for this purpose.
v. In future, it is proposed to make the layers in-situ from Expandable Polystyrene (EPS). This will
eliminate the joining process and layer transportation.
The important advantages of foam pattern making using the proposed RP machine are:
-
-
-
This will be the first automatic method for making foam patterns. Presently, these patterns are made by
injection molding for mass production and manually when only a few castings are required. High cost
and time spent in making these patterns hinders its wide acceptance in the industry.
Very large and intricate prototypes can be produced at lower cost in this process.
Conventional foam pattern manufacture requires the pattern to be made of several simpler pieces which
are glued together. One requires one pair of dies for each such piece. Often, the same die pair cannot
be used for injection molding as well as gluing operation. In the proposed RP process, one does not
require any tooling.
The proposed RP machine can be used for job-shop or small batch running-in production.
If the complexity of the castings such as the engine block is too high requiring several die sets and
gluing operations, the RP process can be economically employed even for mass production of these
castings. Some hollow castings such as engine manifolds are redesigned for lost-foam casting adding
additional flanges. Such a redesign and flanges are not required when the proposed RP machine is used.
This process is under patenting. Development of this machine also has been proposed as a project in the
Technology Development Mission II of MHRD.
(d) Optimal Stock Removal in LOM-RP
In LOM type of Rapid Prototyping processes, after cutting the part profiles, the remaining material of the
stock is cut into small squares. After building all the layers, the part is inside a rectangular block with the
surrounding stock in the form of small parallelopipeds. The part is extracted by removing ('decubing') these
parallelopiped pieces with a sharp tool.
In these processes, the laser beam spends much more time in cutting the stock than the profiles of the
part. We are developing a methodology to minimize the time spent in cutting the stock. Our methodology is
based on the similarities existing between the extraction of the part from the stock and extraction of a
casting from its mould cavity. This work involves the calculation of the convex hull of the part and visibility
study of the surfaces.
(e) A Generic Software for Rapid Prototyping
When Numerical Control was introduced in early 1960s, there were several NC controllers each differing
from one another with respect to the features, the codes and the machine kinematics. Due to such vast
variations, the machine tool builders had to supply the path generation software in addition to machine tool
hardware and machine control software which hindered development. Subsequently, the need for
standardisation was felt which led to the development of a standard format called Cutter Location (CL)
Data. This enabled independent software vendors to develop CAM packages that cater to a variety of NC
machines since they generated output in a common CL format. This CL file is converted into the NC data of
any particular machine using an appropriate post-processor. Today, the same situation prevails among the
RP developers who have to supply specific RP software for slicing and path generation to produce the
desired prototype in addition to the hardware and control software of the RP machine. Since the geometric
processing of the prototype for all these RP processes have a lot in common, it is proposed to develop a
Generic RP software that can cater to the needs of all RP vendors.
All RP processes are based on slicing the solid model and building these slices physically one over the
other. The slicing could be uniform slicing or adaptive slicing (with squared or ruled edge surfaces). Some
Curriculum Vitae of K.P. Karunakaran
5
RP processes require the slices to be rastered inside (e.g., SLA, SLS, FDM etc.) and some processes require
only the contours and hatching of the outside to enable decubing (e.g. LOM). One can also think of more
optimal cuts for removing the stock in LOM-like processes than simply making uniform grids for decubing.
Furthermore, one requires tools for deciding the optimal orientation for building the prototypes, viewing and
repairing the STL input files etc. We have identified all these requirements and are developing a unified
system to be useful for any RP process. The philosophy is similar to that of any NC path generating module
of a CAM package where the initial processing is done at an intermediate generic level called Cutter
Location Data (CL Data). This is customized to any given machine by a Post Processor (PP) that has the
details of the process, machine kinematics and data formats. In the proposed unified RP system also, the
user can customize it using the appropriate menu options. Currently we are working on the slicing
algorithms for this system. This software will consist of the following modules:
i.
ii.
iii.
iv.
v.
vi.
Input Module
Slicing Module
Path Generation Module
Support Building Module
Stock Removal Module
Customizing and Post-Processing Module.
Development of this software has been proposed as a project in the Technology Development Mission
II of MHRD.
9. PATENTS
1. Layered Manufacturing Machine for Polystyrene Objects
Layered Manufacturing (LM) is any automatic process to produce physical prototypes of 3D objects from
their CAD models in a layer by layer manner. Laminated Object Manufacturing (LOM) is a LM process in
which sheets of uniform thickness cut to the desired shape are stacked and glued together to get the physical
prototype. The process proposed here for making polystyrene prototypes is a modified version of the
existing LOM process with certain improvements as follows:
i.
The raw material is input as a block unlike a sheet roll of constant thickness in the existing LOM
process.
ii. Adaptive slicing with 1st order edge approximation is employed. This results in accurate patterns and
parts. For the same accuracy, the number of layers will be considerably less when this type of slicing is
employed. In conventional LOM, adaptive slicing is not possible as it uses sheet roll.
iii. The accuracy requirements of foam objects and the force experienced in cutting them are very less
compared to conventional machining. Therefore, this RP machine needs to have only low accuracy (of
the order of 0.2 mm) and rigidity. However, generally these foam objects are huge. Therefore, it is
proposed to build LM machine with optimal rigidity and accuracy. This will be achieved by employing
simple tubular structures, use of ordinary lead screws or wire-pulley drives instead of ball lead screws,
open loop control using stepper motors instead of servo-motors in closed loop, PC-based control
electronics etc. Due to this approach, even a large machine will cost much less than a CNC machine of
similar size.
iv. The adhesive used in the conventional EPC pattern making is of non-uniform thickness and hence it can
become inclusions due to incomplete burning. This process will use very little adhesive of uniform
thickness since it is applied on horizontal planar surfaces. Subsequently, methods to join the layers
without adhesive would be developed using localised heating. We shall also explore other adhesiveless
joining processes such as use of ultrasonic energy for this purpose.
v. In future, it is proposed to make the layers in-situ from Expandable Polystyrene (EPS). This will
eliminate the joining process and layer transportation.
The important advantages of foam pattern making using the proposed RP machine are:
-
This will be the first automatic method for making foam patterns. Presently, these patterns are made by
injection molding for mass production and manually when only a few castings are required. High cost
and time spent in making these patterns hinders its wide acceptance in the industry.
Curriculum Vitae of K.P. Karunakaran
-
-
6
Very large and intricate prototypes can be produced at lower cost in this process.
Conventional foam pattern manufacture requires the pattern to be made of several simpler pieces which
are glued together. One requires one pair of dies for each such piece. Often, the same die pair cannot
be used for injection molding as well as gluing operation. In the proposed RP process, one does not
require any tooling.
The proposed RP machine can be used for job-shop or small batch running-in production.
If the complexity of the castings such as the engine block is too high requiring several die sets and
gluing operations, the RP process can be economically employed even for mass production of these
castings. Some hollow castings such as engine manifolds are redesigned for lost-foam casting adding
additional flanges. Such a redesign and flanges are not required when the proposed RP machine is used.
2. Elimination of Stock Cutting and Decubing in Laminated Object Manufacturing Type of
Rapid Prototyping
Only when there is remaining stock, the LOM machine requires cross-hatching and decubing. We segment
the remaining stock into drawable chunks and feed their geometry as STL files to the machine along with the
STL file of the required part. The machine treats all of them as useful parts and makes them together. Thus,
there is no grid cutting and decubing. This method results in
[i] Drastic reduction in protopyping time and hence cost
[ii] Improved quality of the parts free from cross-hatching marks.
We also arrived at the optimal gap between these chunks experimentally. We found this optimal gap to be
slightly more than the diameter of the laser beam. For example, for a laser beam diameter of 0.254mm, the
optimal gap is 0.300mm.
10. PUBLICATIONS
a) Papers in international journals:
1. Dhande, S.G., Karunakaran, K.P. and Misra, B.K., "Geometric Modeling of Manufacturing
Processes using Symbolic and Computational Conjugate Geometry" Journal of Engineering for
Industry, Transactions of ASME, Vol. 117, No. 3 (August 1995) pp. 288-296.
2. Dhande, S.G. and Karunakaran, K.P., "Symbolic & Computational Conjugate Geometry of a
Generic Cutter and Machine Tool Assembly", Journal of Design and Manufacture, (1994)4, pp.
167-186.
3. Karunakaran, K.P. and Dhande, S.G., "Computer Aided Design of Cutters for Helicoidal
Surfaces", I MECH E Journal of Engineering Manufacture, Vol. 212, No. B5 pp. 373-382 (August
1998).
4. Karunakaran, K.P. and P. Vivekananda Shanmuganathan, "Swept Volume of a Generic Cutter",
I MECH E Journal of Engineering Manufacture (to appear).
5. Karunakaran, K.P., Shivmurthy Dibbi, P. Vivekananda Shanmuganathan, D. Satyanarayana Raju
and Srinivasarao Kakaraparti, "Optimal Stock Removal in LOM-RP", I MECH E Journal of
Engineering Manufacture (to appear as a short communication).
6. K.P. Karunakaran, P. Vivekananda Shanmuganathan, Sanjay Janardhan Jadhav, Prashant
Bhadauria and Ashish Pandey, “Rapid Prototyping of Metallic Parts and Moulds”, Journal of
Materials Processing Technology (to appear).
7. Karunakaran, K.P., Shivmurthy Dibbi, P. Vivekananda Shanmuganathan, Srinivasarao Kakaraparti
and D.Sathyanarayana Raju, "Efficient Stock Cutting in Laminated Object Manufacturing",
Computer-Aided Design (accepted; under revision).
8. K.P. Karunakaran, P. Vivekananda Shanmuganathan, Manoj Issac, Nitin Gupta, Rahul Kulkarni
and Akshay J. Prabhu, “Conversion of Octree to B-Rep”, Computer-Aided Design
(communicated).
b) Papers in national journals:
1. Karunakaran, K.P., Review of the Book "Shaft Alignment Handbook" by John Piotrowski
published by Marcel Dekker, The Engineers, Institution of Mechanical Engineers (India), Vol. 77,
No. 10, pp. 20 & 21, (August 1996).
Curriculum Vitae of K.P. Karunakaran
c)
7
Papers in international conference proceedings:
1. Dhande, S.G. and Karunakaran, K.P., "Realizability of Computer Aided Design", an invited talk in
Graphics, Design and Visualization, Proceedings of the IFIP International Conference on
Computer Graphics 1993 - ICCG93, Bombay (India) (February, 1993), pp. 259-270.
2. Karunakaran, K.P., Avadhani, P.S. and Dhande, S.G., "Computational Geometry and Animation of
Conjugate Surfaces", 6th International Conference on Engineering Computer Graphics and
Descriptive Geometry, (ICECGDG-94), Tokyo, Japan (August 1994).
3. Karunakaran, K.P. and K. Nilesh Kumar, "Retrofitment of a CNC Machine with a PC-Based
Adaptive Controller", 7th International Manufacturing Conference in China (IMCC-95), Harbin,
China (October 1995).
4. Karunakaran, K.P. and Ushakiran, G., "Development of Non-Developable Surfaces", Proceedings
of the International Conference on Sheet Metal (SheMet-97), University of Ulster at Jordanstown,
Northern Ireland, pp. 319-330, April 8-10, 1997.
5. Karunakaran, K.P., Vivekananda Shanmuganathan P., "Octree Based Volumetric NC Simulation ",
World Manufacturing Congress WMC-96, Canada, (November 1997).
6. Karunakaran, K.P., "Low-Cost Automation for India", Country Paper, Training on Low-Cost
Automation Sponsored by Asian Productivity Organization (APO), Asian Hotel, Bangkok,
Thailand, Nov. 24 - Dec. 4, 1997.
7. Karunakaran K.P., Vivekananda Shanmuganathan P., Roth-Koch S. and Koch Kai Uwe, (1998):
“A Two-step RP Process for Direct and Accurate Manufacture of Tools”, 7th European Conference
of Rapid Prototyping & Manufacture, Aachen, Germany, July 7-9.
8. Karunakaran K.P., Vivekananda Shanmuganathan P., Roth-Koch S. and Koch Kai Uwe, (1998):
“Direct Rapid Prototyping of Tools”, 9th Solid Freeform Fabrication Symposium, Austin, pp. 105112 (August 10-12).
9. Karunakaran, K.P., (1999) "Computer-Integrated Manufacturing (CIM) Systems in India", Country
Paper, Seminar on Computer-Integrated Manufacturing (CIM) Systems Sponsored by Asian
Productivity Organization (APO), Olympia Hotel, Seoul, Korea, Oct. 18 - 23.
10. Karunakaran, K.P., D. Satyanarayana Raju, Srinivasarao Kakaraparti, P. Vivekananda
Shanmuganathan and Shivmurthy Dibbi, "Optimization of Decubing in LOM-RP", 8th European
Conference on Rapid Prototyping, Paris, May 3-4, 2000 pp. 1-7 in the session “From Pattern
Making to Prototyping”.
d) Papers in national conferences:
1. Karunakaran, K.P. and Dhande, S.G., "Cutter Path Simulation and NC Program Optimization",
Proceedings of the National Conference on Design of Mechanical Systems (NACOMM-93), IIT
Kharagpur (India) (December, 1993) pp. 80-93.
2. Karunakaran, K.P. and K. Nilesh Kumar, "Retrofitment of a CNC Machine with a PC-Based
Adaptive Controller", Seminar on CAD/CAM Applications in Aerospace organized by
Aeronautical Society of India, Aeronautical Development Agency and Aeronautics Research &
Development Board, Bangalore, (July 1995) pp. 183-192.
3. Karunakaran K.P., Vivekananda Shanmuganathan P., Tappe N.S and Kota Bapu, "NC Program
Simulation Using Octree Solid Modeling for Verification and Optimization of Cutting Parameters",
UG User Meet 1996, Madras, (September 1996).
4. Karunakaran, K.P., Vivekananda Shanmuganathan P., Roth-Koch S. and Koch Kai Uwe,"Direct
Rapid Prototyping of Tools", AIMTDR, IIT Kharagpur (December 21-23, 1998).
5. Karunakaran, K.P., Shailesh Bhadade and Vivekananda Shanmuganathan P.,"Off-line Adaptive
Control", AIMTDR, IIT Kharagpur (December 21-23, 1998) pp. 53-58.
6. Karunakaran, K.P., Sushant Kumar, T. Karthikeyan, Vivekananda Shanmuganathan P. and Sabine
Roth-Koch, "Photogrammetric Object Synthesis for Reverse Engineering", AIMTDR, IIT
Kharagpur (December 21-23, 1998) pp. 351-356.
7. Karunakaran, K.P., Karthikeyan, T. and Vivekanananda Shanmuganathan, P., “Automation in
Welding”, Invited lecture, Seminar on Welding Productivity through Automation Organized by
Indian Institute of welding (IIW), Ramada Hotel Palm Grove, Juhu, Mumbai, (December 12, 1998)
pp. 1-18 in Technical Session II.
8. Mohanty, R.R., Subash Babu, A. and Karunakaran, K.P., “Systems and Procedures for Quality
Management in Electrical Motor Industry – A Case Study”, Trends in Mechanical Engineering
Education and Research - Proceedings of the 11th ISME Conference, IIT Delhi, February 3-5,
1999, pp. 280-285.
Curriculum Vitae of K.P. Karunakaran
8
e)
Invited lectures:
1. Dhande, S.G. and Karunakaran, K.P., "Realizability of Computer Aided Design", an invited talk in
Graphics, Design and Visualization, Proceedings of the IFIP International Conference on
Computer Graphics 1993 - ICCG93, Bombay (India) (February, 1993), pp. 259-270.
2. Karunakaran, K.P., "Issues of Learning and Teaching Computer Aided Drafting", Guest Lecture in
the Winter School on Computer Aided Drafting, Motilal Nehru Regional Engineering College,
Allahabad (India) (December, 1993).
3. Karunakaran, K.P., “Introduction to Rapid Prototyping & Tooling”, Seminar on Rapid
Prototyping, Organized by GE Silicone, Hotel Blue Diamond, Pune (August 14, 1998).
4. Karunakaran, K.P., “Rapid Prototyping of Metallic Parts and Tools”, Invited lecture, ,DMRL,
Hyderabad (October 29, 1998).
5. Karunakaran, K.P., Karthikeyan, T. and Vivekanananda Shanmuganathan, P., “Automation in
Welding”, Invited lecture, Seminar on Welding Productivity through Automation Organized by
Indian Institute of welding (IIW), Ramada Hotel Palm Grove, Juhu, Mumbai, (December 12,
1998).
6. Karunakaran, K.P., “Development of a Hybrid Layered Manufacturing Process”, School of
Mechanical and Aerospace Engineering, Seoul National University (October 25, 1999).
7. Karunakaran, K.P., “Research on Layered Manufacturing in India”, School of Mechanical and
Aerospace Engineering, Korea Advanced Institute of Science and Technology (KAIST) (October
27, 1999).
8. Karunakaran, K.P., “Introduction to Solid Modeling”, One Day Seminar on Applications of
CAD/CAM Using I-DEAS and Its Relevance to Engineering Design and Manufacturing, K.J.
Somaiya College of Engineering, Mumbai, March 25, 2000.
f)
Books/ monographs/ proceedings:
1. Karunakaran, K.P., (1997): PC-Based Solid Modeling Using AutoCAD - Exercise Book in CADD.
2. Karunakaran K.P., Bapat V.P. and Ravi B., (1998): Rapid Prototyping & Tooling: New Paradigms
in Design and Manufacture, Proceedings of Workshop on RP&T, IIT Bombay, February 6-8.
3. Subash Babu A., Karunakaran K.P. and Deshmukh S.G., (1996): Advanced Manufacturing
Technology, Proceedings of the Second SERC School, IIT Bombay, (December 1996).
11. SHORT-TERM COURSES ORGANIZED
1. K.P. Karunakaran and N. Ramaswamy, Computer Aided Design and Drafting (CADD), 5 Day Open
CEP Course, IIT Bombay, August 28 - September 1, 1995.
2. K.P. Karunakaran and N. Ramaswamy, PC-Based Solid Modeling Using AutoCAD, 4 Day Open CEP
Course, IIT Bombay, June 17-20, 1996.
3. K.P. Karunakaran and N. Ramaswamy, PC-Based Solid Modeling Using AutoCAD, 4 Day Open CEP
Course, IIT Bombay, November 25-28, 1996.
4. K.P. Karunakaran, PC-Based Solid Modeling Using AutoCAD, 4 Day Open CEP Course, IIT Bombay,
April 28 - May 1, 1997.
12. SEMINARS/ WORKSHOPS ORGANIZED
1. V.P. Bapat and K.P. Karunakaran, Rapid Prototyping - A Way to Speed up the Design Process, One
day Seminar, IIT Bombay, January 21, 1996.
2. A. Subhash Babu, K.P. Karunakaran and S.G. Deshmukh, Second SERC School on Advanced
Manufacturing Technology, Sponsored by Department Science & Technology, Held at IIT Bombay,
December 9-21, 1996.
3. B. Ravi, V.P. Bapat, and K.P. Karunakaran, Rapid Prototyping and Tooling, Two day Workshop, IIT
Bombay, April 18 & 19, 1997.
4. K.P. Karunakaran, CII-IIT Training Workshop on PC-Based Solid Modeling Using AutoCAD, IIT
Bombay, November 27-28, 1997.
5. K.P. Karunakaran, V.P. Bapat, and B. Ravi, Workshop on Rapid Prototyping and Tooling, IIT
Bombay, February 6 - 8, 1998.
6. V.P. Bapat, K.P. Karunakaran and B. Ravi, Medical Applications of Rapid Prototyping, One day
Workshop, IIT Bombay, November 1, 1998.
13. SPONSORED RESEARCH PROJECTS
Curriculum Vitae of K.P. Karunakaran
Sl.
No.
Title
9
Sponsoring
Agency
Value of
the Project
Investigators
AICTE’s MODROBS
Project
Rs 6.500
Lacs.
Dr K.P. Karunakaran
(Completed)
2. Upgradation of CAD/CAM/CAE Onward Technologies
facilities in Computer Graphics
Ltd., Mumbai
Laboratory
Rs 0.450
Lacs.
Dr K.P. Karunakaran
(Ongoing)
3. Shape Prototyping – a Module of
IDCM Technology Mission
Executed by IIT Bombay and IIT
Kanpur
Rs 200.000
Lacs
Prof. V.P. Bapat, IDC
Dr K.P. Karunakaran
and others.
1. Modernization and Removal of
Obsolescence in Computer
Graphics Laboratory
MHRD – TDM I
(Completed)
4. Concurrent and Integrated
Department of
Management System for Industrial Electronics (DoE)
Products Enterprises (CIMSIP
Enterprise - 2000)
Rs 37.950
Lacs
Prof. A. Subash Babu
Dr K.P. Karunakaran
5. Development of a Volumetric NC Department of Science
Simulation System for Verification and Technology (DST)
and Optimisation
Rs 9.516
Lacs
Dr K.P. Karunakaran
6. Development of a Layered
Department of
Manufacturing Process for Metallic Electronics (DOE)
Tools
Rs 39.192
Lacs
Dr K.P. Karunakaran
7. LayMan: A Software for Layered
Manufacturing
Aeronautical
Development Agency
(ADA), Bangalore
Rs. 7.015
lakhs
Dr K.P. Karunakaran
8. Rapid Prototyping of Polystyrene
Objects
MHRD – TDM II
Rs. 136.610
lakhs
Dr K.P. Karunakaran
(Ongoing)
(Ongoing)
(New)
(Yet to be approved)
Prof. V.P. Bapat, IDC
(Yet to be approved)
9. Rapid Prototyping of Polystyrene
Patterns
Defence Metallurgical
Research Laboratory
(DMRL), Hyderabad
Rs. 26.000
lakhs
Dr K.P. Karunakaran
Prof. P.D. Solanki
(Yet to be approved)
10. Software for Optimal Stock
Removal in LOM-RP
14. CONSULTANCY PROJECTS
Sl.
Title
No.
MHRD’s R&D Scheme Rs. 10.00
lakhs
Sponsoring
Agency
Value of
The Project
Dr K.P. Karunakaran
(Yet to be approved)
Consultants
1. Development of MUNEST – A
Nesting Software for a Heavy
Engineering Company
Mukand Limited, Thane, Rs. 1.2
Bombay
Lacs.
Dr. S.S. Pande
Dr. K.P. Karunakaran
2. Computer Aided Drafting
VIIT, Bombay
Rs 0.444
Lacs.
Dr K.P. Karunakaran
3. Design of Acrylic Spectacles
Metro, Bombay
Frame and Design and Manufacture
of Injection Moulding Dies for the
Same
Rs 0.30
Lacs.
Dr. K.P. Karunakaran
4. Retainer Consultant in the Area of Geometric Software
Nesting
Services Ltd., Mumbia
Rs. 0.20 lacs. Dr. K.P. Karunakaran
Per month
Curriculum Vitae of K.P. Karunakaran
10
15. AWARDS AND RECOGNITIONS
 I passed B.E. with Honors.
 The project work I did in the final year of B.E. course entitled "Automation of Bobbin Ring Press" won
the KCP Endowment Award for being the best project of the year in Anna University, Madras.
 At the end of the training, I won the "Wilkinson Sword", a prestigious rolling trophy in HAL given to
the best management trainee of the year.
 I am a member of American Society of Mechanical Engineers (ASME).
 I am a member of the Editorial Board of International Journal of CAD/CAM that will be launched
shortly from Seoul National University, Korea.
 I have reviewed papers for journals such as ASME Jr. of Manufacturing Sciences, IEE Journal of
Design and Manufacture etc.
 I received INSA Fellowship to visit Germany during April - June 1998 under INSA-DFG Scientist
Exchange Program.
 I was selected by Asian Productivity Organization (APO) to attend two of their programs, one on LowCost Automation in Bangkok in 1997 and the other on Computer-Integrated Manufacturing (CIM)
Systems in Seoul in 1999.
 I am a member of one of the Steering Committees of Department of Electronics (DoE).
 I am a retainer-consultant to Geometric Software Services Limited, Mumbai.
 I worked as a consultant/ specialist in CNC and RP at Mercedes-Benz Technology Centre of Daimler
Chrysler AG, Sindelfingen, Germany during June 1– July 31, 2k.
 Mercedes-Benz Technology Centre of Daimler Chrysler AG awarded me a cash bonus of DM 3,500 in
appreciation of my contributions in the areas of CNC and RP.
 I was a member of the Evaluation Committee of All India Council for Technical Education (AICTE) for
the year 2000.
16. COUNTRIES VISITED
1) West Germany (June 27 - July 10, 1988):
Place :
Waldrich Siegen Machine Tools, Waldrich.
Purpose :
Training on Programming and Operation of Waldrich Siegen 3-spindle 5-axis CNC
machine. This is the largest CNC machine in India.
2) Thailand (November 23 - December 4, 1997):
Place :
Thailand Productivity Institute, Bangkok.
Purpose :
Training on Low-Cost Automation organized by Asian Productivity Organization (APO).
3) Hong Kong (December 4 - December 11, 1997):
Place :
Hong Kong University of Science & Technology, Kowloon, Hong Kong.
Purpose :
Joint research with Prof. Ajay Joneja on LOM Based RP Process. We worked on an
algorithm during this visit to extract the prototype from its cuboidal stock with minimum
possible cuts.
4) Germany (March 30 - June 30, 1998):
Place :
Fraunhofer Institute for Production Technology and Automation (FhG-IPA), Stuttgart.
Purpose :
Visiting under INSA's Scientist Exchange Programme.
5) Belgium (May 16 – May 20, 1998):
Place :
Katholieke Universiteit, Leuven.
Purpose :
IEEE Conference on Robotics and Automation.
6) Korea (October 17 - 28, 1999):
Place :
Korea Productivity Institute, Seoul.
Purpose :
Seminar on Computer-Integrated Manufacturing (CIM) Systems organized by Asian
Productivity Organization (APO).
I also visited and delivered lectures at Seoul National University and KAIST.
7) France (May 1 - May 5, 2000):
Place :
CNIT, Paris
Purpose :
8th European Conference on Rapid Prototyping organized by AFPR, Paris. I presented a
paper on "Optimization of Decubing in LOM".
8) Germany (June 01 – July 31, 2000):
Place :
Daimler Chrysler, Sindelfingen.
Curriculum Vitae of K.P. Karunakaran
Purpose :
11
DaimlerChrysler AG (DC) is Europe’s leading manufacturer of automobiles and various
types of earthmovers. World famous Benz cars are designed at Mercedes-Benz
Technology Center (MTC) of DaimlerChrysler AG at Sindelfingen. I Worked in MTC for
two months during June 01 - July 31 of this year as a consultant/ specialist in the areas of
CNC and RP. The following are my contributions to MTC during this visit:
i.
I introduced volumetric NC simulation in their NC programming cycle. Better
visualization and optimization of feed rate achieved through volumetric NC
simulation substantially reduces both NC programming cycle time and component
machining time.
ii. I verified experimentally the method I had developed earlier to eliminate stock
cutting and decubing in LOM-RP at their division in Stuttgart. This method reduces
the prototyping time and improves the quality of the prototype. We have jointly
applied for a patent on this method.
iii. DC, in collaboration with a laser equipment manufacturer called Trumpf, have been
using laminated tooling for sheet metal manufacture. DC and Trumpf are now keen to
develop a LOM-RP machine for the automatic manufacture of laminated tools. They
have shown interest in collaborating with us for developing the required software
consisting of modules for healing the STL file, slicing and path generation.
The various divisions of DC and Trumpf have shown interest to offer on-the-jobtraining to our students. We can make use of this offer to provide rich vacation training to
our B.Tech. students at the end of 3rd year and our DD/ M.Tech. students can spend a few
months in these companies during their thesis period.
17. MARITAL STATUS
I am married and we are blessed with three children. First two are daughters aged 13 and 9 respectively.
The last child is a son who is 4 years old.
18. NAMES OF REFEREES
Dr Sanjay G. Dhande
Professor, Mechanical Engg. And Computer Science
Co-Ordinator, CAD Project
Indian Institute of Technology
Kanpur 208016, INDIA
e-mail : [email protected]
Phone : +91-512-250151 Ext. 2408
FAX
: +91-512-250007
Dr A. Subash Babu
Professor
Dept. of Mechanical Engineering
Indian Institute of Technology, Bombay
Powai, Mumbai 400076, INDIA
e-mail : [email protected]
Phone : +91-22-5767532