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Khaja Moiduddin
Advanced Manufacturing Institute, King Saud University, Riyadh-11421, Saudi Arabia

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Journal article
Published: 01 May 2021 in Crystals
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Friction stir alloying (FSA) of commercially pure Cu with Ni, Zn, and Mg is implemented in the current study. Mechanical and microstructural aspects of the successfully fabricated alloy structure have been examined. Energy dispersive X-ray spectroscopy revealed a uniform distribution of alloying elements and coalescence at the atomic level. The compositional and grain size heterogeneity is managed in the stir zone, allowing for microstructural control with FSA. Thus, the present study is essential for the development of novel materials whose fabrication requires temperature well below the melting point of base metals. The alloying process is found to be accompanied by ultra-refined grains, with the smallest grain size being ~0.44 μm. The fabricated alloy managed to retain the FCC phase, and no brittle intermetallic compounds formed, according to X-ray diffraction. The fabricated alloy exhibits maximum and average microhardness enhancements of 18.4% and 6%, respectively. Tensile properties have also been investigated and correlated with microstructural morphology. A shift toward grain bimodality has also been documented, which is a highly sought-after property nowadays, especially to overcome the strength-ductility trade-off.

ACS Style

Khaja Moiduddin; Arshad Siddiquee; Mustufa Abidi; Syed Mian; Muneer Mohammed. On Novel Copper Based Alloys Development via Friction Stir Alloying. Crystals 2021, 11, 498 .

AMA Style

Khaja Moiduddin, Arshad Siddiquee, Mustufa Abidi, Syed Mian, Muneer Mohammed. On Novel Copper Based Alloys Development via Friction Stir Alloying. Crystals. 2021; 11 (5):498.

Chicago/Turabian Style

Khaja Moiduddin; Arshad Siddiquee; Mustufa Abidi; Syed Mian; Muneer Mohammed. 2021. "On Novel Copper Based Alloys Development via Friction Stir Alloying." Crystals 11, no. 5: 498.

Journal article
Published: 17 March 2021 in Metals
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Additive manufacturing (AM), particularly electron beam melting (EBM), is becoming increasingly common in the medical industry because of its remarkable benefits. The application of personalized titanium alloy implants produced using EBM has received considerable attention in recent times due to their simplicity and efficacy. However, these tailored implants are not cost-effective, placing a tremendous strain on the patient. The use of additional materials as support during the manufacturing process is one of the key causes of its high cost. A lot of research has been done to lessen the use of supports through various types of support designs. There is indeed a noticeable paucity of studies in the literature that have examined customized implants produced without or minimal supports. This research, therefore, reports on the investigation of cranial implants fabricated with and without supports. The two personalized implants are evaluated in terms of their cost, fabrication time, and accuracy. The study showed impressive results for cranial implants manufactured without supports that cost 39% less than the implants with supports. Similarly, the implant’s (without supports) build time was 18% less than its equivalent with supports. The two implants also demonstrated similar fitting accuracy with 0.2613 mm error in the instance of implant built without supports and 0.2544 mm for the implant with supports. The results indicate that cranial implants can be produced without EBM supports, which can minimize both production time and cost substantially. However, the manufacture of other complex implants without supports needs further study. The future study also requires a detailed review of the mechanical and structural characteristics of cranial implants built without supports.

ACS Style

Khaja Moiduddin; Syed Mian; Wadea Ameen; Hisham Alkhalefah; Abdul Sayeed. Feasibility Study of the Cranial Implant Fabricated without Supports in Electron Beam Melting. Metals 2021, 11, 496 .

AMA Style

Khaja Moiduddin, Syed Mian, Wadea Ameen, Hisham Alkhalefah, Abdul Sayeed. Feasibility Study of the Cranial Implant Fabricated without Supports in Electron Beam Melting. Metals. 2021; 11 (3):496.

Chicago/Turabian Style

Khaja Moiduddin; Syed Mian; Wadea Ameen; Hisham Alkhalefah; Abdul Sayeed. 2021. "Feasibility Study of the Cranial Implant Fabricated without Supports in Electron Beam Melting." Metals 11, no. 3: 496.

Journal article
Published: 02 February 2021 in Metals
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Titanium alloy is widely used in modern automobile industries due to its higher strength with corrosion resistance. Such higher strength materials can be effectively machined using unconventional machining processes, especially the electro-chemical micro machining (ECMM) process. It is important to enhance the machining process by investigating the effects of electrolytes and process parameters in ECMM. The presented work describes the influence of three different combinations of Sodium Chloride-based electrolytes on machining Titanium (Ti-6Al-4V) alloy. Based on the ECMM process parameters such as applied voltage, electrolytic concentration, frequency and duty cycle on response, characteristics are determined by the Taguchi design of experiments. The highest material removal rate (MRR) was achieved by the Sodium Chloride and Sodium Nitrate electrolyte. The combination of Sodium Chloride and Citric Acid achieve highest Overcut and Circularity. The optimal overcut was observed from the Sodium Chloride and Glycerol electrolyte due to the presence of glycerol. The better conicity was obtained from Sodium Chloride and Citric Acid in comparison with other electrolytes. A Sodium Chloride and Glycerol combination could generate better machined surface owing to the chelating effect of Glycerol.

ACS Style

Geethapriyan Thangamani; Muthuramalingam Thangaraj; Khaja Moiduddin; Syed Mian; Hisham Alkhalefah; Usama Umer. Performance Analysis of Electrochemical Micro Machining of Titanium (Ti-6Al-4V) Alloy under Different Electrolytes Concentrations. Metals 2021, 11, 247 .

AMA Style

Geethapriyan Thangamani, Muthuramalingam Thangaraj, Khaja Moiduddin, Syed Mian, Hisham Alkhalefah, Usama Umer. Performance Analysis of Electrochemical Micro Machining of Titanium (Ti-6Al-4V) Alloy under Different Electrolytes Concentrations. Metals. 2021; 11 (2):247.

Chicago/Turabian Style

Geethapriyan Thangamani; Muthuramalingam Thangaraj; Khaja Moiduddin; Syed Mian; Hisham Alkhalefah; Usama Umer. 2021. "Performance Analysis of Electrochemical Micro Machining of Titanium (Ti-6Al-4V) Alloy under Different Electrolytes Concentrations." Metals 11, no. 2: 247.

Journal article
Published: 26 November 2020 in Mathematics
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Technological advancements in healthcare influence medical practitioners as much as they impact the routine lives of the patients. The mandible reconstruction, which constitutes an important branch in facioplasty, has been a challenging task for medical professionals. As part of scientific innovation, tailor-made implants are valuable for sustaining and regenerating facial anatomy, as well as preserving the natural appearance. The challenge of choosing an acceptable implant design is a tedious process due to the growing number of designs with conspicuous effectiveness. The design should be agreeable, easy-to-design, sustainable, cost-effective, and undemanding for manufacturing. The optimal implant design can efficiently and effectively recover the structure and morphology of the flawed region. Evidently, among the many variants, the choice of appropriate design is one of the prevalent implant design problems and is still under consideration in most studies. This work is focused on the multiattribute decision-making (MCDM) approach to choosing the most effective implant design. The prevalence of subjectivity in decision-making and the presence of inconsistency from multiple sources emphasize the strategies that must take ambiguity and vagueness into account. An integrated MCDM methodology, assimilating two modern and popular techniques is adopted in this work. The preferred approach implements the Fuzzy Analytical Hierarchy Process based on the trapezoidal fuzzy number to extract the criteria weights in decision mapping and the Technique for Order of Preference by Similarity to Ideal Solution and VIKOR to assess design choices. A two-stage mechanism is the cornerstone of the established methodology. The first stage analyses the criteria from the point of view of the designer, the context of fabrication, and consumer experience. The second stage identifies the most viable and feasible design. The procedure applied in this analysis can be considered to choose the optimal implant design and to decide on areas of improvement that ensure greater patient experience.

ACS Style

Khaja Moiduddin; Syed Hammad Mian; Usama Umer; Hisham Alkhalefah; Abdul Sayeed. Fuzzy Multicriteria Decision Mapping to Evaluate Implant Design for Maxillofacial Reconstruction. Mathematics 2020, 8, 2121 .

AMA Style

Khaja Moiduddin, Syed Hammad Mian, Usama Umer, Hisham Alkhalefah, Abdul Sayeed. Fuzzy Multicriteria Decision Mapping to Evaluate Implant Design for Maxillofacial Reconstruction. Mathematics. 2020; 8 (12):2121.

Chicago/Turabian Style

Khaja Moiduddin; Syed Hammad Mian; Usama Umer; Hisham Alkhalefah; Abdul Sayeed. 2020. "Fuzzy Multicriteria Decision Mapping to Evaluate Implant Design for Maxillofacial Reconstruction." Mathematics 8, no. 12: 2121.

Journal article
Published: 25 November 2020 in Materials
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The machining of ceramic materials is challenging and often impossible to realize with conventional machining tools. In various manufacturing applications, rotary ultrasonic milling (RUM) shows strengths, in particular for the development of high-quality micro-features in ceramic materials. The main variables that influence the performance and price of the product are surface roughness, edge chipping (EC), and material removal rate (MRR) during the processing of ceramics. RUM has been considered in this research for the milling of micro-pockets in bioceramic alumina (Al2O3). Response surface methodology in the context of a central composite design (CCD) is being used to plan the experiments. The impacts of important RUM input parameters concerning cutting speed, feed rate, depth of cut, frequency, and amplitude have been explored on the surface roughness in terms of arithmetic mean value (Ra), the EC, and the MRR of the machined pockets. The main effect and the interaction effect of the implemented RUM parameters show that by providing a lower feed rate and cutting depth levels and elevated frequency and cutting speed, the Ra and the EC can be minimized. At greater levels of feed rate and cutting depth, higher MRR can be obtained. The influence of RUM input parameters on the surface morphology was also recorded and analyzed using scanning electron microscopic (SEM) images. The study of the energy dispersive spectroscopy (EDS) shows that there is no modification in the alumina bioceramic material. Additionally, a multi-response optimization method has been applied by employing a desirability approach with the core objectives of minimizing the EC and Ra and maximizing the MRR of the milled pockets. The obtained experimental values for Ra, EC, and MRR at an optimized parametric setting were 0.301 µm, 12.45 µm, and 0.873 mm3/min respectively with a combined desirability index value of 0.73.

ACS Style

Basem M. A. Abdo; Hisham Alkhalefah; Khaja Moiduddin; Mustufa Haider Abidi. Multi-Response Optimization of Processing Parameters for Micro-Pockets on Alumina Bioceramic Using Rotary Ultrasonic Machining. Materials 2020, 13, 5343 .

AMA Style

Basem M. A. Abdo, Hisham Alkhalefah, Khaja Moiduddin, Mustufa Haider Abidi. Multi-Response Optimization of Processing Parameters for Micro-Pockets on Alumina Bioceramic Using Rotary Ultrasonic Machining. Materials. 2020; 13 (23):5343.

Chicago/Turabian Style

Basem M. A. Abdo; Hisham Alkhalefah; Khaja Moiduddin; Mustufa Haider Abidi. 2020. "Multi-Response Optimization of Processing Parameters for Micro-Pockets on Alumina Bioceramic Using Rotary Ultrasonic Machining." Materials 13, no. 23: 5343.

Journal article
Published: 11 November 2020 in Materials
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This paper presents a model for assessing the performance of self-propelled rotary tool during the processing of hardened steel. A finite element (FE) model has been proposed in this analysis to study the hard turning of AISI 51200 hardened steel using a self-propelled rotary cutting tool. The model is developed by utilizing the explicit coupled temperature displacement analysis in the presence of realistic boundary conditions. This model does not take into account any assumptions regarding the heat partitioning and the tool-workpiece contact area. The model can predict the cutting forces, chip flow, induced stresses, and the generated temperature on the cutting tool and the workpiece. The nodal temperatures and heat flux data from the chip formation analysis are used to achieve steady-state temperatures on the cutting tool in the heat transfer analysis. The model outcomes are compared with reported experimental data and a good agreement has been found.

ACS Style

Usama Umer; Hossam Kishawy; Mustufa Haider Abidi; Syed Hammad Mian; Khaja Moiduddin. Evaluation of Self-Propelled Rotary Tool in the Machining of Hardened Steel Using Finite Element Models. Materials 2020, 13, 5092 .

AMA Style

Usama Umer, Hossam Kishawy, Mustufa Haider Abidi, Syed Hammad Mian, Khaja Moiduddin. Evaluation of Self-Propelled Rotary Tool in the Machining of Hardened Steel Using Finite Element Models. Materials. 2020; 13 (22):5092.

Chicago/Turabian Style

Usama Umer; Hossam Kishawy; Mustufa Haider Abidi; Syed Hammad Mian; Khaja Moiduddin. 2020. "Evaluation of Self-Propelled Rotary Tool in the Machining of Hardened Steel Using Finite Element Models." Materials 13, no. 22: 5092.

Journal article
Published: 12 October 2020 in Materials
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Titanium-aluminium-vanadium (Ti 6Al 4V) alloys, nickel alloys (Inconel 718), and duraluminum alloys (AA 2000 series) are widely used materials in numerous engineering applications wherein machined features are required to having good surface finish. In this research, micro-impressions of 12 µm depth are milled on these materials though laser milling. Response surface methodology based design of experiment is followed resulting in 54 experiments per work material. Five laser parameters are considered naming lamp current intensity (I), pulse frequency (f), scanning speed (V), layer thickness (LT), and track displacement (TD). Process performance is evaluated and compared in terms of surface roughness through several statistical and microscopic analysis. The significance, strength, and direction of each of the five laser parametric effects are deeply investigated for the said alloys. Optimized laser parameters are proposed to achieve minimum surface roughness. For the optimized combination of laser parameters to achieve minimum surface roughness (Ra) in the titanium alloy, the said alloy consists of I = 85%, f = 20 kHz, V = 250 mm/s, TD = 11 µm, and LT = 3 µm. Similarly, optimized parameters for nickel alloy are as follows: I = 85%, f = 20 kHz, V = 256 mm/s, TD = 8 µm, and LT = 1 µm. Minimum roughness (Ra) on the surface of aluminum alloys can be achieved under the following optimized parameters: I = 75%, f = 20 kHz, V = 200 mm/s, TD = 12 µm, and LT = 3 µm. Micro-impressions produced under optimized parameters have surface roughness of 0.56 µm, 2.46 µm, and 0.54 µm on titanium alloy, nickel alloy, and duralumin, respectively. Some engineering applications need to have high surface roughness (e.g., in case of biomedical implants) or some desired level of roughness. Therefore, validated statistical models are presented to estimate the desired level of roughness against any laser parametric settings.

ACS Style

Naveed Ahmed; Ateekh Ur Rehman; Kashif Ishfaq; Rakhshanda Naveed; Khaja Moiduddin; Usama Umer; Adham E Ragab; Ayoub Al-Zabidi. Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin. Materials 2020, 13, 4523 .

AMA Style

Naveed Ahmed, Ateekh Ur Rehman, Kashif Ishfaq, Rakhshanda Naveed, Khaja Moiduddin, Usama Umer, Adham E Ragab, Ayoub Al-Zabidi. Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin. Materials. 2020; 13 (20):4523.

Chicago/Turabian Style

Naveed Ahmed; Ateekh Ur Rehman; Kashif Ishfaq; Rakhshanda Naveed; Khaja Moiduddin; Usama Umer; Adham E Ragab; Ayoub Al-Zabidi. 2020. "Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin." Materials 13, no. 20: 4523.

Journal article
Published: 31 August 2020 in Applied Sciences
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Mandibular reconstruction is a complicated task because of the complex nature of the regional anatomy. Computer-assisted tools are a promising means of improving the precision and safety of such complex surgeries. The digital techniques utilized in the reconstruction of mandibular defects based on medical data, computer-aided-design approaches, and three-dimensional (3D) printing are widely used to improve the patient’s aesthetic appearance and function, as well as the accuracy and quality of diagnosis, and surgical outcomes. Nevertheless, to ensure an acceptable aesthetical appearance and functional outcomes, the design must be based on proper anatomical reconstruction, mostly done in a virtual environment by skilled design engineers. Mirroring is one of the widely used techniques in the surgical navigation and reconstruction of mandibular defects. However, there are some discrepancies and mismatches in the mirrored anatomical models. Hence, in order to overcome these limitations in the mirroring technique, a novel approach called the cavity-filled technique was introduced. The objective of this study was to compare the accuracy of the newly recommended cavity-filled technique with the widely used mirror reconstruction technique in restoring mandibular defects. A prominent 3D comparison technique was employed in this work, where the resected and the reconstructed mandibles were superimposed to quantify the accuracy of the two techniques. From the analysis, it can be inferred that the cavity-filled technique with a root-mean-square value of 1.1019 mm produced better accuracy in contrast to the mirroring approach, which resulted in an error of 1.2683 mm. Consequently, by using the proposed cavity-filled design, the discrepancy between the reconstruction plate and the bone contour was mitigated. This method, owing to its high precision, can decrease the number of adjustments and the time of surgery, as well as ensure a quick recovery time with better implant tissue in-growth.

ACS Style

Khaja Moiduddin; Syed Hammad Mian; Wadea Ameen; Mohammed Alkindi; Sundar Ramalingam; Osama Alghamdi. Patient-Specific Surgical Implant Using Cavity-Filled Approach for Precise and Functional Mandible Reconstruction. Applied Sciences 2020, 10, 6030 .

AMA Style

Khaja Moiduddin, Syed Hammad Mian, Wadea Ameen, Mohammed Alkindi, Sundar Ramalingam, Osama Alghamdi. Patient-Specific Surgical Implant Using Cavity-Filled Approach for Precise and Functional Mandible Reconstruction. Applied Sciences. 2020; 10 (17):6030.

Chicago/Turabian Style

Khaja Moiduddin; Syed Hammad Mian; Wadea Ameen; Mohammed Alkindi; Sundar Ramalingam; Osama Alghamdi. 2020. "Patient-Specific Surgical Implant Using Cavity-Filled Approach for Precise and Functional Mandible Reconstruction." Applied Sciences 10, no. 17: 6030.

Journal article
Published: 08 August 2020 in Materials
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Micromachining has gained considerable interest across a wide range of applications. It ensures the production of microfeatures such as microchannels, micropockets, etc. Typically, the manufacturing of microchannels in bioceramics is a demanding task. The ubiquitous technologies, laser beam machining (LBM) and rotary ultrasonic machining (RUM), have tremendous potential. However, again, these machining methods do have inherent problems. LBM has issues concerning thermal damage, high surface roughness, and vulnerable dimensional accuracy. Likewise, RUM is associated with high machining costs and low material-removal rates. To overcome their limits, a synthesis of LBM and RUM processes known as laser rotary ultrasonic machining (LRUM) has been conceived. The bioceramic known as biolox forte was utilized in this investigation. The approach encompasses the exploratory study of the effects of fundamental input process parameters of LBM and RUM on the surface quality, machining time, and dimensional accuracy of the manufactured microchannels. The performance of LRUM was analyzed and the mechanism of LRUM tool wear was also investigated. The results revealed that the surface roughness, depth error, and width error is decreased by 88%, 70%, and 80% respectively in the LRUM process. Moreover, the machining time of LRUM is reduced by 85%.

ACS Style

Basem M. A. Abdo; Syed Hammad Mian; Abdualziz El-Tamimi; Hisham Alkhalefah; Khaja Moiduddin. Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes. Materials 2020, 13, 3505 .

AMA Style

Basem M. A. Abdo, Syed Hammad Mian, Abdualziz El-Tamimi, Hisham Alkhalefah, Khaja Moiduddin. Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes. Materials. 2020; 13 (16):3505.

Chicago/Turabian Style

Basem M. A. Abdo; Syed Hammad Mian; Abdualziz El-Tamimi; Hisham Alkhalefah; Khaja Moiduddin. 2020. "Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes." Materials 13, no. 16: 3505.

Journal article
Published: 29 July 2020 in Sustainability
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The emergence of Industry 4.0, also referred to as the fourth industrial revolution, has entirely transformed how the industry or business functions and evolves. It can be attributed to its broadening focus on automation, decentralization, system integration, cyber-physical systems, etc. Its implementation promises numerous benefits in terms of higher productivity, greater volatility, better control and streamlining of processes, accelerated enterprise growth, sustainable development, etc. Despite the worldwide recognition and realization of Industry 4.0, its holistic adoption is constrained by the requirements of specific skills among the workforce. The personnel are expected to acquire adaptive thinking, cognitive and computational skills, predominantly in the area of information technology, data analytics, etc. Thus, the universities that laid the foundation for future talents or trends in society have to adapt and modernize the existing programs, facilities, and infrastructure. This reshaping of higher education in consonance with the vision of Industry 4.0 possesses its opportunities and challenges. There are, of course, a multitude of factors involved and they need a reasonable assessment to strategically plan this metamorphosis. Therefore, this work aims to explore and analyze the different factors that influence the progression and enactment of Industry 4.0 in universities for sustainable education. For this purpose, a systematic approach based on a questionnaire as well as a SWOT (strengths (S), weaknesses (W), opportunities (O), and threats (T)) integrated with the analytic hierarchy process (AHP) is adopted. The questionnaires are administered to university employees and students (or stakeholders) to assess their viewpoint, as well as to estimate the priority values for individual factors to be included in SWOT. The AHP is implemented to quantify the different factors in terms of weights using a pairwise comparison matrix. Finally, the SWOT matrix is established depending on the questionnaire assessment and the AHP weights to figure out stakeholders’ perspectives, in addition to the needed strategic scheme. The SWOT implementation of this research proposes an aggressive approach for universities, where they must make full use of their strengths to take advantage of the emerging opportunities in Industry 4.0. The results also indicate that there are fundamental requirements for universities in Industry 4.0, including effective financial planning, skilled staff, increased industrial partnerships, advanced infrastructure, revised curricula, and insightful workshops. This investigation undoubtedly underlines the importance of practical expertise and the implementation of digital technologies at the university level to empower novices with the requisite skills and a competitive advantage for Industry 4.0.

ACS Style

Syed Hammad Mian; Bashir Salah; Wadea Ameen; Khaja Moiduddin; Hisham Alkhalefah. Adapting Universities for Sustainability Education in Industry 4.0: Channel of Challenges and Opportunities. Sustainability 2020, 12, 6100 .

AMA Style

Syed Hammad Mian, Bashir Salah, Wadea Ameen, Khaja Moiduddin, Hisham Alkhalefah. Adapting Universities for Sustainability Education in Industry 4.0: Channel of Challenges and Opportunities. Sustainability. 2020; 12 (15):6100.

Chicago/Turabian Style

Syed Hammad Mian; Bashir Salah; Wadea Ameen; Khaja Moiduddin; Hisham Alkhalefah. 2020. "Adapting Universities for Sustainability Education in Industry 4.0: Channel of Challenges and Opportunities." Sustainability 12, no. 15: 6100.

Journal article
Published: 28 July 2020 in Optics & Laser Technology
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The process enhancement plays a vital role in the modern machining techniques during machining of newer materials such as titanium alloys. In the present work, a research endeavor was made to examine the effects of process parameters in laser beam machining process while drilling holes over Titanium (Ti-6Al-4V) alloy under Taguchi approach of experiments. Nozzle distance, power, focal length and gas pressure were chosen as the input process parameters to assess the dimensional accuracy quality measures such as roundness and ovality in laser beam machining process. It was found that power has the most significant impact on determining the dimensional accuracy. 1.2 mm (ND), 2 mm (L), 4 bar (GP) and 2 kW (J) has been chosen as optimal process parameters combination for obtaining better dimensional accuracy among the selected process parameters. It was also observed that the machinability could be highly influenced with lower peak power.

ACS Style

T. Muthuramalingam; Khaja Moiduddin; Ravi Akash; Shravan Krishnan; Syed Hammad Mian; Wadea Ameen; Hisham Alkhalefah. Influence of process parameters on dimensional accuracy of machined Titanium (Ti-6Al-4V) alloy in Laser Beam Machining Process. Optics & Laser Technology 2020, 132, 106494 .

AMA Style

T. Muthuramalingam, Khaja Moiduddin, Ravi Akash, Shravan Krishnan, Syed Hammad Mian, Wadea Ameen, Hisham Alkhalefah. Influence of process parameters on dimensional accuracy of machined Titanium (Ti-6Al-4V) alloy in Laser Beam Machining Process. Optics & Laser Technology. 2020; 132 ():106494.

Chicago/Turabian Style

T. Muthuramalingam; Khaja Moiduddin; Ravi Akash; Shravan Krishnan; Syed Hammad Mian; Wadea Ameen; Hisham Alkhalefah. 2020. "Influence of process parameters on dimensional accuracy of machined Titanium (Ti-6Al-4V) alloy in Laser Beam Machining Process." Optics & Laser Technology 132, no. : 106494.

Journal article
Published: 01 July 2020 in Sensors
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A real-time roundabout detection and navigation system for smart vehicles and cities using laser simulator–fuzzy logic algorithms and sensor fusion in a road environment is presented in this paper. A wheeled mobile robot (WMR) is supposed to navigate autonomously on the road in real-time and reach a predefined goal while discovering and detecting the road roundabout. A complete modeling and path planning of the road’s roundabout intersection was derived to enable the WMR to navigate autonomously in indoor and outdoor terrains. A new algorithm, called Laser Simulator, has been introduced to detect various entities in a road roundabout setting, which is later integrated with fuzzy logic algorithm for making the right decision about the existence of the roundabout. The sensor fusion process involving the use of a Wi-Fi camera, laser range finder, and odometry was implemented to generate the robot’s path planning and localization within the road environment. The local maps were built using the extracted data from the camera and laser range finder to estimate the road parameters such as road width, side curbs, and roundabout center, all in two-dimensional space. The path generation algorithm was fully derived within the local maps and tested with a WMR platform in real-time.

ACS Style

Mohammed A. H. Ali; Musa Mailah; Waheb A. Jabbar; Khaja Moiduddin; Wadea Ameen; Hisham Alkhalefah. Autonomous Road Roundabout Detection and Navigation System for Smart Vehicles and Cities Using Laser Simulator–Fuzzy Logic Algorithms and Sensor Fusion. Sensors 2020, 20, 3694 .

AMA Style

Mohammed A. H. Ali, Musa Mailah, Waheb A. Jabbar, Khaja Moiduddin, Wadea Ameen, Hisham Alkhalefah. Autonomous Road Roundabout Detection and Navigation System for Smart Vehicles and Cities Using Laser Simulator–Fuzzy Logic Algorithms and Sensor Fusion. Sensors. 2020; 20 (13):3694.

Chicago/Turabian Style

Mohammed A. H. Ali; Musa Mailah; Waheb A. Jabbar; Khaja Moiduddin; Wadea Ameen; Hisham Alkhalefah. 2020. "Autonomous Road Roundabout Detection and Navigation System for Smart Vehicles and Cities Using Laser Simulator–Fuzzy Logic Algorithms and Sensor Fusion." Sensors 20, no. 13: 3694.

Journal article
Published: 21 March 2020 in Materials
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The surface measures of machined titanium alloys as dental materials can be enhanced by adopting a decision-making algorithm in the machining process. The surface quality is normally characterized by more than one quality parameter. Hence, it is very important to establish multi-criteria decision making to compute the optimal process factors. In the present study, Taguchi–Grey analysis-based criteria decision making has been applied to the input process factors in the wire EDM (electric discharge machining) process. The recast layer thickness, wire wear ratio and micro hardness have been chosen to evaluate the quality measures. It was found that the wire electrode selection was the most influential factor on the quality measures in the WEDM process, due to its significance in creating spark energy. The optimal arrangement of the input process parameters has been found using the proposed approach as gap voltage (70 V), discharge current (15 A) and duty factor (0.6). It was proved that the proposed method can enhance the efficacy of the process. Utilizing the computed combination of optimal process parameters in surface quality analysis has significantly contributed to improving the quality of machining surface.

ACS Style

Muthuramalingam Thangaraj; Ramamurthy Annamalai; Khaja Moiduddin; Mohammed Alkindi; Sundar Ramalingam; Osama Alghamdi. Enhancing the Surface Quality of Micro Titanium Alloy Specimen in WEDM Process by Adopting TGRA-Based Optimization. Materials 2020, 13, 1440 .

AMA Style

Muthuramalingam Thangaraj, Ramamurthy Annamalai, Khaja Moiduddin, Mohammed Alkindi, Sundar Ramalingam, Osama Alghamdi. Enhancing the Surface Quality of Micro Titanium Alloy Specimen in WEDM Process by Adopting TGRA-Based Optimization. Materials. 2020; 13 (6):1440.

Chicago/Turabian Style

Muthuramalingam Thangaraj; Ramamurthy Annamalai; Khaja Moiduddin; Mohammed Alkindi; Sundar Ramalingam; Osama Alghamdi. 2020. "Enhancing the Surface Quality of Micro Titanium Alloy Specimen in WEDM Process by Adopting TGRA-Based Optimization." Materials 13, no. 6: 1440.

Original article
Published: 08 January 2020 in The International Journal of Advanced Manufacturing Technology
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The restoration of mandibular defects, especially large deformities is regarded as the most challenging surgical procedure owing to complicated anatomy and the requirement of customized design. Presently, the commercially available reconstruction plates with standard shapes and sizes are frequently utilized. However, these typical plates exhibit several disadvantages, including high cost, poor performance, etc. They are ineffective and do not exactly match the bone contours. Besides, trial and miss approach and several revisions associated with these plates involve significant effort and time. To overcome these issues, a framework based on the integration of design, analysis, evaluation, and fabrication phases have been developed and implemented. The objective was the attainment of a cost-effective, reliable, and sturdy design for the mandibular implant. A customized plate merged with a mesh structure matching the patient bone contours as well as guide and support the growth of neighboring bones was the crux of this mandible implant. The proposed methodology was made of three primary pillars: technology unification, multi-disciplinary notion, and a quality emphasis. A lattice structure, instead of a solid framework was utilized to reconstruct the large mandibular defect. Indeed, the various porous structures were analyzed to finally derive the appropriate lattice structure. The scans from computer tomography were utilized to model the customized plate and scaffold framework, while electron beam melting was used to fabricate the implant. Moreover, the proposed implant design was analyzed using finite element analysis as well as the fabricated specimen was validated for mechanical and structural behavior. The biomechanical analysis outcome revealed lower stresses (214.77 MPa) as well as well-connected structures involving proper porosity and robust mechanical properties. The cost analysis also established that the employment of the proposed design would result in a lesser burden on the patient as compared to the existing practices.

ACS Style

Khaja Moiduddin; Syed Hammad Mian; Naveed Ahmed; Wadea Ameen; Hisham Al-Khalefah; Muneer Khan Mohammed; Usama Umer. Integrative and multi-disciplinary framework for the 3D rehabilitation of large mandibular defects. The International Journal of Advanced Manufacturing Technology 2020, 106, 3831 -3847.

AMA Style

Khaja Moiduddin, Syed Hammad Mian, Naveed Ahmed, Wadea Ameen, Hisham Al-Khalefah, Muneer Khan Mohammed, Usama Umer. Integrative and multi-disciplinary framework for the 3D rehabilitation of large mandibular defects. The International Journal of Advanced Manufacturing Technology. 2020; 106 (9-10):3831-3847.

Chicago/Turabian Style

Khaja Moiduddin; Syed Hammad Mian; Naveed Ahmed; Wadea Ameen; Hisham Al-Khalefah; Muneer Khan Mohammed; Usama Umer. 2020. "Integrative and multi-disciplinary framework for the 3D rehabilitation of large mandibular defects." The International Journal of Advanced Manufacturing Technology 106, no. 9-10: 3831-3847.

Journal article
Published: 12 December 2019 in Applied Sciences
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Total alloplastic temporomandibular joint (TMJ) replacement has become common. This in vitro study aimed to evaluate wear response of custom-fabricated electron beam melted titanium (EBM-Ti), zirconia, and acrylic TMJ parts when subjected to biomechanical simulation testing. Eighteen prosthetic TMJ parts (condyle, glenoid fossa) were custom-fabricated using computer aided design and manufacturing (CAD/CAM) techniques based on patient’s radiographic images. Biomechanical simulation testing of TMJ parts (in different combinations) were done in a modified chewing simulator (108,000 cycles, 1 Hz frequency, 45–60 N compression, strokes-downward 0.15–0.25 s/horizontal, 0.4–0.5 s/upward, 0.25–0.45 s/displacement, 1.5–2.0 mm). Qualitative analysis using scanning electron microscopy revealed wear facets on leading edges of vertical and horizontal simulation strokes. Measurement of pre-test and post-test weights of TMJ parts revealed non-significant reduction in weights due to wear. EBM-Ti and acrylic TMJ glenoid fossae articulating against zirconia condyles during simulation testing had significantly higher wear, evidenced by greater mean reduction in weights. Based on results of this preliminary study, custom-fabricated alloplastic prosthetic TMJ are a viable alternative to stock alloplastic joints. While EBM-Ti and acrylic are suitable biomaterials for custom-fabrication, use of zirconia results in greater wear and requires further studies to optimize their role in customized alloplastic TMJ.

ACS Style

Mohammed Alkindi; Sundar Ramalingam; Khaja Moiduddin; Osama Alghamdi; Hisham Alkhalefah; Mohammed Badwelan. In Vitro Biomechanical Simulation Testing of Custom Fabricated Temporomandibular Joint Parts Made of Electron Beam Melted Titanium, Zirconia, and Poly-Methyl Methacrylate. Applied Sciences 2019, 9, 5455 .

AMA Style

Mohammed Alkindi, Sundar Ramalingam, Khaja Moiduddin, Osama Alghamdi, Hisham Alkhalefah, Mohammed Badwelan. In Vitro Biomechanical Simulation Testing of Custom Fabricated Temporomandibular Joint Parts Made of Electron Beam Melted Titanium, Zirconia, and Poly-Methyl Methacrylate. Applied Sciences. 2019; 9 (24):5455.

Chicago/Turabian Style

Mohammed Alkindi; Sundar Ramalingam; Khaja Moiduddin; Osama Alghamdi; Hisham Alkhalefah; Mohammed Badwelan. 2019. "In Vitro Biomechanical Simulation Testing of Custom Fabricated Temporomandibular Joint Parts Made of Electron Beam Melted Titanium, Zirconia, and Poly-Methyl Methacrylate." Applied Sciences 9, no. 24: 5455.

Journal article
Published: 22 November 2019 in Metals
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Reconstruction of zygomatic complex defects is a surgical challenge, owing to the accurate restoration of structural symmetry as well as facial projection. Generally, there are many available techniques for zygomatic reconstruction, but they hardly achieve aesthetic and functional properties. To our knowledge, there is no such study on zygomatic titanium bone reconstruction, which involves the complete steps from patient computed tomography scan to the fabrication of titanium zygomatic implant and evaluation of implant accuracy. The objective of this study is to propose an integrated system methodology for the reconstruction of complex zygomatic bony defects using titanium comprising several steps, right from the patient scan to implant fabrication while maintaining proper aesthetic and facial symmetry. The integrated system methodology involves computer-assisted implant design based on the patient computed tomography data, the implant fitting accuracy using three-dimensional comparison techniques, finite element analysis to investigate the biomechanical behavior under loading conditions, and finally titanium fabrication of the zygomatic implant using state-of-the-art electron beam melting technology. The resulting titanium implant has a superior aesthetic appearance and preferable biocompatibility. The customized mirrored implant accurately fit on the defective area and restored the tumor region with inconsequential inconsistency. Moreover, the outcome from the two-dimensional analysis provided a good accuracy within 2 mm as established through physical prototyping. Thus, the designed implant produced faultless fitting, favorable symmetry, and satisfying aesthetics. The simulation results also demonstrated the load resistant ability of the implant with max stress within 1.76 MPa. Certainly, the mirrored and electron beam melted titanium implant can be considered as the practical alternative for a bone substitute of complex zygomatic reconstruction.

ACS Style

Khaja Moiduddin; Syed Hammad Mian; Usama Umer; Naveed Ahmed; Hisham Alkhalefah; Wadea Ameen. Reconstruction of Complex Zygomatic Bone Defects Using Mirroring Coupled with EBM Fabrication of Titanium Implant. Metals 2019, 9, 1250 .

AMA Style

Khaja Moiduddin, Syed Hammad Mian, Usama Umer, Naveed Ahmed, Hisham Alkhalefah, Wadea Ameen. Reconstruction of Complex Zygomatic Bone Defects Using Mirroring Coupled with EBM Fabrication of Titanium Implant. Metals. 2019; 9 (12):1250.

Chicago/Turabian Style

Khaja Moiduddin; Syed Hammad Mian; Usama Umer; Naveed Ahmed; Hisham Alkhalefah; Wadea Ameen. 2019. "Reconstruction of Complex Zygomatic Bone Defects Using Mirroring Coupled with EBM Fabrication of Titanium Implant." Metals 9, no. 12: 1250.

Journal article
Published: 30 September 2019 in Metals
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The use of additive manufacturing in medical applications has become more prevalent over the last decade. Studies have proved that reconstruction plates with a mesh structure enhance the biocompatibility and bone-ingrowth formation. However, limited studies have been reported in the customization and in vivo clinical assessment of mesh implants. The purpose of this study was to investigate the surgical treatment and implant fitting accuracy using three different reconstruction plates. Fifteen goats were divided into one control and three experimental groups (Groups 1, 2, and 3) with five in each group. An experimental segmental defect was created on these animals and was adopted with customized electron beam melting reconstruction titanium plates with mesh in Group 1 and without mesh in Group 2 and commercial reconstruction plate in Group 3. All the animals were subjected to radiographic analysis before and after surgery. The subjected animals were sacrificed after 3 months and the electron beam melting reconstruction plates were compared with the commercial plate based on clinical and histology analysis and implant fitting accuracy. Both the electron beam melting reconstruction plates (with mesh and without mesh) and commercial plates survived the three months post-operation, revealing good wound-healing with new bone formation and without any foreign-body reaction. The electron beam melting reconstructed plate with mesh (Group 1) was found to have a better implant fitting when compared to the other two groups. The average discrepancy between Groups 2 and 3 was not significant. Certainly, the commercial plate (Group 3) was found to have the least accuracy as compared to other electron beam melting reconstruction plates (Group 1 and Group 2). Custom design electron beam melting fabricated reconstruction plates possessed better functionality, aesthetic outcome, and long-term biocompatibility when compared to commercial plates. Animal results indicated that the electron beam melting plates with mesh (Group 1) were superior in comparison to the other two groups due to its ability to provide better bone-in-growth and osseointegration on its porous microstructure.

ACS Style

Khaja Moiduddin; Syed Hammad Mian; Mohammed Alkindi; Sundar Ramalingam; Hisham Alkhalefah; Osama Alghamdi. An In Vivo Evaluation of Biocompatibility and Implant Accuracy of the Electron Beam Melting and Commercial Reconstruction Plates. Metals 2019, 9, 1065 .

AMA Style

Khaja Moiduddin, Syed Hammad Mian, Mohammed Alkindi, Sundar Ramalingam, Hisham Alkhalefah, Osama Alghamdi. An In Vivo Evaluation of Biocompatibility and Implant Accuracy of the Electron Beam Melting and Commercial Reconstruction Plates. Metals. 2019; 9 (10):1065.

Chicago/Turabian Style

Khaja Moiduddin; Syed Hammad Mian; Mohammed Alkindi; Sundar Ramalingam; Hisham Alkhalefah; Osama Alghamdi. 2019. "An In Vivo Evaluation of Biocompatibility and Implant Accuracy of the Electron Beam Melting and Commercial Reconstruction Plates." Metals 9, no. 10: 1065.

Journal article
Published: 22 July 2019 in Metals
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Electron beam melting (EBM) technology is a novel additive manufacturing (AM) technique, which uses computer controlled electron beams to create fully dense three-dimensional objects from metal powder. It gives the ability to produce any complex parts directly from a computer aided design (CAD) model without tools and dies, and with variety of materials. However, it is reported that EBM has limitations in building overhang structures, due to the poor thermal conductivity for the sintered powder particles under overhang surfaces. In the current study, 2D thermo-mechanical finite element models (FEM) are developed to predict the stresses and deformation associated with fabrication of overhang structures by EBM for Ti-6Al-4V alloy. Different support structure geometries are modeled and evaluated. Finally, the numerical results are validated by experimental work.

ACS Style

Usama Umer; Wadea Ameen; Mustufa Haider Abidi; Khaja Moiduddin; Hisham Alkhalefah; Mohammed Alkahtani; Abdulrahman Al-Ahmari. Modeling the Effect of Different Support Structures in Electron Beam Melting of Titanium Alloy Using Finite Element Models. Metals 2019, 9, 806 .

AMA Style

Usama Umer, Wadea Ameen, Mustufa Haider Abidi, Khaja Moiduddin, Hisham Alkhalefah, Mohammed Alkahtani, Abdulrahman Al-Ahmari. Modeling the Effect of Different Support Structures in Electron Beam Melting of Titanium Alloy Using Finite Element Models. Metals. 2019; 9 (7):806.

Chicago/Turabian Style

Usama Umer; Wadea Ameen; Mustufa Haider Abidi; Khaja Moiduddin; Hisham Alkhalefah; Mohammed Alkahtani; Abdulrahman Al-Ahmari. 2019. "Modeling the Effect of Different Support Structures in Electron Beam Melting of Titanium Alloy Using Finite Element Models." Metals 9, no. 7: 806.

Journal article
Published: 20 June 2019 in Applied Sciences
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A custom made implant is critical in cranioplasty to cushion and restore intracranial anatomy, as well as to recover the appearance and attain cognitive stability in the patient. The utilization of customized titanium alloy implants using three-dimensional (3D) reconstruction technique and fabricated using Electron Beam Melting (EBM) has gained significant recognition in recent years, owing to their convenience and effectiveness. Besides, the conventional technique or the extant practice of transforming the standard plates is unreliable, arduous and tedious. As a result, this work aims to produce a customized cranial implant using 3D reconstruction that is reliable in terms of fitting accuracy, appearance, mechanical strength, and consistent material composition. A well-defined methodology initiating from EBM fabrication to final validation has been outlined in this work. The custom design of the implant was carried out by mirror reconstruction of the skull’s defective region, acquired through computer tomography. The design of the customized implant was then analyzed for mechanical stresses by applying finite element analysis. Consequently, the 3D model of the implant was fabricated from Ti6Al4V ELI powder with a thickness of ≃1.76–2 mm. Different tests were employed to evaluate the bio-mechanical stability and strength of the fabricated customized implant design. A 3D comparison study was performed to ensure there was anatomical accuracy, as well as to maintain gratifying aesthetics. The bio-mechanical analysis results revealed that the maximum Von Mises stress (2.5 MPa), strain distribution (1.49 × 10−4) and deformation (3.26 × 10−6 mm) were significantly low in magnitude, thus proving the implant load resistance ability. The average yield and tensile strengths for the fabricated Ti6Al4V ELI EBM specimen were found to be 825 MPa and 880 MPa, respectively, which were well over the prescribed strength for Ti6Al4V ELI implant material. The hardness study also resulted in an acceptable outcome within the acceptable range of 30–35 HRC. Certainly, the chemical composition of the fabricated EBM specimen was intact as established in EDX analysis. The weight of the cranial implant (128 grams) was also in agreement with substituted defected bone portion, ruling out any stress shielding effect. With the proposed approach, the anatomy of the cranium deformities can be retrieved effectively and efficiently. The implementation of 3D reconstruction techniques can conveniently reduce tedious alterations in the implant design and subsequent errors. It can be a valuable and reliable approach to enhance implant fitting, stability, and strength.

ACS Style

Khaja Moiduddin; Syed Hammad Mian; Usama Umer; Hisham Alkhalefah. Fabrication and Analysis of a Ti6Al4V Implant for Cranial Restoration. Applied Sciences 2019, 9, 2513 .

AMA Style

Khaja Moiduddin, Syed Hammad Mian, Usama Umer, Hisham Alkhalefah. Fabrication and Analysis of a Ti6Al4V Implant for Cranial Restoration. Applied Sciences. 2019; 9 (12):2513.

Chicago/Turabian Style

Khaja Moiduddin; Syed Hammad Mian; Usama Umer; Hisham Alkhalefah. 2019. "Fabrication and Analysis of a Ti6Al4V Implant for Cranial Restoration." Applied Sciences 9, no. 12: 2513.

Journal article
Published: 16 May 2019 in Metals
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Segmental mandibular reconstruction has been a challenge for medical practitioners, despite significant advances in medical technology. There is a recent trend in relation to customized implants, made up of porous structures. These lightweight prosthesis scaffolds present a new direction in the evolution of mandibular restoration. Indeed, the design and properties of porous implants for mandibular reconstruction should be able to recover the anatomy and contour of the missing region as well as restore the functions, including mastication, swallowing, etc. In this work, two different designs for customized prosthesis scaffold have been assessed for mandibular continuity. These designs have been evaluated for functional and aesthetic aspects along with effective osseointegration. The two designs classified as top and bottom porous plate and inner porous plate were designed and realized through the integration of imaging technology (computer tomography), processing software and additive manufacturing (Electron Beam Melting). In addition, the proposed designs for prosthesis scaffolds were analyzed for their biomechanical properties, structural integrity, fitting accuracy and heaviness. The simulation of biomechanical activity revealed that the scaffold with top and bottom porous plate design inherited lower Von Mises stress (214.77 MPa) as compared to scaffold design with inner porous plate design (360.22 MPa). Moreover, the top and bottom porous plate design resulted in a better fit with an average deviation of 0.8274 mm and its structure was more efficiently interconnected through the network of channels without any cracks or powder material. Verily, this study has demonstrated the feasibility and effectiveness of the customized porous titanium implants in mandibular reconstruction. Notice that the design and formation of the porous implant play a crucial role in restoring the desired mandibular performance.

ACS Style

Khaja Moiduddin; Syed Hammad Mian; Hisham Alkhalefah; Usama Umer. Digital Design, Analysis and 3D Printing of Prosthesis Scaffolds for Mandibular Reconstruction. Metals 2019, 9, 569 .

AMA Style

Khaja Moiduddin, Syed Hammad Mian, Hisham Alkhalefah, Usama Umer. Digital Design, Analysis and 3D Printing of Prosthesis Scaffolds for Mandibular Reconstruction. Metals. 2019; 9 (5):569.

Chicago/Turabian Style

Khaja Moiduddin; Syed Hammad Mian; Hisham Alkhalefah; Usama Umer. 2019. "Digital Design, Analysis and 3D Printing of Prosthesis Scaffolds for Mandibular Reconstruction." Metals 9, no. 5: 569.