Books

Kishawy, H.A.*, Hosseini, A. (2019): Machining Difficult-to-Cut Materials, Basic Principles and Challenges. Springer. 240 pp.

This book focus on the challenges faced by cutting materials with superior mechanical and chemical characteristics, such as hardened steels, titanium alloys, super alloys, ceramics and metal matrix composites. Aspects such as costs and appropriate machining strategy are mentioned. The authors present the characteristics of the materials difficult to cut and comment on appropriate cutting tools for their machining. This book also serves as a reference tool for manufacturers working in industry.

Book Chapters

Hosseini, A.*, Kishawy, H.A., Hussein, H.M. (2015): Lean Manufacturing. Modern Manufacturing Engineering. Edited by Davim, J.P. Springer. pp: 249-269.

Manufacturing of parts and products regardless of their shape, geometric features and materials involves a series of processes and operations. Nowadays, it is broadly recognized through the industrial sectors that many manufacturing techniques which are currently implemented in fabricating products lead to production of industrial waste. Lean manufacturing (LM) is a business template that has philosophies designed to eliminate waste in the manufacturing process...

Hosseini, A., Kishawy, H.A.* (2014): Cutting Tool Materials and Tool Wear. Machining of Titanium Alloys. Edited by Davim, J.P. Springer. pp: 31-56.

The chip formation in machining operations is commonly accomplished by a combination of several elements working together to complete the job. Among these components, cutting tool is the key element that serves in the front line of cutting action. Cutting action becomes a challenge when it comes to machining difficult-to-cut materials. Titanium and its alloys are among the most difficult-to-cut materials which are widely used in diverse industrial sectors...

Hosseini, A.*, Kishawy, H.A., Hussein, H.M. (2014): Machinability of Titanium and Its Alloys. Machinability of Advanced Materials. Edited by Davim J.P. John Wiley & Sons Inc. pp: 95-118.

Titanium and its alloys are outstanding materials of choice, and their applications are rapidly growing worldwide in high-value markets such as aerospace, marine, power generation, heat exchangers, automotive and biomedical industries. They owe their popularity to their superior characteristics such as high strength to density ratio, also known as high strength to weight ratio or specific strength, as well as high corrosion resistance. Titanium alloys are used in aerospace industry to protect the fuselage, especially in military aircraft, from corrosion and heat damages caused by air friction in supersonic and hypersonic speeds...

Recent Journal Papers

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...

More Publications

For more publications, please access the lab directors' Google Scholar profiles below.