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...

Nguyen, N., Hosseini, A.* (2023): Direct Calculation of Johnson-Cook Constitutive Material Parameters for Oblique Cutting Operations. Journal of Manufacturing Processes. 92: 226-237.

Characteristics and behaviors of materials during manufacturing processes highly depend on their mechanical properties and microstructures. However, these characteristics and behaviors can be greatly influenced by other factors such as strain, strain rate, and temperature during the process. The Johnson-Cook (J-C) constitutive material model has been extensively used to describe the material behavior under such circumstances. The J-C parameters are usually determined using the Split Hopkinson Pressure Bar (SHPB) test which is time consuming and costly...

Kishawy, H.A., Nguyen, N., Hosseini, A., Elbestawi, M.* (2023): Machining Characteristics of Additively Manufactured Titanium, Cutting Mechanics and Chip Morphology, CIRP Annals, 72: 49-52.

Application of additively manufacturing (AM) metals is growing rapidly; however, post-process finish machining is still required to improve dimensional accuracy and surface quality. Determining the high-strain high-temperature behavior of AM metals is critical in simulating finish machining, designing appropriate cutting tools, and predicting surface integrity. This paper investigated the machining characteristics of AM Ti-6Al-4V produced using powder bed fusion. High-strain high-temperature behavior of AM Ti-6Al-4V was determined numerically and used in simulating the process...

T. Clarke, Hosseini, A.* (2023): Effects of print parameters on tensile characteristics of additively manufactured polyethylene terephthalate-glycol (PETG), The International Journal of Advanced Manufacturing Technology, 125 (11-12): 4953-4974

Determining the mechanical characteristics of additively manufactured materials has been an active topic of research in recent years. Many studies have been performed analyzing the impact of different 3D print parameters on the tensile properties of the printed material. However, compared to typical metals and polymers, there is no widely adopted standard for testing additively manufactured polymers. Consequently, the test results reported by the researchers in this field exhibit high amounts of variability between studies...

B, DeBoer*, A, Hosseini, C, Rossa (2023): Model Predictive Control of an Active Ankle-Foot Orthosis with Non-linear Actuation Constraints, Control Engineering Practice, 136: 105538

The goal of active ankle-foot orthoses (AAFO) is to assist the user in recreating a nominal gait motion. Previously proposed control systems for AAFOs have been reactive, with controllers based on the current tracking error. However, the optimal AAFO controller must ensure adequate trajectory tracking while minimizing the amount of assistance provided to the user. To this end, a model predictive controller (MPC) can be considered to determine the optimal control sequence for a given trajectory...

Imad, M., Kishawy, H.A., Yussefian, N.Z., Hosseini, A.* (2022): Effect of Cutting Edge Radius when Milling Hardened Steels: A Finite Element Analysis and Surface Integrity Investigation. Machining Science and Technology, 26(4): 571-594

This work investigated the impact of cutting tools varying edge radii by presenting a 3-dimensional finite element analysis (3D FEA) model during the milling of hardened steels. The proposed numerical model was able to capture the effect of micro geometrical changes between cutting tools of five different edge radii (25 μm, 30 μm, 35 μm, 40 μm, and 45 μm ). Experimental milling tests were performed to validate the numerical model and close agreement was reported between the experimentally acquired cutting forces and the numerically simulated ones...

Kishawy, H.A., Salem, A., Hegab, H., Hosseini, A., Elbestawi, M.* (2022): An Analytical Model for the Optimized Design of Micro-Textured Cutting Tools. CIRP Annals, Manufacturing Technology. 71(1): 49-52.

Proper design of micro-textured cutting tools is an effective strategy to improve the machining performance by reducing the tool-chip contact length and the resultant friction and thus improving tool life and workpiece surface integrity. In this paper, an Oxely-based analytical model is developed to optimize micro-textured cutting tool design(s) which eliminate the occurrence of derivative cutting. The model accommodates any workpiece material, tool geometry, and machining parameter...

DeBoer, B.*, Hosseini, A., Rossa, C. (2022): A Discrete Non-Linear Series Elastic Actuator for Active Ankle-Foot Orthoses. IEEE Robotics and Automation Letters. 7(3): 6211-6217.

This letter outlines the modelling, design, and experimental validation of a novel power-efficient actuator for an active ankle-foot orthosis (AAFO). The actuator is based on a new principle of discrete non-linear stiffness. Two or more linear springs are discretely compressed at specified displacement intervals to reduce the peak mechanical power required to actuate the AAFO. The actuator uses a crank-rocker configuration...

Imad, M., Hopkins, C., Hosseini, A.*, Yussefian, N.Z., Kishawy, H.A. (2021): Intelligent Machining, a Review of Trends, Achievements and Current Progress. International Journal of Computer Integrated Manufacturing. 35(4-5): 359-387.

Manufacturing industries are constantly pressured by market demands to produce low-cost, high-quality products. Market demands tend to be complex and full of variations, especially in fast-paced industrial settings. To cope with the rising market demands, traditional manufacturing techniques are forced to develop and adapt advanced practices and methods. However, as advances in manufacturing technology grow, so does the need to implement them in an efficient and cost-effective manner...

Kishawy, H.A., Salem, A., Hegab, H., Hosseini, A., M. Balazinski*. (2021): Micro-Textured Cutting Tools: Phenomenological Analysis and Design Recommendations. CIRP Annals, Manufacturing Technology. 70(1): 65-68.

One of the effective strategies to improve dry machining processes is the implementation of micro-textured cutting tools. Micro-textures decrease the chip-tool contact length and thus reduce friction and heat which lead to better surface quality and longer tool life. However, micro-cutting of the bottom side of the chip, known as derivative cutting, is an issue when using textured tools. Derivative cutting increases the cutting forces, heat, and ultimately tool wear...

DeBoer, B., Nguyen, N., Diba, F., Hosseini, A.* (2021): Additive, Subtractive, and Formative Manufacturing of Metal Components: A Life Cycle Assessment Comparison. The International Journal of Advanced Manufacturing Technology. 115(1): 413-432.

Manufacturing processes are typically divided into three categories: formative, subtractive, and additive. While formative and subtractive manufacturing processes are considered more traditional, additive manufacturing (AM) is a family of evolving technologies that are rapidly growing with techniques and constraints yet to be explored. In this paper, a life cycle assessment comparison of casting (formative), machining (subtractive), and three AM methods, namely, binder jetting (BJ), powder bed fusion (PBF), and novel bound powder extrusion (BPE) has been performed...