Gracious Ngaile

Professor

  • 919-515-5222
  • Engineering Building III (EB3) 3160
  • Visit My Website

Dr. Ngaile’s long-term goal is to contribute to the dramatic reduction of the use of toxins in metal forming lubricants.

At the undergraduate level, Dr. Ngaile teaches Modern Manufacturing Processes (MAE 495M) and Mechanical Engineering Design (MAE 416). In his manufacturing course, the students receive a hands-on introduction to modern manufacturing processes. Dr. Ngaile conveys his own experiences in manufacturing and takes the students on a tour of a manufacturing plant. In his design course, Dr. Ngaile places an emphasis on the general features of the design processes – addressing issues that go beyond the design project being completed that semester.

Dr. Ngaile teaches Materials Processing by Deformation (MAE 731), which exposes the students to a wide range of metal forming processes including state-of-the-art techniques, and he teaches Applied Finite Element Method (MAE 589). In his applied finite element course, the focus is on developing the capability to solve a wide range of problems involving solids, thermal, fluids, and vibration. In MAE he collaborates with Dr. Fang.

Dr. Ngaile’s graduate students have a strong interest in solid mechanics. They gain experiences with numerical modeling of metal forming processes and hands-on experiences with machine design.

Outside of work, Dr. Ngaile enjoys to travel.

Education

Ph.D.

Mechanical Engineering

Kumamoto University

M.S.

Mechanical Engineering

Kumamoto University

B.S.

Mechanical Engineering

University of Dar Es Salaam

Research Description

Dr. Ngaile is interested in design and manufacturing, tribology in manufacturing, modeling and optimization of manufacturing processes, material characterization, and finite element analysis. Dr. Ngaile is developing new formulations of metal forming lubricants, and is studying how to tailor metal forming processes to minimize the quantity of toxic-rich lubricants needed in these processes. Also, he is studying the influence of ultrasonic vibration on microforming processes.

Publications

Scalability of conventional tube hydroforming processes from macro to micro/meso
Lowrie, James and Ngaile, Gracious (2018), PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE, 232(12), 2164-2177.
Weight reduction of heavy-duty truck components through hollow geometry and intensive quenching
Lowrie, J. and Pang, H. and Ngaile, G. (2017), Journal of Manufacturing Processes, 28(), 523-530.
A novel hybrid heating method for mechanical testing of miniature specimens at elevated temperature
Li, L. and Ngaile, G. and Hassan, T. (2017), Journal of Micro and Nano-Manufacturing, 5(2), .
Analytical modeling of hydrodynamic lubrication in a multiple-reduction drawing die
Lowrie, J. and Ngaile, G. (2016), Procedia Manufacturing, 5(), 707-723.
New punch design for the elimination of punch ejection load through manipulation of the elastic strain field in the punch nose
Lowrie, J. and Ngaile, G. (2016), Journal of Manufacturing Processes, 22(), 49-59.
Preliminary investigation of the process capabilities of hydroforging
Alzahrani, B. and Ngaile, G. (2016), Materials, 9(1), .
A novel hybrid heating method for elevated temperature mechanical testing of miniature specimens
Li, L. and Ngaile, G. and Hassan, T. (2016), Proceedings of the ASME 11th International Manufacturing Science and Engineering Conference, 2016, vol 1, (), .
Die-less hydroforming of multi-lobe tubular structures
Hummel, S. and Ngaile, G. (2015), Proceedings of the Institution of Mechanical Engineers. Part B, Journal of Engineering Manufacture, 229(3), 435-452.
Novel extrusion punch design for improved lubrication and punch ejection
Lowrie, J. and Ngaile, G. (2015), Proceedings of the ASME 10th International Manufacturing Science and Engineering Conference, 2015, vol 1, (), .
Development of chemically produced hydrogen energy-based impact bonding process for dissimilar metals
Ngaile, G. and Lohr, P. and Lowrie, J. and Modlin, R. (2014), Journal of Manufacturing Processes, 16(4), 518-526.
Enhancement of tribological performance via innovative tooling design for extrusion processes
Lowrie, J. B. and Ngaile, G. (2014), Proceedings of the ASME 9th International Manufacturing Science and Engineering Conference, 2014, vol 2, (), .
Optimal load path input in tube hydroforming machines
Ngaile, G. and Welch, G. (2012), Proceedings of the Institution of Mechanical Engineers. Part B, Journal of Engineering Manufacture, 226(B4), 694-707.
Advances in plastic forming of metals
Ngaile, G. and Kinsey, B. (2011), Journal of Manufacturing Science and Engineering, 133(6), .
Database for real-time loading path prediction for tube hydroforming using multidimensional cubic spline interpolation
Ghosh, A. and Deshmukh, K. and Ngaile, G. (2011), Proceedings of the ASME International Manufacturing Science and Engineering Conference 2010, vol 1, (), 609-618.
Influence of ultrasonic vibration on micro-extrusion
Bunget, C. and Ngaile, G. (2011), Ultrasonics, 51(5), 606-616.
Preform design for tube hydroforming based on wrinkle formation
Yang, C. and Ngaile, G. (2011), Journal of Manufacturing Science and Engineering, 133(6), .
Real-time friction error compensation in tube hydroforming process control
Ngaile, G. and Yang, C. and Kilonzo, O. (2011), Journal of Manufacturing Science and Engineering, 133(6), .
Database for real-time loading path prediction for tube hydroforming using multidimensional cubic spline interpolation
Ghosh, A. and Deshmukh, K. and Ngaile, G. (2010), Journal of Materials Processing Technology, (), .
Preform design for forging and extrusion processes based on geometrical resemblance
Yang, C. and Ngaile, G. (2010), Proceedings of the Institution of Mechanical Engineers. Part B, Journal of Engineering Manufacture, 224(), 1409-1423.
Analytical model for the characterization of the guiding zone tribotest for tube hydroforming
Ngaile, G. and Yang, C. (2009), Journal of Manufacturing Science and Engineering, 131(2), .
Analytical model for characterizing the pear-shaped tribotest for tube hydroforming. Part 1
Ngaile, G. and Yang, C. (2008), Proceedings of the Institution of Mechanical Engineers. Part B, Journal of Engineering Manufacture, 222(7), 849-863.
Analytical model for planar tube hydroforming: Prediction of formed shape, corner fill, wall thinning, and forming pressure
Yang, C. and Ngaile, G. (2008), International Journal of Mechanical Sciences, 50(8), 1263-1279.
Applications of analytical model for characterizing the pear-shaped tribotest for tube hydroforming. Part 2
Ngaile, G. and Yang, C. (2008), Proceedings of the Institution of Mechanical Engineers. Part B, Journal of Engineering Manufacture, 222(7), 865-873.
Performance of graphite and boron-nitride-silicone based lubricants and associated lubrication mechanisms in warm forging of aluminum
Ngaile, G. and Botz, F. (2008), Journal of Tribology, 130(2), .
Evaluation of new cold forging lubricants without zinc phosphate precoat
Gariety, M. and Ngaile, G. and Altan, T. (2007), International Journal of Machine Tools & Manufacture, 47(3-4), 673-681.
Formulation of polymer-based lubricant for metal forming
Ngaile, G. and Cochran, J. and Stark, D. (2007), Proceedings of the Institution of Mechanical Engineers. Part B, Journal of Engineering Manufacture, 221(4), 559-568.
A tribo-testing method for high performance cold forging lubricants
Ngaile, G. and Hiroyuki, S. and Ruan, L. and Marumo, Y. (2007), Wear, 262(), 684-692.
Enhancing tribological conditions in tube hydroforming by using textured tubes
Ngaile, G. and Gariety, M. and Altan, T. (2006), Journal of Tribology, 128(3), 674-676.
Progressive die sequence design for deep drawing round cups using finite element analysis
Altan, T. and Jain, N. T. and Shi, X. X. and Ngaile, G. and Pax, B. and Harman, B. and Homan, G. (2006), Journal of Manufacturing Science and Engineering, 128(1), 366-369.
Evaluation of stamping lubricants at various temperature levels using the ironing test
Chandrasekharan, S. and Palaniswamy, H. and Jain, N. and Ngaile, G. and Altan, T. (2005), International Journal of Machine Tools & Manufacture, 45(05-Apr), 379-388.
Determination of flow stress for sheet metal forming using the viscous pressure bulge (VPB) test
Gutscher, G. and Wu, H.-C. and Ngaile, G. and Altan, T. (2004), Journal of Materials Processing Technology, 146(), 1-7.
Finite element simulation of magnesium alloy sheet forming at elevated temperatures
Palaniswamy, H. and Ngaile, G. and Altan, T. (2004), Journal of Materials Processing Technology, 146(), 52-60.
Hydraulic crimping: Application to the assembly of tubular components
Shirgaokar, M. and Ngaile, G. and Altan, T. and Yu, J.-H. and Balconi, J. and Rentfrow, R. and Worrell, W. J. (2004), Journal of Materials Processing Technology, 146(), 44-51.
Lubrication in tube hydroforming (THF). Part I: Lubrication mechanisms and development of model tests to evaluate lubricants and die coatings in the transition and expansion zones
Ngaile, G. and Jaeger, S. and Altan, T. (2004), Journal of Materials Processing Technology, 146(), 108-115.
Lubrication in tube hydroforming (THF). Part II: Performance evaluation of lubricants using LDH test and pear-shaped tube expansion test
Ngaile, G. and Jaeger, S. and Altan, T. (2004), Journal of Materials Processing Technology, 146(), 116-123.
Optimization of blank dimensions to reduce springback in the flexforming process
Palaniswamy, H. and Ngaile, G. and Altan, T. (2004), Journal of Materials Processing Technology, 146(), 28-34.
Optimization of mechanical crimping to assemble tubular components
Shirgaokar, M. and Cho, H. and Ngaile, G. and Altan, T. and Yu, J.-H. and Balconi, J. and Rentfrow, R. and Worrell, W. J. (2004), Journal of Materials Processing Technology, 146(), 35-43.
Optimizing tube hydroforming using process simulation and experimental verification
Aue-u-lan, Y. and Ngaile, G. and Altan, T. (2004), Journal of Materials Processing Technology, 146(), 137-143.
Simultaneous determination of flow stress and interface friction by finite element based inverse analysis
Cho, H. and Ngaile, G. and Altan, T. (2003), CIRP Annals ... Manufacturing Technology, 52(1), 221-224.
Characterization of adhesive strength of phosphate coatings in cold metal forming
Saiki, H. and Ngaile, G. and Ruan, L. (1997), Journal of Tribology, 119(), 667-671.

View all publications via NC State Libraries

Grants

Enhancing Tool Life by Manipulating Punch & Die Elastic Strain Field during Forging
Forging Industry Educational and Research Foundation (FIERF)(7/15/18 - 1/14/20)
Advancements towards ASME nuclear code case for compact heat exchangers
US Dept. of Energy (DOE)(10/01/17 - 9/30/19)
Development of a Manufacturing Process for High-Power-Density Hollow Shafts
FIA (Forging Industry Association)(7/15/16 - 12/31/18)
North Carolina Consortium for Manufacturing Data Science (NC-CMDS)
University of North Carolina System Office (formerly UNC - General Administration)(8/01/16 - 6/30/17)
Optimization of DuraForce Fastening System via Numerical Modeling
DuraForce Fastener Systems, LLC (5/16/16 - 5/30/17)
ASME Code Application of the Compact Heat Exchanger for High Temperature Nuclear Service
US Dept. of Energy (DOE)(10/01/16 - 9/30/19)
Novel Multi-Functional Hybrid Drawing Process (Area: Material Processes)
US Army - Army Research Office(6/20/16 - 11/19/18)
Study on Weight Reduction of Forged Parts Used in Heavy-Duty Truck Vehicles via Innovative Forging Techniques and Material Substitution
Forging Industry Educational and Research Foundation (FIERF)(10/12/15 - 5/31/17)
Study on Weight Reduction of Forged Parts Used in Light-and Heavy-Duty Truck Vehicles via Innovative Forging Techniques and Material Substitution
Forging Industry Educational and Research Foundation (FIERF)(11/30/-1 - 5/31/17)
Reactive Supersonic Diesel Jets Under Extreme High Injection Pressure
National Science Foundation (NSF)(8/01/14 - 1/31/16)