Fahraz Ali - Academia.edu (original) (raw)

Papers by Fahraz Ali

Research paper thumbnail of Analysis of part quality produced by a fused deposition modelling machine: a pragmatic study

International Journal of Rapid Manufacturing, 2015

Research paper thumbnail of An Integrated Approach towards Achieving Agility in Design and Development of a Broken Free-form Object

Journal of Mechanical Engineering

This paper attempts to introduce a unified approach for design and development of a broken free-f... more This paper attempts to introduce a unified approach for design and development of a broken free-form object in order to achieve agility in the process. A combination of reverse engineering (RE), re-engineering (ReE) and rapid product development (RpD) approach has been tailored to address the design and development issues of the broken free-form object. A broken clutch shoe from a centrifugal clutch assembly is selected for demonstrating the efficacy of the proposed integrated methodology. To achieve agility in the process, RE is employed for quick recovery of technical data and re-construction of the entire part model. Subsequently, re-engineering is sustained through geometric dimensioning and tolerancing (GD&T) which is used as a validation tool for inspection/comparison of the reference and digitized parametric computer aided design (CAD) models. Furthermore integration of finite element analysis (FEA) is performed iteratively for optimization of influential factors of the part ...

Research paper thumbnail of Slicing Issues in CAD Translation to STL in Rapid Prototyping

The rapid prototyping (RP) process is being used widely with great potential for rapid manufactur... more The rapid prototyping (RP) process is being used widely with great potential for rapid manufacturing of functional parts. The RP process involves translation of the CAD file to STL format followed by slicing of the model into multiple horizontal layers, each of which is reproduced physically in making the prototype. The thickness of the resulting slices has a profound effect on the surface finish and build time of the prototype. The purpose of this paper is to show the effects of slice thickness on the surface finish, layering error, and build time of a prototype, as well as to show how an efficient STL file can be developed. Three objects were modeled and STL files were generated. One STL file for each object was sliced using different slice thicknesses, and the build times were obtained. Screenshots were used to show the slicing effect on layering error and surface finish and to demonstrate the means to a more efficient STL file. From the results, it is clear that the surface fini...

Research paper thumbnail of Part Design and Evaluation through Reverse Engineering Approach

Most manufacturing enterprises focus on the delivery of increased productivity with high quality ... more Most manufacturing enterprises focus on the delivery of increased productivity with high quality products through integration of computer aided design (CAD)/computer aided manufacturing (CAM) with computer aided engineering (CAE) tools. When this concept is applied to reverse engineering (RE), the challenge lies in quickly editing and modifying point cloud data collected from scanning the object to design of a three

Research paper thumbnail of An investigation for improvement of the 3D-digitization process: a reverse engineering approach

Journal of Manufacturing Technology Management, 2011

Purpose – The purpose of this paper is to provide a comprehensive work flow for the improvement o... more Purpose – The purpose of this paper is to provide a comprehensive work flow for the improvement of the Reverse Engineering (RE) process in producing non-uniform rational B-splines (NURBS) models from scanned point cloud data. This should become a reliable guide in the creation of desired 3D-CAD models in order to improve efficiency of downstream operations and further to make

Research paper thumbnail of An integrated design approach for rapid product development: A case study through application of reverse engineering, re-engineering and fast prototyping tools

Journal of Engineering, Design and Technology, 2013

ABSTRACT Purpose – The purpose of this paper is to present an integrated design approach for rapi... more ABSTRACT Purpose – The purpose of this paper is to present an integrated design approach for rapid product development (RpD) of a broken product. Design/methodology/approach – Reverse engineering (RE), re-engineering (ReE) and RpD systems have been incorporated to infuse agile characteristics in the proposed design and development process. A case study involving a broken clutch shoe was selected to demonstrate the efficacy of the proposed integrated approach. Findings – Integration of RE, ReE and RpD presented an unconventional approach towards achieving reduced lead times for design and development of products. Agile characteristics have been manifested for the broken clutch shoe by retrieval of a digitized parametric computer aided design (CAD) model. Moreover, development and selection of an enhanced feasible design (M3) as well as delivery of the corresponding prototype was accomplished just in one week. Originality/value – The proposed integrated approach for RpD can provide solutions to similar industrial situations wherein agility in the product design and development process can be infused so that the developed part can be delivered quickly to the customer at the reduced time and costs.

Research paper thumbnail of Slicing issues in CAD translation to STL in rapid prototyping

Proceedings of The, 2008

The rapid prototyping (RP) process is being used widely with great potential for rapid manufactur... more The rapid prototyping (RP) process is being used widely with great potential for rapid manufacturing of functional parts. The RP process involves translation of the CAD file to STL format followed by slicing of the model into multiple horizontal layers, each of which is reproduced physically in making the prototype. The thickness of the resulting slices has a profound effect on the surface finish and build time of the prototype. The purpose of this paper is to show the effects of slice thickness on the surface finish, layering error, and build time of a prototype, as well as to show how an efficient STL file can be developed. Three objects were modeled and STL files were generated. One STL file for each object was sliced using different slice thicknesses, and the build times were obtained. Screenshots were used to show the slicing effect on layering error and surface finish and to demonstrate the means to a more efficient STL file. From the results, it is clear that the surface finish and build time are important factors that are affected by slice thickness.

Research paper thumbnail of Computer Aided Engineering Approach to the Development of a Lawnmower Blade: A Reverse Engineering Application to Reduce Noise Levels

Engineering seeks to improve the quality of life taking into consideration factors of safety and ... more Engineering seeks to improve the quality of life taking into consideration factors of safety and environment amongst others. The use of the lawnmower in landscape maintenance is quite common throughout various parts of the world with significant noise generated during its operation. This study seeks to develop a blade design via Computer Aided Engineering (CAE) that will reduce the noise intensity of the lawnmower while in use; thereby, reducing discomfort to the user and environs. The design of the blade was developed by utilization of engineering techniques such as reverse engineering (RE) and re-engineering (ReE) of an actual blade, coupled with computer aided design (CAD), for simulation of performance prior to the production of a prototype. The results of design simulation as well as from physical testing of the prototype were compared to determine the success of the CAE approach based on variations of both test results. The various procedures, from RE of the lawnmower blade and simulation of its improved design via CAD to the physical experimentation, proved that CAE was effective, since the prototype developed yielded a decrease in noise intensity when compared to the original lawnmower blade. Therefore, this study demonstrates the use of CAD and CAE in the development and enhancement of the blade design, as an effective approach, towards the improvement of quality of life based on reduced noise intensity.

Research paper thumbnail of Analysis of part quality produced by a fused deposition modelling machine: a pragmatic study

International Journal of Rapid Manufacturing, 2015

Research paper thumbnail of An Integrated Approach towards Achieving Agility in Design and Development of a Broken Free-form Object

Journal of Mechanical Engineering

This paper attempts to introduce a unified approach for design and development of a broken free-f... more This paper attempts to introduce a unified approach for design and development of a broken free-form object in order to achieve agility in the process. A combination of reverse engineering (RE), re-engineering (ReE) and rapid product development (RpD) approach has been tailored to address the design and development issues of the broken free-form object. A broken clutch shoe from a centrifugal clutch assembly is selected for demonstrating the efficacy of the proposed integrated methodology. To achieve agility in the process, RE is employed for quick recovery of technical data and re-construction of the entire part model. Subsequently, re-engineering is sustained through geometric dimensioning and tolerancing (GD&T) which is used as a validation tool for inspection/comparison of the reference and digitized parametric computer aided design (CAD) models. Furthermore integration of finite element analysis (FEA) is performed iteratively for optimization of influential factors of the part ...

Research paper thumbnail of Slicing Issues in CAD Translation to STL in Rapid Prototyping

The rapid prototyping (RP) process is being used widely with great potential for rapid manufactur... more The rapid prototyping (RP) process is being used widely with great potential for rapid manufacturing of functional parts. The RP process involves translation of the CAD file to STL format followed by slicing of the model into multiple horizontal layers, each of which is reproduced physically in making the prototype. The thickness of the resulting slices has a profound effect on the surface finish and build time of the prototype. The purpose of this paper is to show the effects of slice thickness on the surface finish, layering error, and build time of a prototype, as well as to show how an efficient STL file can be developed. Three objects were modeled and STL files were generated. One STL file for each object was sliced using different slice thicknesses, and the build times were obtained. Screenshots were used to show the slicing effect on layering error and surface finish and to demonstrate the means to a more efficient STL file. From the results, it is clear that the surface fini...

Research paper thumbnail of Part Design and Evaluation through Reverse Engineering Approach

Most manufacturing enterprises focus on the delivery of increased productivity with high quality ... more Most manufacturing enterprises focus on the delivery of increased productivity with high quality products through integration of computer aided design (CAD)/computer aided manufacturing (CAM) with computer aided engineering (CAE) tools. When this concept is applied to reverse engineering (RE), the challenge lies in quickly editing and modifying point cloud data collected from scanning the object to design of a three

Research paper thumbnail of An investigation for improvement of the 3D-digitization process: a reverse engineering approach

Journal of Manufacturing Technology Management, 2011

Purpose – The purpose of this paper is to provide a comprehensive work flow for the improvement o... more Purpose – The purpose of this paper is to provide a comprehensive work flow for the improvement of the Reverse Engineering (RE) process in producing non-uniform rational B-splines (NURBS) models from scanned point cloud data. This should become a reliable guide in the creation of desired 3D-CAD models in order to improve efficiency of downstream operations and further to make

Research paper thumbnail of An integrated design approach for rapid product development: A case study through application of reverse engineering, re-engineering and fast prototyping tools

Journal of Engineering, Design and Technology, 2013

ABSTRACT Purpose – The purpose of this paper is to present an integrated design approach for rapi... more ABSTRACT Purpose – The purpose of this paper is to present an integrated design approach for rapid product development (RpD) of a broken product. Design/methodology/approach – Reverse engineering (RE), re-engineering (ReE) and RpD systems have been incorporated to infuse agile characteristics in the proposed design and development process. A case study involving a broken clutch shoe was selected to demonstrate the efficacy of the proposed integrated approach. Findings – Integration of RE, ReE and RpD presented an unconventional approach towards achieving reduced lead times for design and development of products. Agile characteristics have been manifested for the broken clutch shoe by retrieval of a digitized parametric computer aided design (CAD) model. Moreover, development and selection of an enhanced feasible design (M3) as well as delivery of the corresponding prototype was accomplished just in one week. Originality/value – The proposed integrated approach for RpD can provide solutions to similar industrial situations wherein agility in the product design and development process can be infused so that the developed part can be delivered quickly to the customer at the reduced time and costs.

Research paper thumbnail of Slicing issues in CAD translation to STL in rapid prototyping

Proceedings of The, 2008

The rapid prototyping (RP) process is being used widely with great potential for rapid manufactur... more The rapid prototyping (RP) process is being used widely with great potential for rapid manufacturing of functional parts. The RP process involves translation of the CAD file to STL format followed by slicing of the model into multiple horizontal layers, each of which is reproduced physically in making the prototype. The thickness of the resulting slices has a profound effect on the surface finish and build time of the prototype. The purpose of this paper is to show the effects of slice thickness on the surface finish, layering error, and build time of a prototype, as well as to show how an efficient STL file can be developed. Three objects were modeled and STL files were generated. One STL file for each object was sliced using different slice thicknesses, and the build times were obtained. Screenshots were used to show the slicing effect on layering error and surface finish and to demonstrate the means to a more efficient STL file. From the results, it is clear that the surface finish and build time are important factors that are affected by slice thickness.

Research paper thumbnail of Computer Aided Engineering Approach to the Development of a Lawnmower Blade: A Reverse Engineering Application to Reduce Noise Levels

Engineering seeks to improve the quality of life taking into consideration factors of safety and ... more Engineering seeks to improve the quality of life taking into consideration factors of safety and environment amongst others. The use of the lawnmower in landscape maintenance is quite common throughout various parts of the world with significant noise generated during its operation. This study seeks to develop a blade design via Computer Aided Engineering (CAE) that will reduce the noise intensity of the lawnmower while in use; thereby, reducing discomfort to the user and environs. The design of the blade was developed by utilization of engineering techniques such as reverse engineering (RE) and re-engineering (ReE) of an actual blade, coupled with computer aided design (CAD), for simulation of performance prior to the production of a prototype. The results of design simulation as well as from physical testing of the prototype were compared to determine the success of the CAE approach based on variations of both test results. The various procedures, from RE of the lawnmower blade and simulation of its improved design via CAD to the physical experimentation, proved that CAE was effective, since the prototype developed yielded a decrease in noise intensity when compared to the original lawnmower blade. Therefore, this study demonstrates the use of CAD and CAE in the development and enhancement of the blade design, as an effective approach, towards the improvement of quality of life based on reduced noise intensity.