Youssef Ziada, Ph.D. Email and Phone Number

As the Battery Manufacturing Process Engineering Lead, I am responsible for the Electrode production and Cell Assembly, Formation, Module assembly and Factory Automation technology that supports the BOSK joint venture with SK. Building three of the biggest battery plants in North America.

As the corporate Digital Manufacturing Technical Expert I was responsible for leading the development and implementation of analytical manufacturing models, the further development of dynamic modelling capabilities and the monitoring of process and asset health (IIoT). These technologies assist Powertrain Manufacturing in meeting the business objectives of shortening the product cycle, improving quality and reducing costs.

• Optimized machining operations based on FEA & semi empirical models to reduce cutting forces and improve part quality.• Developed physics based FEA models, in Nastran & Abaqus, of machining operations for powertrain component.• Advised changes in the part or machining process, based on simulation, to improve final part quality or verify that components can be manufactured to tolerance. • Provided feedback to product development on machinability of components in pre-program stage. • Acted as lead CAE engineer for all RWD programs as well as for an I4 block program. • Developed fixturing strategy for V Engine Blocks. • Developed numerous novel simulation techniques for simulating powertrain machining. •Mentored junior engineers in FEA and machining principles.

Simulated metal cutting in order to predict machining induced residual stresses. - Physics Based FEA Model of the cutting process - High Strain and Strain Rate Analysis - Introduced phase transformation prediction into the model.- Vastly improved accuracy of residual stress prediction. Performed orthogonal cutting tests for validation purposes- Hands on Experience with various CNC machining operations. - Experienced in the use, setup and calibration of dynamometer equipment. - 3-D tool wear profile measurement to evaluate tools. - Metallographic testing for microstructure analysis.

- Acted as First point of contact for junior group members - Responsible for training all new members of research group - Directed experimental procedures and provided technical guidance- Typically overseeing between 4 and 6 projects at a time- Developed significant expertise in multidisciplinary projects.

3FE3 - Prepared and delivered a third year Finite Element Analysis Course.Course focused on teaching a fundamental understanding of the finite element analysis as well as an applied understanding of ANSYS. (Course Evaluation: 9.5/10)3CT3 - Instructed and Supervised the Laboratory portion of a third year controls course. Lab sections focused on hands on understanding of PID and ON-OFF control of a number of simple systems, as well as a more fundamental understanding of controls. (Course Evaluation 9/10)3TS3 - Instructed and Supervised the Laboratory portion of a third year fluids course.Lab sections involved characterizing a wide variety of fluid systems, ranging from a couple of different turbine types, to impact of jet on a plate and even an Osborne Reynolds Apparatus. (Course Evaluation 9/10)

- Developed in depth knowledge of the Electrical Discharge Machining (EDM) Process. - Created complex EDM tool paths in order to improve flushing conditions. - Developed EDM tool wear predictions.- Implemented high speed data acquisition (>10 MS/s per Channel). - Investigated acoustic emission monitoring for spark location monitoring. - Designed comprehensive test matrices.

- Developed accelerated tool wear testing methodologies for milling operations. - Hands on experience with both manual and CNC mills and lathes.- Performed optical tool wear measurements.- Developed a test rig for in-situ cutting experiments inside a scanning electron microscope.