Deep drawing process to produce square cup is very complex process due to a lot of process parame... more Deep drawing process to produce square cup is very complex process due to a lot of process parameters which control on this process, therefore associated with it many of defects such as earing, wrinkling and fracture. Study of the effect of some process parameters to determine the values of these parameters which give the best result, the distributions for the thickness and depths of the cup were used to estimate the effect of the parameters on the cup numerically, in addition to experimental verification just to the conditions which give the best numerical predictions in order to reduce the time, efforts and costs for producing square cup with less defects experimentally is the aim of this study. The numerical analysis is used to study the effect of some parameters such as die profile radius, radial clearance between die and punch, blank diameter on the length and thickness distributions on the cup, dynamic-explicit (ANSYS11) code based on finite element method is utilized to simu...
A new hydroforming setup with a die was designed, made, and assembled. • The new setup enhances t... more A new hydroforming setup with a die was designed, made, and assembled. • The new setup enhances the formability of (1006) AISI steel in square deep drawing. • The hydroforming deep drawing was compared to the conventional one for cup forming. • Hydroforming enhances low-carbon steel formability by reducing thinning. • Conventional deep drawing only reaches 70% depth due to corner thinning. An effort has been made to improve the formability of ( ) AISI steel alloy sheets in deep drawing of square-shaped parts with flat bases through hydroforming. To achieve this goal, the manufacturing process involved the use of a newly developed experimental setup for sheet hydroforming with a die, which was created by the researchers. The key design features of this setup aimed for simplicity and modularity, allowing for potential utilization with oil pressures of up to 100 MPa. The obtained results were compared with those of conventional deep drawing. Both processes were examined under specific conditions to form identical cups up to the full depth of the provided die. Indicators of formability considered for comparison included the minimum possible corner radius, the maximum achievable depth without failure, and the maximum percentage of thinning at the corners. This study demonstrates that hydroforming can enhance the formability of low-carbon steel alloy sheets by improving the flow of metal into the die cavity and reducing thinning at critical regions, when compared to conventional deep drawing processes. In conventional deep drawing, only 70% of the full depth could be achieved before failure due to high local deformations resulting in significantly higher thinning at the corners.
Fused Deposition Modeling (FDM) represents the latest technique in additive manufacturing, capabl... more Fused Deposition Modeling (FDM) represents the latest technique in additive manufacturing, capable of producing complex 3D parts efficiently and cost-effectively without the need for complicated or expensive dies. Among the most commonly used materials in 3D printers is the Acrylonitrile Butadiene Styrene (ABS) filament, which is renowned for its mechanical properties. Despite these advantageous properties, the ABS filament is susceptible to printing challenges, particularly the occurrence of warping defects. These defects can result in print failures and subsequent dislocation of the 3D-printed components from the printing bed. The objective of this study is to eliminate or mitigate the warping defects by implementing a temperature control system within the enclosure to prevent rapid cooling during the 3D printing process. The adopted design system incorporates a thermostat controller, a wire heater, and an enclosure to regulate temperature as required. Experimental tests were conducted using various sample shapes and sizes at three different controlled temperatures (40 °C, 50 °C, and 60 °C). The findings revealed that the maximum measured error of 1.463 mm was observed at 40 °C. This discrepancy was attributed to inadequate temperature control and a substantial sample volume of 2827.44 mm 3. Conversely, the minimum error of 0.223 mm was identified at the higher temperatures of 60 °C, with a reduced sample volume of 530.14 mm 3. It was determined that warping, in addition to layer shifting at vertical levels, is a significant contributor to the warping error. In addition, the present study underscores the pivotal function of employing an enclosure-controlled temperature in enhancing the quality and precision of the 3D-printed ABS components.
Simulation of metal forming processes using the Finite Element Method (FEM) is a well-established... more Simulation of metal forming processes using the Finite Element Method (FEM) is a well-established procedure, being nowadays possible to develop alternative approaches, such as inverse methodologies, in solving complex problems. This study investigated the effect of orientation and pre-tension on stresses distribution numerically by software ANSYS 19 using the finite element method. The pre-tension is 55% from total strained in each rolling direction. The results show that the orientation has a significant effect on stresses distribution and stress value before and after pre-tension 55%. Although there is a regular distribution of stresses in three direction, but there is significant difference in the values of stresses in each of (0, 45, 90) degrees. The highest value of the stress is in the 0̊ to rolling direction, while the least value of the stress recorded in 45̊ to rolling direction. The pre-tension has a greater impact on stresses distribution and stress value. Although, there...
Management Systems in Production Engineering, 2025
To increase the process stability and improve the product quality in the sheet hydroforming with ... more To increase the process stability and improve the product quality in the sheet hydroforming with die process, it is crucial for identifying and analyzing the dependence of forming pressure on process parameters. The effects of process parameters (blank holder force, frictional condition) on the forming fluid pressure were thoroughly studied experimentally. The main objective is to establish a relationship between the forming fluid pressure and several factors such as blank holder force and friction between die and sheet. The results demonstrate that the maximum fluid pressure increases with increasing blank holder force and friction. Finally, this relationship aims to support calculations and design data and provide control during the SHF-D process.
Journal of Mechanical Engineering Research and Developments, 2020
Incremental forming is a rather innovative process in which sheet metal is formed into complex sh... more Incremental forming is a rather innovative process in which sheet metal is formed into complex shapes by stretching the sheet with forming tool whose path is controlled by a computer numerical control machine, this kind of process is suitable for low patch production and customized parts. The blank is fully clamped at its perimeter, so there is no any drawing operation occurs to sheet blank during forming process, therefore an excessive thinning would appear along the wall of the formed parts. Study the influence of some process parameters on the thinning ratio, find suitable parameters to minimize the thinning in single point incremental forming and find some methods to reduce it that is the aim of this research. Ansys workbench software based on finite element method is used to simulate the forming process and analyze the thickness reduction along the wall parts, numerical results are verified experimentally. The results showed the forming angle has great effect while the feed speed has the little effect on the thinning ratio on the formed parts.
Asymmetric rolling refers to the conditions wherein velocities or diametersof two work rolls are ... more Asymmetric rolling refers to the conditions wherein velocities or diametersof two work rolls are different. Compared to symmetrical rolling, asymmetric rolling is more effective on microstructure modification and texture evolution. Intense shear deformation can be introduced into asymmetric rolling to enhance the ductility and formability of aluminum alloy and this is the aim of current research. The process of the asymmetrical rolling was done on specimens with different reductions (10%,15%, and 20% reductions). Then the tensile test was conducted at room temperature at the strain rate range between 0.33×10-3s-1 -3.33×10-3s-1 to study the ductility property of the asymmetric rolling-deformed samples and also compared with as-received samples. The results show that the as-received specimen gave the highest elongation of42.7%, while the lowest elongation of 22.4% was obtained by the (20%) thickness reduction specimen. Also, the as-received sample at an initial strain rate of 3.33×10-3s-1 gives the highest tensile strength value equal to 550MPa.
IOP Conference Series: Materials Science and Engineering, 2020
The effect of extrusion parameters on the extrusion of A1100 pure aluminum was investigated with ... more The effect of extrusion parameters on the extrusion of A1100 pure aluminum was investigated with the aid of numerical methods. With this regard, the process parameters, three die angles (15 º ,30 º ,45 º), and three forming velocities (1,2,3 mm/min) were studied. Besides, the experimental results were analyzed using the finite element analysis (FEA) using ANSYS 16. All the experimental and numerical results were compared to each other and it was concluded from the results that the effect of die geometry on the forming load is more dominant than forming velocity. In addition, it was observed that the increase in the extrusion speed causes a significant increase in the forming load for all die angles.
Association of Arab Universities Journal of Engineering Sciences, 2019
The objective of this work is to investigate the affecting variables of milling process to optimi... more The objective of this work is to investigate the affecting variables of milling process to optimize surface roughness and material removal rate during machining of 7024 Al-alloy. The machining operation is implemented on C-TEK CNC milling machine. The effects of the selected parameters on the chosen characteristics have been accomplished using Taguchi's parameter design approach; also ANOVA is used to evaluate the contribution of each parameter on the process outputs. Different feed rates are studied ranging from (60, 80 and 100) mm/min. It is found that high feed rates give a high material removal rates and good surface roughness. On the other hand, it is found that a higher spindle speeds gives better surface roughness with a little effect on material removal rate MRR. The process results showed that maximum MRR achieved (2.40) mm3/min when machining feed rate (100) mm/min, spindle speed (1000) r.p.m, and depth of cut (0.6) mm. While good surface roughness (0.41 µm) is obtained when machining feed rate was (100) mm/min, spindle speed (1000) r.p.m, and depth of cut (0.2) mm. The level of importance of the machining parameters for material removal rate and surface roughness is determined by using Taguchi designing experiments and the variance analysis (ANOVA).
the quality of the cups drawn in the deep drawing process are secured by the rate of metal flow i... more the quality of the cups drawn in the deep drawing process are secured by the rate of metal flow into the die cavity, efficiently control on the metal flow can reduce and eliminate a lot of defects such as wrinkling, tearing and earing especially in the square deep drawing due to the non-uniform stresses induced along die cavity. This control is obtained using a restraining force supplied by blank holder tool or draw beads or both. Therefore this research focuses on the study these parameters numerically and experimentally. Ansys software based on finite element method was used to model and analyze the influence of blank holder gap and draw bead parameters in the forming process. Appropriate number of the experiments were done to compare and verify the results obtained in the numerical simulation.
Advances in Science and Technology Research Journal, 2025
Layer adhesion refers to the evaluation of the bond strength between layers in a 3D-printed part.... more Layer adhesion refers to the evaluation of the bond strength between layers in a 3D-printed part. Generally, 3D printed products are built layer by layer, where the adhesion between layers may vary depending on many factors, also according to the materials used. Furthermore, all the 3D printed parts experience layer separation over time. This issue mainly mainly stems from the effect of temperature during 3D printing operations. In this research, a new technique that focuses on studying and controlling the temperature of the environment around the 3D printer was developed. This approach aims to enhance the adhesion or welding process between printed layers, wherein the proper temperature the layer becomes more elastic, which facilitates the fusion process of the new layer with existing ones, thereby increasing the mechanical properties of the 3D printed parts. There are many techniques applied to control the temperature. In this study, the implemented control system consists of a digital thermostat equipped with sensors. The system monitors and adjusts the temperature by using an electrical wire heater placed inside the enclosure. Many materials are used as base material in 3D printers, e.g. PLA, ABS, PETG, etc., and each of these materials has a different optimum temperature. This study focused on PLA as the test material, even though it is widely used in 3d printer field, having a good printing flexibility. On the other hand, this material is affected by the weather conditions to the greatest extent, which can lead to failure between layers after a short while of time. The experiments were done by selecting three environment temperatures (40, 45 and 50 ℃), the number of walls (4, 6, and 8 walls), and finally printing speed (70, 80 and 90 mm/sec) to test the adhesion between layers. The results exhibited that the effect of enclosure temperature on the 3d printer process was 62.07% over all the other printer parameters, Notably, the increase in the strength of adhesion for the printed parts reached 32.37% at an enclosure temperature of 40 ℃.
The control accurately of internal pressure, axial feeding and paths
of loading which have import... more The control accurately of internal pressure, axial feeding and paths of loading which have important influences on the final tube quality. In this research an impact of loading path of the tube hydroforming process and final part requirements ( i.e. thickness specification and shape conformation) were studied numerically. Small bulge shape tube hydroforming parts were utilized in the finite element analyses to get several guidelines on the effect of the relation between the internal pressure and axial compressive feeding programs. Two dimension model of bulge shape tube (50 mm) bulge width has been developed from cylindrical tube with thickness (2mm) of the copper and (60 mm) outer diameter. A commercial available finite element program code (ANSYS 11), is used to perform the numerical simulation of the tube hydroforming operation. The results demonstrate that, the loading path has very important influenced on the thickness distribution over the tube and capability attained the target shape of the required product.
Incremental sheet metal forming process is an advanced flexible manufacturing process to produce ... more Incremental sheet metal forming process is an advanced flexible manufacturing process to produce various 3D products without using dedicated tool as in conventional metal forming. There are a lot of process parameters that have effect on this process, studying the effect of some parameters on the strain distributions of the product over the length of deformation is the aim of this study. In order to achieve this goal, three factors (tool forming shape, feed rate and incremental step size) are examined depending on three levels on the strain distributions over the wall of the product. Strain measurement was accomplished by using image processing technique using MATALB program. The significance of the control factors are explored using two statistical methods: analysis of variance (ANOVA) and main effect plot (MEP). All experiments were carried out on a sheet of Aluminum alloy (Al1050) with thickness 0.9 mm by using 3 axes CNC machine to produce frustum pyramid product. The result showed that the feed rate is a parameter that has large effect on the values of the effective strain percentage contribution of (42.86% and 51.42%), respectively, and is followed by step size (25.1% and 30.60%) percentage contributions and finally the tool shape with (21.79% and 10.54%) on the (55° and 45°) wall angle, respectively. The maximum and minimum average effective strain computed on the 55◦ forming angle were (0.580 and 0.399), respectively. Finally, the maximum and minimum average effective strain computed on the 45◦ forming angle were equal to (0.412 and 0.324), repectively
Deep drawing process to produce square cup is very complex process due to a lot of process parame... more Deep drawing process to produce square cup is very complex process due to a lot of process parameters which control on this process, therefore associated with it many of defects such as earing, wrinkling and fracture. Study of the effect of some process parameters to determine the values of these parameters which give the best result, the distributions for the thickness and depths of the cup were used to estimate the effect of the parameters on the cup numerically, in addition to experimental verification just to the conditions which give the best numerical predictions in order to reduce the time, efforts and costs for producing square cup with less defects experimentally is the aim of this study. The numerical analysis is used to study the effect of some parameters such as die profile radius, radial clearance between die and punch, blank diameter on the length and thickness distributions on the cup, dynamic-explicit (ANSYS11) code based on finite element method is utilized to simulate the square deep drawing operation. Experiments were done for comparison and verification the numerical predictions. effective square cup with less defects and acceptable thickness distributions were produced in this study. It is concluded the most thinning appear in the corner cup due to excessive stretching occur in this region and also it is found the cup thickness and height prediction by numerical analysis and in general in harmony with experimental analysis.
Association of Arab Universities Journal of Engineering Sciences, 2018
The objective of this research is to obtain an optimal setting of CNC turning parameters [cutting... more The objective of this research is to obtain an optimal setting of CNC turning parameters [cutting speed (165, 200 and 250 m/min), feed rate (0.05, 0.06 and 0.07 mm/rev) and depth of cut (0.5, 0.75 and 1 mm)] which result in an optimal value of material removal rate (MRR). It's necessary to find a suitable optimization process to obtained optimum values of cutting parameters for maximum material removal rate. In machining process was carried out on aluminum ENAC-43400 alloy in a CNC turning machine by using a carbide cutting tool. The model for the material removal rate (MRR), as a function of cutting parameters, is obtained using Adaptive Neuro Fuzzy Inference System (ANFIS) in MATLAB 7.2 Software for optimization of MRR in CNC turning. The results obtained, material removal rate (MRR) are about (4125-17500 mm 3 /min), and max. material removal rate obtained (17500 mm 3 /min) at condition higher cutting speed (250 m/min), higher feed rate (0.07 mm/rev) and higher depth of cut (1 mm). The ANFIS modeling technique can be effectively used for the optimization of material removal rate at the error of training data 2.255%..
An effort has been made to improve the formability of (1006) AISI steel alloy sheets in deep draw... more An effort has been made to improve the formability of (1006) AISI steel alloy sheets in deep drawing of square-shaped parts with flat bases through hydroforming. To achieve this goal, the manufacturing process involved the use of a newly developed experimental setup for sheet hydroforming with a die, which was created by the researchers. The key design features of this setup aimed for simplicity and modularity, allowing for potential utilization with oil pressures of up to 100 MPa. The obtained results were compared with those of conventional deep drawing. Both processes were examined under specific conditions to form identical cups up to the full depth of the provided die. Indicators of formability considered for comparison included the minimum possible corner radius, the maximum achievable depth without failure, and the maximum percentage of thinning at the corners. This study demonstrates that hydroforming can enhance the formability of low-carbon steel alloy sheets by improving the flow of metal into the die cavity and reducing thinning at critical regions, when compared to conventional deep drawing processes. In conventional deep drawing, only 70% of the full depth could be achieved before failure due to high local deformations resulting in significantly higher thinning at the corners.
Incremental sheet forming (ISF) is a novel technology to takes part in solving a lot of problems ... more Incremental sheet forming (ISF) is a novel technology to takes part in solving a lot of problems from classical sheet forming operation in terms of more flexibility, cheap, low production time, convenient for small batches and particularly rapid prototype production. This paper aims to provide enough information for understanding of the incremental forming process, especially focusing on numerical two point incremental sheet forming mechanism and multi stages incremental forming. The influence of some process parameters such as incremental step size and forming tool radius, on thickness distribution across the wall of the part is studied, as well as, studying the thickness distribution and strain analyses for three stages in multi stages incremental forming during forming the product with vertical angle.2-D model of cone shaped part with right forming angle has been developed in the three stages from sheet with thickness (1mm) of the aluminum alloy (AA1070). A commercial available finite element program code (ANSYS 11), is used to carry out the numerical simulation of the multistage incremental sheet forming. The results show that, when considering multi-stage incremental sheet forming, the task is even more difficult because the strain and thickness distribution resulting from the first stage will influence the subsequent results. Decreasing in the forming tool radius will increase in the thinning of the wall product due to excessive stretch will occurs, while the incremental step size is not significant effect on the numerical results (thickness, strain) distribution of the product. Finally, the goal to attain a vertical wall angle and equally maintain wall thickness and strain over the wall part is pursued. Mechanical tests, computer programming, geometry and design were required.
The paper presents an analysis of the multistage deep drawing process considering the three
defor... more The paper presents an analysis of the multistage deep drawing process considering the three deformation stages namely drawing reverse and reverse redrawing respectively. This work aim to study the mechanism of deformation during the redrawing process where the second and the third stages were done in reverse redrawing and study the effect of this mechanism on produced cup wall thickness, strain distribution across the wall of the drawn part. 2-D model of cylindrical cup (46.75mm) diameter has been developed in the first stage from sheet with thickness (0.5mm) of the low carbon steel (AISI 1008) and (85mm) diameter, while for second and third stages of drawing a punch diameter (32.725mm, 27.489mm) respectively, and inside diameter of dies equal to (33.825mm, 28.589mm) respectively, the clearance is chosen for three stage equal to 0.55mm. A commercial available finite element program code (ANSYS 11), is used to perform the numerical simulation of the multistage deep drawing. The results show that, when considering multi-stage drawing, the task is even more difficult because the strain and thickness distribution resulting from the first stage will influence the subsequent results, increase in thinning in the wall cup will appear in the second and third stages. Finally this work introduces new method (multi reverse redrawing) to produce circular cup throw three stages of drawing reduction in one stroke without the need to the loading and unloading the tools among the stages as in direct redrawing which means reducing the cost, time, efforts and enhancing cup production.
This work aim to study the effect of process parameters used in square deep drawing operation suc... more This work aim to study the effect of process parameters used in square deep drawing operation such as ; die and punch profile radius, blank size, blank shape, on produced cup wall thickness, strain distribution across the wall of the drawn part, punch force, earing shape and height of the drawn cup. 3-D model of square cup (41.4mm by 41.4mm), and 0.7 mm thickness from Low carbon steel (AISI 1008), has been developed. Because of the symmetry in the specimen geometry, only one fourth portion of the model was needed to be analyzed using finite element method, a commercial available finite element program code (ANSYS 11), is used to perform the numerical simulation of the deep drawing operation, and the numerical results of earing shape were compared with the experimental work. In this work, three types of blank shape (circular, square, and octagonal), with different sizes, four types of punch profile radii of 3, 5, 6, and 7mm and three types of die profile radii of 3, 5, 7mm have been chosen to form a square cup. The results show that, excessive earing will appear in the square cup when square blank was used, due to excessive material in the corner and minimum material in the flat side, and when using octagonal blank which have an equivalent surface area to the square blank, the earing in the cup corner is reduced because of extraction of the excessive material from the corner of the blank. The best results were obtained from the circular blank, according to useful drawing height and earing.
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Papers by Adil Shbeeb
of loading which have important influences on the final tube quality. In this
research an impact of loading path of the tube hydroforming process and
final part requirements ( i.e. thickness specification and shape conformation) were studied numerically. Small bulge shape tube hydroforming parts were utilized in the finite element analyses to get several guidelines on the effect of the relation between the internal pressure and axial compressive feeding programs. Two dimension model of bulge shape tube (50 mm) bulge width has been developed from cylindrical tube with thickness (2mm) of the copper and (60 mm) outer diameter. A commercial available finite element program code (ANSYS 11), is used to perform the numerical simulation of the tube hydroforming operation. The results demonstrate that, the loading path has very important influenced on the thickness distribution over the tube and
capability attained the target shape of the required product.
products without using dedicated tool as in conventional metal forming. There are a lot of process parameters that have
effect on this process, studying the effect of some parameters on the strain distributions of the product over the length of
deformation is the aim of this study.
In order to achieve this goal, three factors (tool forming shape, feed rate and incremental step size) are examined
depending on three levels on the strain distributions over the wall of the product. Strain measurement was accomplished
by using image processing technique using MATALB program. The significance of the control factors are explored
using two statistical methods: analysis of variance (ANOVA) and main effect plot (MEP). All experiments were
carried out on a sheet of Aluminum alloy (Al1050) with thickness 0.9 mm by using 3 axes CNC machine to produce
frustum pyramid product. The result showed that the feed rate is a parameter that has large effect on the values of the
effective strain percentage contribution of (42.86% and 51.42%), respectively, and is followed by step size (25.1% and
30.60%) percentage contributions and finally the tool shape with (21.79% and 10.54%) on the (55° and 45°) wall angle,
respectively. The maximum and minimum average effective strain computed on the 55◦ forming angle were (0.580 and
0.399), respectively. Finally, the maximum and minimum average effective strain computed on the 45◦ forming angle
were equal to (0.412 and 0.324), repectively
deep drawing. Both processes were examined under specific conditions to form identical cups up to the full depth of the provided die. Indicators of formability considered for comparison included the minimum possible corner radius, the maximum achievable depth without failure, and the maximum percentage of thinning at the corners. This study demonstrates that hydroforming can enhance the formability of low-carbon steel alloy sheets by improving the flow of metal into the die cavity and reducing thinning at critical regions, when compared to
conventional deep drawing processes. In conventional deep drawing, only 70% of the full depth could be achieved before failure due to high local deformations resulting in significantly higher thinning at the corners.
deformation stages namely drawing reverse and reverse redrawing respectively. This work aim to
study the mechanism of deformation during the redrawing process where the second and the third
stages were done in reverse redrawing and study the effect of this mechanism on produced cup wall
thickness, strain distribution across the wall of the drawn part. 2-D model of cylindrical cup
(46.75mm) diameter has been developed in the first stage from sheet with thickness (0.5mm) of the
low carbon steel (AISI 1008) and (85mm) diameter, while for second and third stages of drawing a
punch diameter (32.725mm, 27.489mm) respectively, and inside diameter of dies equal to
(33.825mm, 28.589mm) respectively, the clearance is chosen for three stage equal to 0.55mm. A
commercial available finite element program code (ANSYS 11), is used to perform the numerical
simulation of the multistage deep drawing. The results show that, when considering multi-stage
drawing, the task is even more difficult because the strain and thickness distribution resulting from
the first stage will influence the subsequent results, increase in thinning in the wall cup will appear
in the second and third stages. Finally this work introduces new method (multi reverse redrawing)
to produce circular cup throw three stages of drawing reduction in one stroke without the need to
the loading and unloading the tools among the stages as in direct redrawing which means reducing
the cost, time, efforts and enhancing cup production.