Samy Ebeid - Academia.edu (original) (raw)

Papers by Samy Ebeid

Proceedings of the Twenty-Fourth International Machine Tool Design and Research Conference, 1984

The subject matter of this investigation involves the definition of progressive shape formations ... more The subject matter of this investigation involves the definition of progressive shape formations for a certain arbitrary tool design in the course of electrochemical broaching. The objective is to enable the designer allocate the appropriate parameters related to a broaching tool design as well as machining conditions, for attaining a reguired component configuration. The scope comprises the study of the progressive processed shapes for a sguare or triangular shape broaching tools. Comparison between experimental and analytical results proved the validity of the use of the side gap equation for predicting the processed profiles and evaluating the power consumption. The results show that the rounding-off angle is governed mainly by the tool end geometry being insensitive to its overall geometry. Improved conformity was found to be a result of the increase in both tool feed rate and approach and pyramidical angles. The results also indicate that for triangular tools, both concavity and rounding-off characterize the workpiece profile.

One of the most recent non-conventional shaping processes is the abrasive water jet shaping proce... more One of the most recent non-conventional shaping processes is the abrasive water jet shaping process. Abrasive water jet shaping has many beneficial parameters such as shaping the various materials; hard to soft; electrically conductive to insulators, flexibility in shaping, small cutting forces and rapid to shape. The abrasive water jet shaping of materials has various variables and parameters. This work focuses on which of the process variables affect the plain water jet (PWJ) milling process of pockets. In the focusing, machining process variables such as water jet traverse speed, water jet pressure, stand-off distance and abrasive flow rate have been investigated to study the effect of each on the PWJ milling process parameters. The water jet milling process is evaluated by examining the pockets’ process parameters; namely depth of cut, surface roughness and material removal rate. The material used in the experimental investigation in this work is Aluminum alloy called Alumec 89....

Advances in Manufacturing Science and Technology, 2003

（Abstract）The fabrication of textile reinforced polymer composites requires the pre-forming of te... more （Abstract）The fabrication of textile reinforced polymer composites requires the pre-forming of textiles over open, or within closed moulds before the introduction of the resin. This study is therefore concerned with the draping behavior of jute and glass fibres of various areal densities over double curvature moulds. Experimental investigation of the draping behavior was performed over a specially designed mould comprising different geometries of fillets and sharp edges. Simulation of the deformation behavior using PamForm2G application revealed similar results. Large shear deformations are found around large curves and acute angles. The interaction of geometries further forces woven fabrics to undergo severe shear deformations often leading to the creation of wrinkles.

The process of electrochemical wire cutting can be a cost-effective industrial potential in deali... more The process of electrochemical wire cutting can be a cost-effective industrial potential in dealing with difficult-to-cut materials. This article presents the outcome of an experimental investigation into the parameter influence on EC wire cutting in an endeavour to combine minimum energy consumption with dimensional accuracy of cut. The process will then resolve into either “Slitting” or “Component Profiling”. A simple model for the action of cutting was adopted to estimate the width of cut, the values of electrolysing current and material removal rate for various parameters. Both analytical and experimental results proved the beneficial influence of increased feed rates regarding the desirable reduced width. of cut. Optimum feed rates for circular and rectangular shape wires with different sizes were defined.

—This paper presents a method to investigate the characteristics of single screw extruders and ev... more —This paper presents a method to investigate the characteristics of single screw extruders and evaluate the performance of various types of screw under different working conditions using finite element analysis. Finite element analysis is used to master a technique to evaluate the radial displacement of the used screw, while analytical solution is used to clearly describe the polymer behavior affecting the proposed screw. This performance is of great importance to determine the chance of the screw lock up in the barrel. A finite element model of two types of screw extruder is presented, taking into account bearing support contact, pressure and temperature profiles generated along the screw. The results show that the minimum displacement occurred at the metering zone, while the maximum displacement occurred at the feed zone moving to the compression zone for traditional screw.

The flanged joint is one of the weakest elements on the piping system because of leakage. The lea... more The flanged joint is one of the weakest elements on the piping system because of leakage. The leakage free joint is the target of the standard codes and many analytical and experimental studies. The codes usually focus on the conventional flanged joints containing gaskets. The gasketed joint which is classified in the standard codes was studied under different operating conditions to investigate its performance and its sealing capability. The nonparallel face flanged joint has been studied under different mechanical loads to be developed and it showed high efficiency than the conventional joint. The present paper studies the non-parallel face flanges as a 3D finite element model to investigate the behaviour of the joint under combined mechanical and thermal loading. The suggested model for the joint was established for different flange thicknesses under various operating temperatures and internal pressures.

Technology of abrasive water jet (AWJ) is one of the most important processes for machining due t... more Technology of abrasive water jet (AWJ) is one of the most important processes for machining due to its advantages over other technologies. It has proved to be an efficient process for plain milling of various materials. The paper presents a new predictive model of AWJ milling of aluminum alloy. The model is developed to predict some interesting process parameters from process variables. As AWJ is a complicated multi input-output system, its model is developed using artificial neural network (ANN) as one of the artificial intelligent models. A feed forward neural network based on back error propagation is used. The ANN training set is generated by extensive experimental work. The tests considered four process variables, which are traverse speed, water jet pressure, stand-off distance and abrasive flow rate and three process parameters, namely surface roughness, depth of cut and material removal rate. The study of the relation between process variables and parameters yields to eliminate the stand-off distance from the training set. Therefore, the ANN has been designed to have three input neurons for process variables and three output neurons for process parameters. The designed ANN was trained and tested. The ANN succeeded to model the AWJ process by extracting the process parameters from process variables with a regression factor above 90%. This paper is a step towards a better understanding, modeling and controlling of AWJ milling process.

Journal of Manufacturing Processes, 2018

Carbon Black filled Acrylonitrile Butadiene Styrene (ABS) was used to prepare a polymer composite... more Carbon Black filled Acrylonitrile Butadiene Styrene (ABS) was used to prepare a polymer composite by Fused Deposition Modeling (FDM) technology. The effect of printing setup on the strain sensing behavior of the composite was investigated, targeting the fabrication of a functionalized composite that is able to detect stress or strain changes in engineering members. Experimental work revealed that internal stresses can be detected based on monitoring the change in resistance as a response to strain. Measurements across sample thickness were found to be most suitable for making general statements about the resistivity of the samples. Hereby, the resistance depends on the intrinsic and the process specific properties of the material. The printing setup was systematically varied in terms of raster angle and gap width. to yield the most sensitive constellation for conductivity The use of a negative gap between the individual rasters in combination with a raster angle of +/−45°w as observed to have a positive influence on intensifying the detected signals, making this constellation most sensible for strain sensing applications. Hence, the intrinsic properties of material were enhanced by the adequate selection of processing parameters. This study shows that the functionalized composite can be used as a strain sensor as for health monitoring purposes, to give an example.

Fibers and Polymers, 2013

The investigation of the shear behaviour of technical natural fibres is vital for the insurance o... more The investigation of the shear behaviour of technical natural fibres is vital for the insurance of aesthetics and performance of light weight, high strength, and eco-friendly composites. In this study, Egyptian jute fibre plain weave fabrics of various areal densities were investigated to describe their shear behaviour in terms of shear forces, shear angles and shear lock angles, using the Bias-Extension and the Picture Frame test methods. Results show that both methods are valid for natural fibres and produce comparable results. Whereas the Bias-Extension test presents a fast and simple test procedure, the analysis of the results is more complex due to the interaction of non-shear components. On the other hand, the Picture Frame test proves to be time consuming and in need of a more complex test rig, but results in pure shear deformations throughout the sample.

The behaviour of smooth 90-degree pipe bends under combined internal pressure and cyclic bending ... more The behaviour of smooth 90-degree pipe bends under combined internal pressure and cyclic bending loads has received a substantial attention in recent few years where shakedown and ratcheting boundaries have been determined. However such data are scarcely found for those pipe bends suffering from local wall thinning. This paper quantifies the effect of local wall thinning parameters on both elastic and shakedown boundaries via a non cyclic-numerical technique developed by Abdalla et al. [1]. The effect of local wall thinning parameters is investigated also on limit loads of pipe bends under the internal pressure and bending moments based on a systematic FE limit loads using elastic perfect plastic material model. The limit load study has been verified with the proposed approximations developed by Oh et al. [2] and Kim et al. [3]. The thinning geometry is assumed to be rectangular rather than circular but the geometrical nonlinearities are considered. Finite and fully circumferential ...

Abstract The use of natural fibres in polymer composite applications has gained great attention o... more Abstract The use of natural fibres in polymer composite applications has gained great attention over the last decade, due to weight, economic and environmental aspects. Processing textile reinforced composites in various lay-up, resin infusion or compression moulding techniques requires good reproduction of mould shape. Thus, this study is concerned with the analysis of deformation and draping behaviour of woven fabrics over single curvatures. Experimental investigations of draping several jute and glass fibre woven fabrics of varying densities over a standard circular disc have been performed. Draping behaviour was analysed using image processing techniques and MATLAB application. Further simulation of the draping patterns has been achieved using PamForm software. Good prediction of draping behaviour of woven textiles is accessible, but requires a set of preliminary experiments to well characterise the fabric in question.

Materialwissenschaft und Werkstofftechnik, 2015

3D printing is nowadays used not only to rapidly produce prototypes, but is further applied for t... more 3D printing is nowadays used not only to rapidly produce prototypes, but is further applied for the fabrication of functional parts. Amongst other factors, processing parameters such as scaffolding angle and raster gap greatly affect the behaviour of such printed parts. Little attention has been given so far to the tribological behaviour of such prints. In this study the above mentioned parameters on the friction behaviour, in terms of friction coefficient and wear rate, is investigated. For this purpose the Fused Deposition Modelling is used as one of state of the art 3D printing methods. Graphite flakes were further added to the reference acrylonitrile butadiene styrene (ABS) matrix in an attempt to enhance the properties. Results show that the scaffolding angle only affects the behaviour, if a positive printing gap is applied – when a negative gap is used, the angle has no significant effect on properties. Maximum coefficient of friction at acceptable values of specific wear rates can be attained at a scaffolding angle of 90° with negative gap. The incorporation of graphite further increases the friction coefficient on the expense of reduced wear properties. Heute wird die 3-D-Drucktechnologie nicht nur zur schnellen Herstellung von Prototypen eingesetzt, sondern unter anderem auch um Funktionsbauteile zu fertigen. Unter anderem spielen Prozessparameter, wie z. B. Druckwinkel und Rasterspalt eine entscheidende Rolle und beeinflussen das Verhalten der gedruckten Teile. Bislang wird in der Literatur wenig uber das tribologische Verhalten solcher 3D Bauteile berichtet. In dieser Studie wird die Wirkung der oben genannten Parameter auf das Abriebverhalten, anhand von Reibungskoeffizient und Verschleisrate untersucht. Hierzu wird das Fused Deposition Modelling als eines der modernen 3D-Druckverfahren herangezogen. Bei dem Versuch das Reibungsverhalten zu verbessern, wurde dem Ausgangsmaterial Acrylnitril-Butadien-Styrol (ABS) Lammellengraphit zugegeben. Die Ergebnisse zeigen, dass der Druckwinkel nur bei positivem Rasterspalt eine Rolle spielt – bei einem negativen Spalt, scheint der Winkel keinen signifikanten Einfluss zu haben. Maximale Reibwerte bei moderatem Verschleis konnten bei einem Druckwinkel von 90° und negativem Spalt festgestellt werden. Der Zusatz von Graphit erhohte masgeblich den Reibungskoeffizienten, allerdings auf Kosten verringerter Verschleiseigenschaften.

Proceedings of the 34th International MATADOR Conference, 2004

Composites Part B: Engineering, 2013

Journal of Manufacturing Processes, 2016

）The fabrication of textile reinforced polymer composites requires the pre-forming of textiles ov... more ）The fabrication of textile reinforced polymer composites requires the pre-forming of textiles over open, or within closed moulds before the introduction of the resin. This study is therefore concerned with the draping behavior of jute and glass fibres of various areal densities over double curvature moulds. Experimental investigation of the draping behavior was performed over a specially designed mould comprising different geometries of fillets and sharp edges. Simulation of the deformation behavior using PamForm2G application revealed similar results. Large shear deformations are found around large curves and acute angles. The interaction of geometries further forces woven fabrics to undergo severe shear deformations often leading to the creation of wrinkles.