Research

MRL is a multidisciplinary lab, conducting research on additive, subtractive and hybrid of additive and subtractive manufacturing.

SEM images of chip produced by machining at feed and speed of 0.13 mm/tooth and 50 m/min on (a) vertically printed, (b) horizontally printed, and (c) wrought block.

Lab Members

The MRL lab is made up of a diverse group of undergraduate and graduate students, who study a broad range of processing and applications, and relations to industry.

Dr. Hossam Kishawy

Dean of Faculty of Engineering and Applied Science, Professor

BSc, MSc, PhD, P.Eng

Dr. Sayyed Ali Hosseini

Associate Professor

BSc, MSc, PhD, P.Eng

Latest Publications

Narayanan, Y., Nguyen, N., Hosseini, A.* (2024): Milling of additively manufactured AlSi10Mg with microstructural porosity defects, finite element modeling and experimental analysis, The Journal of Manufacturing Processes 118, 242-260

Metal additive manufacturing finds its applications in various sectors, especially the automotive and aerospace industries, wherein weight reduction of components is of paramount importance with respect to performance and fuel consumption. However, additively manufactured metallic components usually undergo post-processing steps to make them ready for end use application. One of these steps is finish machining that is employed to overcome the surface irregularities and poor tolerances produced as a result of additive manufacturing (AM). These finish machining processes involve turning, milling, drilling, reaming, or grinding...

Elbanhawy, O., Hassan, M., Mohany, A., Kishawy, H. (2024): A numerical model to investigate the irradiation effect on the dynamics of nuclear fuel bundles, Nuclear Engineering and Design 418, 112874

The severe operation conditions in nuclear reactors, such as highly turbulent coolant flow, high temperatures and excessive irradiation doses, can compromise the structural integrity of nuclear fuel bundles. Specifically, the irradiation doses influence the microstructure of the material in terms of segregation and precipitation in addition to swelling. This leads to changes in the mechanical properties of the material and consequently, the dynamic characteristics will be altered. The current study presents a fully-coupled, three-dimensional, numerical, structural model that takes...

Molazadeh, S., Diba, F., Hosseini, A.* (2023): Anisotropic modeling of material behavior for additively manufactured parts made by material extrusion, The International Journal of Advanced Manufacturing Technology, 1-21

Material extrusion is an additive manufacturing (AM) technique that provides an innovative and layer-by-layer fabrication method for components with intricate geometry. Due to the effect of various process parameters and the layerwise nature of material extrusion, the material behavior of parts made by this method is not isotropic. Considering the anisotropic material behavior of parts made by material extrusion, developing a finite element (FE) model to predict their mechanical properties is the focus of this study. Experiments including tensile tests, digital image correlation (DIC), and torsion tests were conducted to acquire the material constants for building an accurate FE model. Tensile behavior of specimens printed flat with different raster angles was investigated through a tensile test and modeled by FE software, Abaqus...

Sanderson, B., Diba, F., Kishawy, H.A., Hosseini, A.* (2023): Finite element analysis of additive manufacturing of polymers using selective laser sintering, The International Journal of Advanced Manufacturing Technology, 129: 1631-1647

Additive manufacturing (AM) is experiencing widespread adoption in many sectors including aerospace and biomedical. Several research works have already studied AM to ensure high quality final parts can be consistently achieved. To aid in virtually simulating the additive manufacturing processes, companies like ANSYS have developed simulation packages for their finite element software. These packages have been proven to be effective in predicting and minimizing distortion and warping, but their capability in predicting resultant mechanical characteristics requires further investigation. This paper...