Daniel Walczyk Associate Professor 4026 Jonsson Engineering Center Tel: (518) 276-2397; Fax: (518) 276-2623; E-Mail: walczd@rpi.edu [ MANE || Faculty ]

Daniel F. Walczyk, Ph.D., PE is an Assistant Professor in the Department of Mechanical Engineering, Aerospace Engineering and Mechanics. He received a B.S. from Syracuse University in 1986, a M.S. from Rensselaer Polytechnic Institute in 1991, a P.E. License from New York State in 1994 and a Ph.D. from Massachusetts Institute of Technology in 1996, all in mechanical engineering. Prior to his graduate work, Dr. Walczyk worked in industry, primarily with the GE Company, as a mechanical design engineer. Since becoming an academic in January 1996, he has received several awards and honors including a DAAD Fellowship, NSF Faculty Early CAREER Development Award in 1998, Loctite Corp. Summer Engineering Faculty Fellowship in 1998, and a Presidential Early Career Awards for Scientists and Engineers (PECASE) in 1999. He is also a holder of two U.S. patents.

Research Interests and Activities

His research interests are generally in developing rapid manufacturing methods. Specific research projects include:
· Development and Implementation of Laminated Tooling Methods
· Reconfigurable Discrete (bed-of-pins) Tooling
· Simplified Fixturing Methods for Compliant Parts
· Reconfigurable Fixturing Devices for Compliant Parts
· Fixture-less Assembly Methods for Compliant Parts
· Laser Forming of Exotic Metals (e.g., titanium)

 

Teaching Interests

Dr. Walczyk's teaching interests include mechanical design, machine design, and manufacturing.

Selected Publications

Walczyk, D.F., and Longtin, R.S., "Fixturing of Compliant Parts Using a Matrix of Reconfigurable Pins," submitted to the ASME Journal of Manufacturing Science and Engineering.

Im, Y.-T., Walczyk, D.F., Schwarz, R.C., Papazian, J., "A Comparison of Pin Actuation Schemes for Large-scale Discrete Dies," submitted to the SME Journal of Manufacturing Systems.

Walczyk, D.F., and Im, Y.-T., "Control of a Hydraulically-Actuated Reconfigurable Tool for Flexible Fabrication," scheduled for publication in the May 2000 issue of the ASME Journal of Manufacturing Science and Engineering.

Walczyk, D.F., and Raju, V., "Simplifying the Development and Usage of Fixtures for Sheet Metal and Composite Aircraft Parts," scheduled for publication as a Technical Brief in the February 2000 issue of the ASME Journal of Manufacturing Science and Engineering.

Walczyk, D.F., Raju, V., and Miller, R., "Fixture-less Assembly of Sheet Metal Parts for the Aircraft Industry," accepted for publication in the Proceedings of the Institution of Mechanical Engineers: Journal of Engineering Manufacture.

Walczyk, D.F. and Hardt, D.E., "A Comparison of Rapid Fabrication Methods for Sheet Metal Forming Dies," ASME Journal of Manufacturing Science and Engineering, Vol. 121, No. 1, 1999.

Misiolek, W. Z., Walczyk, D.F., and Rock, S.J., "Rapid Prototyping and Rapid Tooling Methods for Metal Forming," Proceedings of Rudy Metale, R 43, 1998, No. 5, pp. 619-625.

Walczyk, D.F., "Bevel Cutting Methods and Cutting Trajectory Control for Steel Laminations Used in Tooling," Proceedings of the Ninth Solid Freeform Fabrication Symposium, Austin, TX, Aug. 10-12, 1998.

Walczyk, D.F. and Hardt, D.E., "Design and Analysis of Reconfigurable Discrete Dies for Sheet Metal Forming," SME Journal of Manufacturing Systems, Vol. 17, No. 6, 1998, pp. 436-454.

Walczyk, D.F., Lakshmikanthan, J., and Kirk, D., "A Reconfigurable Tool for Forming Aircraft Body Panels," Journal of Manufacturing Systems, Vol. 17, No. 4, 1998, pp. 287-296.

Walczyk, D.F., and Hardt, D.E., "Rapid Tooling for Sheet Metal Forming using Profiled-Edge Laminations-Design Principles and Demonstration," Journal of Manufacturing Science and Engineering, Vol. 120, No. 4, November 1998, pp. 746-754.

Walczyk, D.F. and Dolar, N.Y., "Bonding Methods for Laminated Tooling," Proceedings of the Eighth Solid Freeform Fabrication Symposium, Austin, TX, Aug. 11-13, 1997, pp. 211-222.