Charles L Tucker, III

Education

• Ph.D. ME Massachusetts Institute of Technology 1978
• S.M. ME Massachusetts Institute of Technology 1977
• S.B. ME Massachusetts Institute of Technology 1975

Academic Positions

• Alexander Rankin Professor Emeritus, July 2017-date
• Research Professor, July 2017-date
• Vice Provost for Undergraduate Education and Innovation, UIUC, Feb. 2013-Jun. 2017
• Associate Dean for Undergraduate Programs, College of Engineering, UIUC, 2008-Jan. 2013
• Associate Head for Undergraduate Programs, Department of Mechanical Science and Engineering, UIUC, Aug. 2003-Aug. 2007
• Alexander Rankin Professor, Department of Mechanical Science and Engineering, UIUC, 2003-2017
• W. Grafton and Lillian B. Wilkins Professor, Department of Mechanical and Industrial Engineering, UIUC, 1998-2002
• Professor, Department of Mechanical Science and Engineering, UIUC, Aug. 1989-date
• Associate Professor, Department of Mechanical and Industrial Engineering, UIUC, 1983-1989
• Assistant Professor, Department of Mechanical and Industrial Engineering, UIUC, 1978-83

Major Consulting Activities

• Cerus Corporation, Concord, CA, 2002
• Husch & Eppenberger, Peoria, IL, 2001-03
• Kenyon & Kenyon, New York, NY, 2001-04

Research Statement

Professor Tucker has had a major impact on engineering practice by developing models and methods to predict fiber orientation patterns in injection-molded composite parts. Flow during mold filling imparts a pattern of preferential orientation to these fibers, which in turn controls the mechanical properties of the molded part. Professor Tucker developed a governing equation for flow-induced fiber orientation and introduced the use of tensor moment equations to create a model that can be solved with a practical amount of computer time. The resulting model has been adopted by every commercial software program for injection molding, and is used worldwide hundreds of times each day to predict the fiber orientation pattern and mechanical properties of molded parts.

Professor Tucker has a long record of original research contributions related to manufacturing processes for polymers and composite materials. In addition to his model for fiber orientation, he developed some of the first computer simulations of mold filling for compression and liquid composite molding. He pioneered the use of analytical sensitivity methods for optimal design of extrusion dies and injection molds. He showed that thermal dispersion was a significant effect in liquid composite molding and showed how to model it. He also applied these techniques to compute optimal curing cycles for thermoset-matrix composites. He developed a technique, now patented, for controlling the orientation of carbon fibers to enhance the electrical conductivity of fuel cell separator plates. He introduced computationally-efficient models for droplet deformation in polymer blends, based on Eshelby's inclusion theory, and used these models to show that droplet stretching statistics follows certain universal rules in chaotic mixing flows.

Research Interests

• Heat transfer
• Rheology
• Fluid mechanics
• Numerical methods
• Modeling and simulation of manufacturing processes
• Processing of polymers and composite materials

Books Authored or Co-Authored (Original Editions)

• Dantzig, J. A. and C. L. Tucker, Modeling in Materials Processing, Cambridge University Press, New York, NY, 363 pp., 2001.

Books Edited or Co-Edited (Original Editions)

• Tucker, C. L., ed., Fundamentals of Computer Modeling for Polymer Processing, Carl Hanser Verlag, Munich, 1989.

Chapters in Books

• Tucker, C. L., “Mixing of Miscible Liquids,” in Mixing and Compounding of Polymers, Theory and Practice, Second Edition, I. Manas-Zloczower, ed., Hanser Publishers, pp. 5-39, 2009.
• Tucker, C. L., “Modeling: Scaling Analysis,” Encyclopedia of Materials: Science and Technology, K. H. J. Buschow, et al., eds., Elsevier Science Ltd., 5726-5733, 2001.
• Tucker, C. L., "Forming of Advanced Composites," in Advanced Composites Manufacturing, T. G. Gutowski, ed., Wiley, New York, 297-372, 1997.
• Tucker, C. L. and S. G. Advani, "Processing of Short-Fiber Systems," in Flow and Rheology in Polymer Composites Manufacturing, S. G. Advani, ed., Elsevier, Amsterdam, 147-202, 1994.
• Tucker, C. L. and R. B. Dessenberger, "Governing Equations for Flow and Heat Transfer in Stationary Fiber Beds," in Flow and Rheology in Polymer Composites Manufacturing, S. G. Advani, ed., Elsevier, Amsterdam, 257-323, 1994.
• Tucker, C. L., "Principles of Mixing Measurement," in Mixing in Polymer Processing, C. Rauwendaal, ed., Marcel Dekker, 101-127, 1991.
• Tucker, C. L., "Compression Molding of Polymers and Short Fiber Composites," in Injection and Compression Molding Fundamentals, A. I. Isayev, ed., Marcel Dekker, 481-565, 1987.

Selected Articles in Journals

• Sharma, B. N., S. A. Kijewski, L. S. Fifield, Y. Shin, C. L. Tucker and M. D. Sangid, "Reliability in the Characterization of Fiber Length Distributions in Injection Molded Long Carbon Fiber Composites," Polymer Composites, DOI 10.1002/pc.24571, 2018.
• Sharma, B. N., D. Naragani, B. N. Nguyen, C. L. Tucker and M. D. Sangid, "Uncertainty Quantification of Fiber Orientation Distribution Measurements for Long-Fiber-Reinforced Thermoplastic Composites," Journal of Composite Materials, 52, 1781-1979, 2018.
• Phelps, J. H., A. I. Abd El-Rahman, V. Kunc, and C. L. Tucker, "A Model for Fiber Length Attrition in Long-Fiber Injection-Molded Composites," Composites Part A - Applied Science and Manufacturing, 51, 11-21, 2013.
• Abd El-Rahman, A. I. and C. L. Tucker, "Mechanics of Random Discontinuous Long-Fiber Thermoplastics—Part II: Direct Simulation of Uniaxial Compression," J. Rheology, 57, 1463-1489, 2013.
• Abd El-Rahman, A. I. and C. L. Tucker, "Mechanics of Random Discontinuous Long-Fiber Thermoplastics—Part I: Generation and Characterization of Initial Geometry," Journal of Applied Mechanics, 80, 2013.
• Phelps, J. H. and C. L. Tucker, “An Anisotropic Rotary Diffusion Model for Fiber Orientation in Short– and Long-Fiber Thermoplastics,” Journal of Non-Newtonian Fluid Mechanics, 156, 165-176, 2009.
• Nguyen, B. N., S. K. Bapanapalli, V. Kunc, J. H. Phelps and C. L. Tucker, “Prediction of the Elastic-Plasti Stress/Strain Response for Injection-Molded Long-Fiber Thermoplastics,” Journal of Composite Materials, 43, 217-246, 2009.
• Wang, J., J. O’Gara and C. L. Tucker, “An Objective Model for Slow Orientation Kinetics in Concentrated Fiber Suspensions: Theory and Rheological Evidence,” J. Rheology, 52, 1179-1200, 2008.
• Nguyen, B. N., S. K. Bapanapalli, J. D. Holbery, and M. T. Smith, V. Kunc, B. J. Frame, J. H. Phelps, C. L. Tucker, “Fiber Length and Orientation in Long-Fiber Injection-Molded Thermoplastics - Part I: Modeling of Microstructure and Elastic Properties,” Journal of Composite Materials, 42,1003-1029, 2008.
• Wang, J., C. A. Silva, J. C. Viana, F. W. J. van Hattum, A. M. Cunha, and C. L. Tucker, “Prediction of Fiber Orientation in a Rotating Compressing and Expanding Mold,” Polymer Engineering and Science, 48, 1405-1413,, 2008.
• Phelps, J. H. and C. L. Tucker, “Lagrangian Particle Calculations of Distributive Mixing: Applications and Limitations,” Chemical Engineering Sciences, 61, 6826-6836, 2006.
• Florek, C. A. and C. L. Tucker, “Stretching Distributions in Chaotic Mixing of Droplet Dispersions with Unequal Viscosities,” Physics of Fluids, 17, 053101, 2005.
• T. N. Pham and C. L. Tucker, “Stretch and Shape Distributions of Droplets with Interfacial Tension in Chaotic Mixing,” International Polymer Processing, 20, 128-135, 2005.
• Yu, W., C. Zhou, C. L. Tucker, and M. Bousmina, “Theory for Droplet Deformation in Viscoelastic Systems,” J. Rheology, 48, 417-438, 2004.
• Tucker, C. L. and G. W. M. Peters, “Global Measures of Distributive Mixing and Their Behavior in Chaotic Flows,” Korea-Australia Rheology Journal, 15, 197-208, 2004.
• Seo, D., J. R. Youn, and C. L. Tucker, “Numerical Simulation of Mold Filling in Foam Reaction Injection Molding,” Int. J. Numer. Meth. Fluids, 42, 1105-1134, 2003.
• Jackson, N. E. and C. L. Tucker, “A Model for Large Deformation of an Ellipsoidal Droplet with Interfacial Tension, J. Rheology, 47, 659-682, 2003.
• Dessenberger, R. B. and C. L. Tucker, “Ideal Forming Analysis for Random Fiber Preforms,” ASME J. Manuf. Sci. Eng., 125, 146-153, 2003.
• Blunk, R. H. J., D. J. Lisi, Y.-E. Yoo, and C. L. Tucker, “Enhanced Conductivity of Fuel Cell Plates through Controlled Fiber Orientation,” AIChE J., 49, 18-29, 2003.
• VerWeyst, B. E. and C. L. Tucker, “Fiber Suspensions in Complex Geometries: Flow/Orientation Coupling,” Canadian J. Chem. Eng., 80, 1093-1106, 2002.
• Li, M. and C. L. Tucker, “Modeling and Simulation of Two-Dimensional Consolidation for Thermoset Matrix Composites,” Composites A, 33, 877-892, 2002.
• Anderson, P. D., O. S. Galaktionov, G. W. M. Peters, H. E. H. Meijer, and C. L. Tucker, “Material Stretching in Laminar Mixing Flows: Extended Mapping Technique Applied to the Journal Bearing Flow,” International Journal of Numerical Methods in Fluids, 40, 189-196, 2002.
• Li, M. and C. L. Tucker, “Optimal Curing of Thermoset Matrix Composites: Thermochemical and Consolidation Consideration,” Polymer Composites, 23, 739-757, 2002.
• Galaktionov, O. S., P. D. Anderson, G. W. M. Peters, and C. L. Tucker, “A Global, Multi-Scale Simulation of Laminar Fluid Mixing: The Extended Mapping Method,” International Journal of Multiphase Flow, 28, 497-523, 2002.
• Tucker III, C. L. and P. Moldenaers, “Microstructural Evolution in Polymer Blends,” Annual Review of Fluid Mechanics,” 34, 177-210, 2002.
• Wetzel, E. D. and C. L. Tucker, “Microstructural Evolution During Complex Laminar Flow of Liquid-Liquid Mixtures,” Journal of Non-Newtonian Fluid Mechanics, 101, 21-41, 2001.
• Zhu, Q., M. Li, P. H. Geubelle, and C. L. Tucker III, “Dimensional Accuracy of Thermoset Composites: Simulation of Process-Induced Residual Stresses,” Journal of Composite Materials, 35, 2171-2205, 2001.
• Comas-Cardona, S. and C. L. Tucker III, “Measurements of Droplet Deformation in Simple Shear Flow with Zero Interfacial Tension,” Journal of Rheology, 45:1, 259-273, 2001.
• Li, M., Q. Zhu, P. H. Geubelle, and C. L. Tucker III, “Optimal Curing for Thermoset Matrix Composites: Thermochemical Considerations,” Polymer Composites, 22:1, 118-131, 2001.
• Pillai, K. M., C. L. Tucker, and F. R. Phelan, “Numerical Simulation of Injection/Compression Liquid Composite Molding. Part 2: Preform Compression,” Composites A, 32, 207-220, 2001.
• Wetzel, E. D. and C. L. Tucker III, “Droplet Deformation in Dispersions with Unequal Viscosities and Zero Interfacial Tension,” Journal of Fluid Mechanics, 426, 199-228, 2001.
• Pillai, K. M., C. L. Tucker III, and F. R. Phelan, Jr., “Numerical Simulation of Injection/Compression Liquid Composite Molding. Part 1. Mesh Generation,” Composites: Part A, 31, 87-94, 2000.
• VerWeyst, B. E., C. L. Tucker III, P. H. Foss, and J. F. O’Gara, “Fiber Orientation in 3-D Injection Molded Features: Prediction and Experiment,” International Polymer Processing, XIV:4, 409-420, 1999.
• Wetzel, E. D. and C. L. Tucker III, “Area Tensors for Modeling Microstructure During Laminar Liquid-Liquid Mixing,” International Journal of Multiphase Flow, 25, 35-61, 1999.
• Tucker III, C. L. and E. Liang, “Stiffness Predictions for Unidirectional Short-Fiber Composites: Review and Evaluation,” Composites Science and Technology, 59, 655-671, 1999.
• Dessenberger, R. B. and C. L. Tucker III, “Forming Limit Measurements for Random-Fiber Mats,” Polymer Composites, 19:4, 370-376, 1998.
• Smith, D. E., D. A. Tortorelli, and C. L. Tucker III, "Analysis and Sensitivity Analysis for Polymer Injection and Compression Molding," Computer Methods in Applied Mechanics and Engineering, 167, 325-344, 1998.
• Smith, D. E., D. A. Tortorelli, and C. L. Tucker III, "Optimal Design for Polymer Extrusion. Part II: Sensitivity Analysis for Weakly-Coupled Nonlinear Steady-State Systems," Computer Methods in Applied Mechanics and Engineering, 167, 303-323, 1998.
• Smith, D. E., D. A. Tortorelli, and C. L. Tucker III, "Optimal Design for Polymer Extrusion. Part I: Sensitivity Analysis for Nonlinear Steady-State Systems," Computer Methods in Applied Mechanics and Engineering, 167, 283-302, 1998.
• VerWeyst, B. E., C. L. Tucker III, and P. H. Foss, "The Optimized Quasi-Planar Approximation for Predicting Fiber Orientation in Injection-Molded Composites," International Polymer Processing, XII:3, 238-248, 1997.
• Tucker III, C. L., "Heat Transfer and Reaction Issues in Liquid Composite Molding," Polymer Composites, 17:1, 60-72, 1996.
• Dessenberger, R. B. and C. L. Tucker III, "Thermal Dispersion in Resin Transfer Molding," Polymer Composites, 16:6, 495-506, 1995.
• Kim, C., H. Teng, C. L. Tucker III, and S. R. White, "The Continuous Curing Process for Thermoset Polymer Composites. Part 1: Modeling and Demonstration," J. Compos. Mater., 29:9, 1222-1253, 1995.
• Cintra, J. S. and C. L. Tucker III, "Orthotropic Closure Approximations for Flow-Induced Fiber Orientation," J. Rheology, 39:6, 1095-1122, 1995.
• Liang, E. W. and C. L. Tucker III, "A Finite Element Method for Flow in Compression Molding of Thin and Thick Parts," Polymer Composites, 16, 70-82, 1995.
• Bay, R. S. and C. L. Tucker III, "Fiber Orientation in Simple Injection Moldings, Part II: Experimental Results," Polymer Composites, 13:4, 322-342, 1992.
• Bay, R. S. and C. L. Tucker III, "Fiber Orientation in Simple Injection Moldings, Part I: Theory and Numerical Methods," Polymer Composites, 13:4, 317-321, 1992.
• Bay, R. S. and C. L. Tucker III, "Stereological Measurement and Error Estimates for Three-Dimensional Fiber Orientation," Polymer Engineering and Science, 32:4, 240-253, 1992.
• Tucker III, C. L., "Flow Regimes for Fiber Suspensions in Narrow Gaps," J. Non-Newtonian Fluid Mech., 39, 239-268, 1991.
• Hwang, S.-J. and C. L. Tucker III, "Heat Transfer Analysis of Continuous Fiber/Thermoplastic Matrix Composites During Manufacture," J. Thermoplastic Composites, 3, 41-51, 1990.
• Camacho, C. W., C. L. Tucker III, S. Yalvac, and R. L. McGee, "Stiffness and Thermal Expansion Predictions for Hybrid Short Fiber Composites," Polymer Composites, 11:4, 229-239, 1990.
• Advani, S. G. and C. L. Tucker III, "Closure Approximations for Three-Dimensional Structure Tensors," Journal of Rheology, 34, 367-386, 1990.
• Advani, S. G. and C. L. Tucker III, "A Numerical Simulation of Short Fiber Orientation in Compression Molding," Polymer Composites, 11:3, 164-173, 1990.
• Osswald, T. A. and C. L. Tucker III, "Compression Mold Filling Simulation for Non-Planar Parts ," International Polymer Processing V, 2, 79-87, 1990.
• Tucker III, C. L., "Predicting Fiber Orientation in Short Fiber Composites," The Manufacturing Science of Composites, T. G. Gutowski, ed., ASME, New York, IV, 95-104, 1988.
• Osswald, T. A. and C. L. Tucker III, "A Boundary Element Simulation of Compression Mold Filling," Polymer Engineering and Science, 28:7, 413-420, 1988.
• Advani, S. G. and C. L. Tucker III, "The Use of Tensors to Describe and Predict Fiber Orientation in Short Fiber Composites," Journal of Rheology, 31:8, 751-784, 1987.
• Lee, C.-C. and C. L. Tucker III, "Flow and Heat Transfer in Compression Mold Filling," Journal of Non-Newtonian Fluid Mechanics, 24, 245-264, 1987.
• Jackson, W. C., S. G. Advani, and C. L. Tucker III, "Predicting the Orientation of Short Fibers in Thin Compression Moldings," Journal of Composite Materials, 20, 539-557, 1986.
• Lee, C.-C., F. Folgar, and C. L. Tucker III, "Simulation of Compression Molding for Fiber-Reinforced Thermosetting Polymers," Journal of Engineering for Industry, 106, 114-125, 1984.
• Chen, C.-Y. and C. L. Tucker III, "Mechanical Property Predictions for Short Fiber/Brittle Matrix Composites," Journal of Reinforced Plastics and Composites, 3, 120-129, 1984.
• Folgar, F. and C. L. Tucker III, "Orientation Behavior of Fibers in Concentrated Suspensions," Journal of Reinforced Plastics and Composites, 3, 98-119, 1983.
• Tucker III, C. L. and F. Folgar, "A Model of Compression Mold Filling," Polymer Engineering and Science, 23:2, 69-74, 1983.
• Tucker, C. L., "Sample Variance Measurement of Mixing," Chemical Engineering Science, 36:11, 1829-1839, 1981.
• ¶ Tucker III, C. L. and N. P. Suh, "Mixing for Reaction Injection Molding: II. Impingement Mixing of Fiber Suspensions," Polymer Engineering and Science, 20:13, 887-898, 1980.
• ¶ Tucker III, C. L. and N. P. Suh, "Mixing for Reaction Injection Molding: I. Impingement Mixing of Liquids," Polymer Engineering and Science, 20:13, 875-886, 1980.
• Suh, N. P. and C. L. Tucker III, "A Metering Device for Capacitive Discharge RIM Machines," Science and Technology of Polymer Processing, N. P. Suh and N. H. Sung, eds., MIT Press, 626-640, 1979.
• Suh, N. P. and C. L. Tucker III, "Fundamentals of Liquid Injection Molding," Science and Technology of Polymer Processing, N. P. Suh and N. H. Sung, eds., MIT Press, 132-168, 1979.
• Tucker III, C. L. and N. P. Suh, "Fluid Delivery and Metering for Reaction-Injection Molding," Journal of Engineering for Industry, Series B, 99:3, 678-681, 1977 (American Society of Mechanical Engineers Paper 76-WA/PID-19).
• Tucker III, C. L. and N. P. Suh, "Electrostatic Powder Mixing," Polymer Engineering and Science, 16:10, 657-663, 1976.

Journal Editorships

• Member, Editorial Board, International Polymer Processing (1990-date)
• Member, Editorial Board, Polymer Engineering and Science (1991-1998)

Professional Societies

• Fellow, American Society of Mechanical Engineers

Teaching Honors

• Campus Award for Excellence in Advising Undergraduate Students, 2007
• Accenture Campus Award for Excellence in Advising, College of Engineering, UIUC, 2003
• Engineering Council Advisor List for Outstanding Advising, UIUC, 1995, 1996, 2003, 2005
• Harriet and Charles Luckman Distinguished Undergraduate Teaching Award (the highest campus teaching award), UIUC, 1994
• Five-Year Alumni Effective Teacher Award, Mechanical and Industrial Engineering Alumni Board, UIUC, 1987, 1998, 2000
• Two-Year Alumni Effective Teacher Award, Mechanical and Industrial Engineering Alumni Board, UIUC, 1983, 1992, 2005
• Everitt Award for Teaching Excellence, College of Engineering, UIUC, 1981
• Listed in the Daily Illini “Incomplete List of Teachers Ranked as Excellent by Their Students” for Fall 1981, Spring and Fall 1982, Fall 1983, Spring 1984, Fall 1985, Spring and Fall 1986, Fall 1987, Spring and Fall 1988, Spring and Fall 1989, Spring and Fall 1990, Spring 1991, Spring and Fall 1992, Spring and Fall 1993, Spring 1994, Spring and Fall 1995, Spring and Fall 1996, Spring and Fall 1997, Spring and Fall 1998, Spring and Fall 2000, Spring 2001, Spring 2002, Spring 2003, Fall 2003, Fall 2004, Fall 2005, Fall 2006, Fall 2007

Research Honors

• Alexander Rankin Professor, Department of Mechanical and Industrial Engineering, UIUC, 2003-2017
• W. Grafton and Lillian B. Wilkins Professor, Department of Mechanical and Industrial Engineering, UIUC, 1998-2002
• Fellow, American Society of Mechanical Engineers, 1996
• Best Paper Award, Society of Plastic Engineers Annual Technical Conference, Engineering Structure and Properties Division, 1988
• Outstanding Young Manufacturing Engineer Award, Society of Manufacturing Engineers, 1985
• Visiting Fellow Commoner, Churchill College, Cambridge University, England, 1984-85
• TRW Postdoctoral Award in Manufacturing Engineering, 1984
• National Science Foundation Presidential Young Investigator Award, 1984
• Union Oil Young Faculty Award, 1983
• Ralph R. Teetor Award, Society of Automotive Engineers, 1980

Other Honors

• Honorary Knight of St. Patrick, College of Engineering, UIUC, 2009