Browsing by Author "Abdelkawy, Abdallah"

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Investigating Tool Wear, Chip Behaviour and Spring Back Action Using FEM
(October university for modern sciences and Arts (MSA), 2022-09) El-Hossainy, Tarek; Abdrabou, Mahmoud; Abdelkawy, Abdallah
The tool wear found in machining processes represents main obstacle for machinability due to its detrimental effects on surface roughness, material removal rate and machining economy. A nonlinear thermomechanical finite element model was developed to simulate the tool chip interaction. This model predicts not only the chip morphology and chip flow direction, cutting forces values, stress distribution, but also can use to predict tool wear. Furthermore, the effect of elastic deformation (spring back) and the thermal effect have been considered in the model. Cutting force was predicted and compared with the conducted experimental work. Dry turning operation was carried out on low carbon steel using carbide tool. The tool/workpiece interface stress on flank face was calculated and compared with the FEM. Predicted results show good correlation with the FEM. FE model was verified experimentally by measuring the cutting force. The friction on the flank face and spring back concentrates the stress on the flank face.
Investigating Tool Wear, Chip Behaviour and Spring Back Action Using FEM
(October university for modern sciences and Arts MSA, 2022) El-Hossainy, Tarek; Abdrabou, Mahmoud; Abdelkawy, Abdallah
The tool wear found in machining processes represents main obstacle for machinability due to its detrimental effects on surface roughness, material removal rate and machining economy. A nonlinear thermomechanical finite element model was developed to simulate the tool chip interaction. This model predicts not only the chip morphology and chip flow direction, cutting forces values, stress distribution, but also can use to predict tool wear. Furthermore, the effect of elastic deformation (spring back) and the thermal effect have been considered in the model. Cutting force was predicted and compared with the conducted experimental work. Dry turning operation was carried out on low carbon steel using carbide tool. The tool/workpiece interface stress on flank face was calculated and compared with the FEM. Predicted results show good correlation with the FEM. FE model was verified experimentally by measuring the cutting force. The friction on the flank face and spring back concentrates the stress on the flank face.
Machining process parameters optimization using soft computing technique
(Springer Nature Switzerland AG, 2023-01) El Hossainy, Tarek M; Zeyada, Yasser; Abdelkawy, Abdallah
This work introduces an approach for optimization machinability measures of power consumption, machining time, and the surface roughness (PMS). This approach is starting with market customer’s demands, passing by optimizing the machinability measures (PMS), and ending by the optimized cutting conditions. The fuzzy logic was used to defne the weights of each of required machinability measurement using method through expert rules depending on factory requirements. Genetic algorithm was formulated for giving optimum output values based on the customer’s demands. A neural network was designed for controlling the input cutting conditions with the PMS output parameters. The proposed soft computing technique creates reasonable results compared to experimental results and gives rich investigations for optimizing the output parameters not only for increasing productivity and quality demands but also for saving power consumed. The variation of consumed power, machining time, and surface roughness was calculated based on diferent customer demand levels. When the machining time and power consumed importance increased, the proposed technique reduced them by about 20% and 10% for the testes case.