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H.A. Kishawy
Faculty of Engineering and Applied Science, University of Ontario Institute of Technology (UOIT), Oshawa, Ontario, Canada

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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: 14 October 2020 in Sustainability
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Due to rising demands of replacing traditional cooling strategies with sustainable cooling strategies, the development of sustainable strategies such as minimum quantity lubrication (MQL) of nano-cutting fluids (NCFs) is on the rise. MQL of NCFs has received a lot of attention due to its positive impact on machining process efficiency. However, environmental and human health impacts of this strategy have not been fully investigated yet. This work aims to investigate the impacts of MQL of molybdenum disulfide (MoS2), multi-walled carbon nanotubes (MWCNTs), titanium dioxide (TiO2), and aluminum oxide (Al2O3) NCFs by employing a cradle-to-gate type of life cycle assessment (LCA). Besides, this paper provides a comparison of the impacts and machining performance when utilizing MQL of NCFs with other cooling strategies such as traditional flood cooling (TFC) of conventional cutting fluids and MQL of vegetable oils. It was found that NCFs have higher impacts than conventional cutting fluids and vegetable oils. The impacts of TiO2-NCF and MoS2-NCF were lower than the impacts of MWCNTs-NCF and Al2O3-NCF. MQL of NCFs presented higher impacts by 3.7% to 35.4% in comparison with the MQL of vegetable oils. TFC of conventional CFs displayed the lowest impact. However, TFC of conventional cutting fluids is contributing to severe health problems for operators. MQL of vegetable oils displayed higher impacts than TCFs of conventional cutting fluids. However, vegetable oils are considered to be environmentally friendly. According to the findings, the MQL of vegetable oils is the most sustainable strategy for machining processes with associated low/medium cutting temperatures. While MQL of TiO2 and MoS2 NCFs are the sustainable strategy for machining processes associated with high cutting temperatures.

ACS Style

Amr Salem; Connor Hopkins; Mohamd Imad; Hussien Hegab; Basil Darras; Hossam Kishawy. Environmental Analysis of Sustainable and Traditional Cooling and Lubrication Strategies during Machining Processes. Sustainability 2020, 12, 8462 .

AMA Style

Amr Salem, Connor Hopkins, Mohamd Imad, Hussien Hegab, Basil Darras, Hossam Kishawy. Environmental Analysis of Sustainable and Traditional Cooling and Lubrication Strategies during Machining Processes. Sustainability. 2020; 12 (20):8462.

Chicago/Turabian Style

Amr Salem; Connor Hopkins; Mohamd Imad; Hussien Hegab; Basil Darras; Hossam Kishawy. 2020. "Environmental Analysis of Sustainable and Traditional Cooling and Lubrication Strategies during Machining Processes." Sustainability 12, no. 20: 8462.

Journal article
Published: 24 June 2020 in Metals
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Finite element (FE) models and the multi objective genetic algorithm (MOGA-II) have been applied for tool performance optimization while machining aluminum-based metal matrix composites. The developed and verified FE models are utilized to generate data for the full factorial design of experiment (DOE) plan. The FE models consist of a heterogenous workpiece, which assumes uniform distribution of reinforced particles according to size and volume fraction. Cutting forces, chip morphology, temperature contours, stress distributions in the workpiece and tool by altering cutting speed, feed rate, and reinforcement particle size can be estimated using developed FE models. The DOE data are then utilized to develop response surfaces using radial basis functions. To reduce computational time, these response surfaces are used as solver for optimization runs using MOGA-II. Tool performance has been optimized with regard to cutting temperatures and stresses while setting a limit on specific cutting energy. Optimal solutions are found with low cutting speed and moderate feed rates for each particle size metal matrix composite (MMC).

ACS Style

Usama Umer; Mustufa Haider Abidi; Jaber Abu Qudeiri; Hisham Alkhalefah; Hossam Kishawy. Tool Performance Optimization While Machining Aluminium-Based Metal Matrix Composite. Metals 2020, 10, 835 .

AMA Style

Usama Umer, Mustufa Haider Abidi, Jaber Abu Qudeiri, Hisham Alkhalefah, Hossam Kishawy. Tool Performance Optimization While Machining Aluminium-Based Metal Matrix Composite. Metals. 2020; 10 (6):835.

Chicago/Turabian Style

Usama Umer; Mustufa Haider Abidi; Jaber Abu Qudeiri; Hisham Alkhalefah; Hossam Kishawy. 2020. "Tool Performance Optimization While Machining Aluminium-Based Metal Matrix Composite." Metals 10, no. 6: 835.

Original article
Published: 06 January 2020 in The International Journal of Advanced Manufacturing Technology
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Metal matrix composites (MMCs) are utilized in various industries due to their unique characteristics. Despite their spreading applications in different fields, the MMC manufacturing industry is still facing a major challenge, particularly the prediction and improvement of the quality and integrity of machined surfaces. This paper is focused on subsurface damage, which is considered to be an important aspect of surface integrity of machined parts. A novel model for prediction of the depth of damage beneath the machined surface is presented and discussed. The model is developed through investigation of plastic deformations along with the fracture and debonding of reinforcements. Comparison with data from machining experiments is performed to verify the accuracy of model predictions.

ACS Style

A. Ghandehariun; H. A. Kishawy. A novel approach towards prediction of subsurface damage during machining metal matrix composites. The International Journal of Advanced Manufacturing Technology 2020, 106, 3515 -3521.

AMA Style

A. Ghandehariun, H. A. Kishawy. A novel approach towards prediction of subsurface damage during machining metal matrix composites. The International Journal of Advanced Manufacturing Technology. 2020; 106 (7-8):3515-3521.

Chicago/Turabian Style

A. Ghandehariun; H. A. Kishawy. 2020. "A novel approach towards prediction of subsurface damage during machining metal matrix composites." The International Journal of Advanced Manufacturing Technology 106, no. 7-8: 3515-3521.

Journal article
Published: 01 January 2020 in IFAC-PapersOnLine
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An intelligent process planning for additive manufacturing (AM) is proposed in a paper presented at IFAC-IMS 20191. An important aspect of the intelligent process planning is to directly slice CAD models to generate paths for AM machines. In this paper an experimental approach is carried out to investigate the improvements in the results of fabrication using direct slicing approach. In the proposed process, a CAD model is directly sliced and layer contours are extracted from the ideal surface. The curvature based parametrization using a multi-step method is implemented for finding the position of layers. The dimensional errors are investigated first by comparing the errors generated during the tessellation process with the ideal surfaces. Then the results of printing using paths generated from STL files and the ideal surface defined in an IGES file are compared. The results show considerable improvements in surface continuity and dimensional accuracy of the parts fabricated form the direct slicing approach.

ACS Style

Hossein Gohari; Ahmad Barari; Hossam Kishawy; Marcos S.G. Tsuzuki. Effect of Direct Slicing on Precision Additive Manufacturing. IFAC-PapersOnLine 2020, 53, 11982 -11987.

AMA Style

Hossein Gohari, Ahmad Barari, Hossam Kishawy, Marcos S.G. Tsuzuki. Effect of Direct Slicing on Precision Additive Manufacturing. IFAC-PapersOnLine. 2020; 53 (2):11982-11987.

Chicago/Turabian Style

Hossein Gohari; Ahmad Barari; Hossam Kishawy; Marcos S.G. Tsuzuki. 2020. "Effect of Direct Slicing on Precision Additive Manufacturing." IFAC-PapersOnLine 53, no. 2: 11982-11987.

Journal article
Published: 02 November 2019 in IFAC-PapersOnLine
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This paper introduces an intelligent approach for process planning of additive manufacturing (AM) in digital environment. A global adaptive slicing algorithm is developed and embedded in the introduced concept, which determines the layer thicknesses and widths based on the minimization of the deviations between the CAD model boundary and its stepped approximation. It is discussed that there are different metrics to measure the deviations such as cusp height, cusp volume and surface roughness criteria. A new criterion is developed to globally minimize the overall volumetric deviations of the final product from the desired geometric model. The proposed methodology uses the locally optimized layer thicknesses as the inputs to calculate the globally optimized layer thicknesses and the optimal contour for each layer. The global optimization problem is highly nonlinear that can be solved with a metaheuristic algorithm such as Simulated Annealing.

ACS Style

Hossein Gohari; Ahmad Barari; Hossam Kishawy; Marcos S.G. Tsuzuki. Intelligent Process Planning for Additive Manufacturing. IFAC-PapersOnLine 2019, 52, 218 -223.

AMA Style

Hossein Gohari, Ahmad Barari, Hossam Kishawy, Marcos S.G. Tsuzuki. Intelligent Process Planning for Additive Manufacturing. IFAC-PapersOnLine. 2019; 52 (10):218-223.

Chicago/Turabian Style

Hossein Gohari; Ahmad Barari; Hossam Kishawy; Marcos S.G. Tsuzuki. 2019. "Intelligent Process Planning for Additive Manufacturing." IFAC-PapersOnLine 52, no. 10: 218-223.

Review
Published: 02 November 2019 in IFAC-PapersOnLine
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Manufacturing industries are always pressured by market demands to produce low-cost, high-quality products. Market demands tend to be complex, and full of challenges especially in fast-paced industrial settings. In order to satisfy rising demands, traditional manufacturing techniques are forced to develop and adapt new practices and methods of planning, control, and parameter optimization. The research and development of optimization methodologies have transformed traditional manufacturing methods into intelligent manufacturing techniques that are able to manufacture high quality products, at a lower cost, and a faster production rate. This work’s aim is to review and discuss recent trends and methods of optimization techniques in the emerging field of intelligent machining. The main discussion includes the application of optimization techniques in three areas: the intelligent process planning and scheduling, intelligent process control/management, and process parameter selection.

ACS Style

M. Imad; A. Hosseini; H.A. Kishawy. Optimization Methodologies in Intelligent Machining Systems - A Review. IFAC-PapersOnLine 2019, 52, 282 -287.

AMA Style

M. Imad, A. Hosseini, H.A. Kishawy. Optimization Methodologies in Intelligent Machining Systems - A Review. IFAC-PapersOnLine. 2019; 52 (10):282-287.

Chicago/Turabian Style

M. Imad; A. Hosseini; H.A. Kishawy. 2019. "Optimization Methodologies in Intelligent Machining Systems - A Review." IFAC-PapersOnLine 52, no. 10: 282-287.

Journal article
Published: 24 July 2019 in Journal of Manufacturing and Materials Processing
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The implementation of sustainable machining process can be accomplished by different strategies including process optimization and selection of the proper lubrication techniques and cutting conditions. The present study is carried out from the perspective of a sustainability assessment of turning Ti-6Al-4V by employing minimum quantity lubrication (MQL) and MQL-nanofluid with consideration of the surface quality, tool wear, and power consumption. A sustainability assessment algorithm was used to assess the cutting processes of Ti-6Al-4V alloy under a minimum quantity of lubrication–nanofluid to estimate the levels of sustainable design variables. The assessment included the sustainable indicators as well as the machining responses in a single integrated model. The sustainable aspects included in this study were; environmental impact, management of waste, and safety and health issues of operators. The novelty here lies in employing a comprehensive sustainability assessment model to discuss and understand the machining process with MQL-nanofluid, by not only considering the machining quality characteristics, but also taking into account different sustainability indicators. In order to validate the effectiveness of the sustainability results, a comparison between the optimal and predicted responses was conducted and a good agreement was noticed. It should be stated that MQL-nanofluid showed better results compared to the cutting tests conducted under using classical MQL.

ACS Style

Hossam A. Kishawy; Hussien Hegab; Ibrahim Deiab; Abdelkrem Eltaggaz. Sustainability Assessment during Machining Ti-6Al-4V with Nano-Additives-Based Minimum Quantity Lubrication. Journal of Manufacturing and Materials Processing 2019, 3, 61 .

AMA Style

Hossam A. Kishawy, Hussien Hegab, Ibrahim Deiab, Abdelkrem Eltaggaz. Sustainability Assessment during Machining Ti-6Al-4V with Nano-Additives-Based Minimum Quantity Lubrication. Journal of Manufacturing and Materials Processing. 2019; 3 (3):61.

Chicago/Turabian Style

Hossam A. Kishawy; Hussien Hegab; Ibrahim Deiab; Abdelkrem Eltaggaz. 2019. "Sustainability Assessment during Machining Ti-6Al-4V with Nano-Additives-Based Minimum Quantity Lubrication." Journal of Manufacturing and Materials Processing 3, no. 3: 61.

Book chapter
Published: 05 June 2019 in CIRP Encyclopedia of Production Engineering
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ACS Style

Hossam A Kishawy. Self-Propelled Rotary Tool. CIRP Encyclopedia of Production Engineering 2019, 1517 -1520.

AMA Style

Hossam A Kishawy. Self-Propelled Rotary Tool. CIRP Encyclopedia of Production Engineering. 2019; ():1517-1520.

Chicago/Turabian Style

Hossam A Kishawy. 2019. "Self-Propelled Rotary Tool." CIRP Encyclopedia of Production Engineering , no. : 1517-1520.

Review
Published: 10 October 2018 in Sustainability
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The implementation of sustainable systems is an essential requirement in modern manufacturing, in order to minimize the environmental and health concerns, and conserves energy and natural resources. The sustainable manufacturing approach is identified through three main levels, namely: product, process, and system scales. The interactions among these levels provide the required sustainable target. To achieve a sustainable manufacturing system, it is very important to understand and define the concepts and needs related to the sustainability approach. In addition, defining and understanding the implementation steps as well as the assessment method to build a sustainable manufacturing system is required. In this work, a study discussing the sustainable manufacturing approach is presented in terms of concepts, implementation steps, and assessment methods.

ACS Style

Hossam A. Kishawy; Hussien Hegab; Elsadig Saad. Design for Sustainable Manufacturing: Approach, Implementation, and Assessment. Sustainability 2018, 10, 3604 .

AMA Style

Hossam A. Kishawy, Hussien Hegab, Elsadig Saad. Design for Sustainable Manufacturing: Approach, Implementation, and Assessment. Sustainability. 2018; 10 (10):3604.

Chicago/Turabian Style

Hossam A. Kishawy; Hussien Hegab; Elsadig Saad. 2018. "Design for Sustainable Manufacturing: Approach, Implementation, and Assessment." Sustainability 10, no. 10: 3604.

Journal article
Published: 03 August 2018 in Procedia Manufacturing
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Drilling of composite material is a widely used operation in the aerospace industry. Despite of all precautions during the drilling process, the exit-ply delamination is still one of the major problems that affect the integrity and service life of the parts. The exit-ply delamination is directly related to the mechanical properties of composite materials as well as the nature of the induced thrust force along the cutting and chisel edges. In the current study, an attempt is made to model the induced thrust force. Both point and linear distributed loads models were utilized with consideration of elliptical delamination area. In order to validate the proposed model, a comparison between previous analytical models, measured forces, and the current proposed model is presented and discussed. The presented work was based on two scenarios. The first scenario considers the first mode of fracture only, while the second scenario considers the mixed- fracture mode criterion. The 1st scenario offers an average model accuracy about 77.9%, while the 2nd scenario offers an accuracy about 94.7% when compared to the predicted and measured data. It must be stated that both scenarios offer better prediction when compared to available model in the open literature. Thus, it can be concluded that the proposed model effectively demonstrates the delamination behaviour when drilling laminate composites.

ACS Style

Z. Fattahi; H. Hegab; H.A. Kishawy. Analytical Prediction of Delamination during Drilling Composite Laminates. Procedia Manufacturing 2018, 26, 237 -244.

AMA Style

Z. Fattahi, H. Hegab, H.A. Kishawy. Analytical Prediction of Delamination during Drilling Composite Laminates. Procedia Manufacturing. 2018; 26 ():237-244.

Chicago/Turabian Style

Z. Fattahi; H. Hegab; H.A. Kishawy. 2018. "Analytical Prediction of Delamination during Drilling Composite Laminates." Procedia Manufacturing 26, no. : 237-244.

Journal article
Published: 02 August 2018 in Journal of Manufacturing and Materials Processing
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Difficult-to-cut materials have been widely employed in many engineering applications, including automotive and aeronautical designs because of their effective properties. However, other characteristics; for example, high hardness and low thermal conductivity has negatively affected the induced surface quality and tool life, and consequently the overall machinability of such materials. Inconel 718, is widely used in many industries including aerospace; however, the high temperature generated during machining is negatively affecting its machinability. Flood cooling is a commonly used remedy to improve machinability problems; however, government regulation has called for further alternatives to reduce the environmental and health impacts of flood cooling. This work aimed to investigate the influence of dispersed multi-wall carbon nanotubes (MWCNTs) and aluminum oxide (Al2O3) gamma nanoparticles, on enhancing the minimum quantity lubrication (MQL) technique cooling and lubrication capabilities during turning of Inconel 718. Machining tests were conducted, the generated surfaces were examined, and the energy consumption data were recorded. The study was conducted under different design variables including cutting speed, percentage of added nano-additives (wt.%), and feed velocity. The study revealed that the nano-fluids usage, generally improved the machining performance when cutting Inconel 718. In addition, it was shown that the nanotubes additives provided better improvements than Al2O3 nanoparticles.

ACS Style

Hussien Hegab; Hossam A. Kishawy. Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication. Journal of Manufacturing and Materials Processing 2018, 2, 50 .

AMA Style

Hussien Hegab, Hossam A. Kishawy. Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication. Journal of Manufacturing and Materials Processing. 2018; 2 (3):50.

Chicago/Turabian Style

Hussien Hegab; Hossam A. Kishawy. 2018. "Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication." Journal of Manufacturing and Materials Processing 2, no. 3: 50.

Original article
Published: 20 June 2018 in The International Journal of Advanced Manufacturing Technology
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Monitoring and controlling of metal cutting processes is an essential task in any modern precision machining setup. The implementation of proper monitoring process leads to promising results in terms of cutting tool life, machining costs, and production rates. Several techniques have been used to detect, monitor, and analyze different parameters associated with the cutting processes such as cutting tool wear, chip breakage and fracture, chatter vibrations, and formation of built-up edge (BUE). In this work, a review study is presented to discuss the research activities using the acoustic emission (AE) signals to monitor and control various machining processes. The discussed work does not only present an investigation of the AE signals, measured variables, and AE sensor setup during machining processes, but also shows several methods used for analyzing and processing the AE signals. The work focuses on studies, which employed AE in monitoring, and analyzing some specific characteristics such as chip formation and morphology, surface quality, and tool wear evolution for different machining operations and materials.

ACS Style

H. A. Kishawy; H. Hegab; U. Umer; Atef Mohany. Application of acoustic emissions in machining processes: analysis and critical review. The International Journal of Advanced Manufacturing Technology 2018, 98, 1391 -1407.

AMA Style

H. A. Kishawy, H. Hegab, U. Umer, Atef Mohany. Application of acoustic emissions in machining processes: analysis and critical review. The International Journal of Advanced Manufacturing Technology. 2018; 98 (5-8):1391-1407.

Chicago/Turabian Style

H. A. Kishawy; H. Hegab; U. Umer; Atef Mohany. 2018. "Application of acoustic emissions in machining processes: analysis and critical review." The International Journal of Advanced Manufacturing Technology 98, no. 5-8: 1391-1407.

Original paper
Published: 09 June 2018 in International Journal on Interactive Design and Manufacturing (IJIDeM)
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The use of austempered ductile iron (ADI) is rapidly increasing in many engineering applications such as automotive due to its unique and promising characteristics, for example; high strength to weight ratio, high wear and corrosion resistance, high yield stress, and high toughness. However, other properties such as low thermal conductivity undesirably affects ADI machinability and accelerate cutting tool failure. Additionally, other issues associated with cutting ADI are the high cutting temperature, high pressure and dynamic loads, and tendency of chip to adhere to cutting tool face. To overcome such issues, a proper coolant should be applied. However, flood coolant has sufficient effects in reducing the generated cutting heat, further alternatives are still required to decease its environmental and health impacts. Minimum quantity lubrication (MQL) serves as the best alternative to flood cooling from an environmental perspective as it minimizes the amount of cutting fluid; however, its heat capacity is lower than the traditional flood coolant. To improve the cooling and lubricating efficiency of MQL, aluminum oxide (\(\hbox {Al}_{2}\hbox {O}_{3}\)) gamma nanoparticles are used in this work and its effect on the tool wear behavior during cutting of ADI is investigated. The combination of MQL-nanofluid at cutting speed of 120 m/min and feed rate of 0.2 mm/rev showed the best tool life, while test 3 which has been performed at cutting speed of 240 m/min and feed rate of 0.2 mm/rev using classical MQL provided the worst flank wear value.

ACS Style

A. Eltaggaz; H. Hegab; I. Deiab; H. A. Kishawy. Hybrid nano-fluid-minimum quantity lubrication strategy for machining austempered ductile iron (ADI). International Journal on Interactive Design and Manufacturing (IJIDeM) 2018, 12, 1273 -1281.

AMA Style

A. Eltaggaz, H. Hegab, I. Deiab, H. A. Kishawy. Hybrid nano-fluid-minimum quantity lubrication strategy for machining austempered ductile iron (ADI). International Journal on Interactive Design and Manufacturing (IJIDeM). 2018; 12 (4):1273-1281.

Chicago/Turabian Style

A. Eltaggaz; H. Hegab; I. Deiab; H. A. Kishawy. 2018. "Hybrid nano-fluid-minimum quantity lubrication strategy for machining austempered ductile iron (ADI)." International Journal on Interactive Design and Manufacturing (IJIDeM) 12, no. 4: 1273-1281.

Reference work
Published: 04 June 2018 in CIRP Encyclopedia of Production Engineering
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ACS Style

Hossam A. Kishawy. Self-Propelled Rotary Tool. CIRP Encyclopedia of Production Engineering 2018, 1 -5.

AMA Style

Hossam A. Kishawy. Self-Propelled Rotary Tool. CIRP Encyclopedia of Production Engineering. 2018; ():1-5.

Chicago/Turabian Style

Hossam A. Kishawy. 2018. "Self-Propelled Rotary Tool." CIRP Encyclopedia of Production Engineering , no. : 1-5.

Journal article
Published: 01 January 2018 in Journal of Cleaner Production
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ACS Style

H.A. Hegab; Basil Darras; H.A. Kishawy. Towards sustainability assessment of machining processes. Journal of Cleaner Production 2018, 170, 694 -703.

AMA Style

H.A. Hegab, Basil Darras, H.A. Kishawy. Towards sustainability assessment of machining processes. Journal of Cleaner Production. 2018; 170 ():694-703.

Chicago/Turabian Style

H.A. Hegab; Basil Darras; H.A. Kishawy. 2018. "Towards sustainability assessment of machining processes." Journal of Cleaner Production 170, no. : 694-703.

Original article
Published: 07 December 2017 in The International Journal of Advanced Manufacturing Technology
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Slicing the geometric models has been a crucial computational task for various manufacturing processes in which significant academic research has been dedicated for its efficiency, accuracy, and generalizability. Meanwhile, the feasibility of direct slicing of the modeled geometric surfaces needs more investigation due to the demands for precise geometrical information in applications such as multi-axis machining, layer-based manufacturing and 3D printing, coordinate metrology, and robotics. The purpose of this study is to introduce a method to find the best patches of a non-uniform rational B-spline (NURBS) surface for a direct slicing procedure. Formulating the relation between the spatial coordinates on the surface and the surface parameters is created by a parameterization process. Adams–Bashforth multi-step method is used in this methodology to calculate the most accurate series of the slicing parameters. This paper provides the conception, implementation, and verification of the developed methodology. The resulting solution is very practical and beneficial for direct slicing of CAD models in additive manufacturing systems.

ACS Style

Hossein Gohari; Ahmad Barari; Hossam Kishawy. An efficient methodology for slicing NURBS surfaces using multi-step methods. The International Journal of Advanced Manufacturing Technology 2017, 95, 3111 -3125.

AMA Style

Hossein Gohari, Ahmad Barari, Hossam Kishawy. An efficient methodology for slicing NURBS surfaces using multi-step methods. The International Journal of Advanced Manufacturing Technology. 2017; 95 (9-12):3111-3125.

Chicago/Turabian Style

Hossein Gohari; Ahmad Barari; Hossam Kishawy. 2017. "An efficient methodology for slicing NURBS surfaces using multi-step methods." The International Journal of Advanced Manufacturing Technology 95, no. 9-12: 3111-3125.

Journal article
Published: 17 November 2017 in Journal of Manufacturing Science and Engineering
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Cutting edge microgeometry has gained special attention of late in the machining research community. Machine tool vibration, tool life, and workpiece surface integrity are all influenced by cutting edge size/shape. To optimize the machining process, variable microgeometry (VMG) cutting tools, in which the edge microgeometry varies along the edgeline with respect to specific variables (such as machining parameters or expected tool wear), are manufactured. Despite the advantages of VMG tools, a major hindrance in their development is the manufacturing complexity that demands high precision multi-axis edge preparation processes following extensive machine setup, fixturing, and programming. This paper details the proof of concept of a design criterion, which leads to the manufacturing of VMG cutting tools by only traditional edge preparation processes. The present method relies on the existing relationship between the edge radius subsequent to the edge preparation process and the tool wedge angle. The validity of the proposed method is first examined by a numerical simulation of the edge preparation. Carbide cutting tool inserts are then designed based on the proposed idea. Robust VMG generation subsequent to edge preparation by microblasting is demonstrated through microgeometric measurements. VMG chemical vapor deposition-coated carbide tools manufactured by the proposed approach are evaluated for turning hardened steel, and optimal designs are identified with respect to tool life and workpiece surface roughness. To address the design consideration, finite element (FE) modeling provides valuable insight into the machining process. FE modeled stress and temperature distribution clarify the experimental observations and reveal the design constraints.

ACS Style

N. Z. Yussefian; A. Hosseini; K. Hosseinkhani; H. A. Kishawy. Design for Manufacturing of Variable Microgeometry Cutting Tools. Journal of Manufacturing Science and Engineering 2017, 140, 011014 .

AMA Style

N. Z. Yussefian, A. Hosseini, K. Hosseinkhani, H. A. Kishawy. Design for Manufacturing of Variable Microgeometry Cutting Tools. Journal of Manufacturing Science and Engineering. 2017; 140 (1):011014.

Chicago/Turabian Style

N. Z. Yussefian; A. Hosseini; K. Hosseinkhani; H. A. Kishawy. 2017. "Design for Manufacturing of Variable Microgeometry Cutting Tools." Journal of Manufacturing Science and Engineering 140, no. 1: 011014.

Journal article
Published: 05 August 2016 in The International Journal of Advanced Manufacturing Technology
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This paper presents the development, implementation and application of a methodology to predict and control the surface quality of the additive manufacturing products based on an accurate representation of the cusps’ geometric model. A non-uniform rational B-spline (NURBS) model representing the geometry of cusps generated by layer-based manufacturing is employed, and its parameters are extracted by running experimental study of the fabricated test specimens. The significant difference of the results obtained using the developed models with what is used in common practice is discussed and demonstrated. Using the developed model, a unified solution to estimate the surface roughness based on the local surface gradient on the part and the selected fabrication layer thickness is presented. The results show that the developed methodology effectively estimates the local surface roughness of the fabricated products.

ACS Style

A. Barari; H. A. Kishawy; F. Kaji; M. A. Elbestawi. On the surface quality of additive manufactured parts. The International Journal of Advanced Manufacturing Technology 2016, 89, 1969 -1974.

AMA Style

A. Barari, H. A. Kishawy, F. Kaji, M. A. Elbestawi. On the surface quality of additive manufactured parts. The International Journal of Advanced Manufacturing Technology. 2016; 89 (5-8):1969-1974.

Chicago/Turabian Style

A. Barari; H. A. Kishawy; F. Kaji; M. A. Elbestawi. 2016. "On the surface quality of additive manufactured parts." The International Journal of Advanced Manufacturing Technology 89, no. 5-8: 1969-1974.

Journal article
Published: 01 March 2016 in International Journal of Mechanical Sciences
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Exceptional mechanical characteristics make metal matrix composites (MMCs) a popular choice in various industries. However, the knowledge related to the behavior of MMCs during machining is very limited. This is mainly due to complications in mechanics of chip formation arising from existence of very hard reinforcements. This paper aims to improve the understanding of MMC’s behavior during cutting by developing a novel constitutive equation, which describes the explicit relationship between MMC’s behavior during cutting and its main unique features, namely reinforcement size and volume fraction. Comparison with machining experiments for various MMCs verifies the validity of the proposed model.

ACS Style

A. Ghandehariun; H. Kishawy; M. Balazinski. On machining modeling of metal matrix composites: A novel comprehensive constitutive equation. International Journal of Mechanical Sciences 2016, 107, 235 -241.

AMA Style

A. Ghandehariun, H. Kishawy, M. Balazinski. On machining modeling of metal matrix composites: A novel comprehensive constitutive equation. International Journal of Mechanical Sciences. 2016; 107 ():235-241.

Chicago/Turabian Style

A. Ghandehariun; H. Kishawy; M. Balazinski. 2016. "On machining modeling of metal matrix composites: A novel comprehensive constitutive equation." International Journal of Mechanical Sciences 107, no. : 235-241.