Ahmed A. D. Sarhan

• DR ENG, KYOTO UNIVERSITY JAPAN
• Professor (Associate) at King Fahd University of Petroleum and Minerals

The aim of this research is to develop an ANFIS modeling for smart drilling to maximize the utilization of cutting tools. In this study, first, the tool wear behavior is investigated and clearly recognized. Second, the torque and thrust force signals are measured through a series of experiments at different drilling parameters conditions (flank wea...

Actuated rotational adaptive optics has emerged as a pivotal advancement in the realm of optical engineering, particularly enhancing the capability to correct complex wavefront aberrations more effectively than traditional adaptive optics systems. This study provides a comprehensive examination of these advancements through detailed theoretical mod...

SiCp/Al Metal matrix composite (MMCs) materials are known as hard to machine materials despite of their demanding application in aerospace, automobiles and heavy-duty industries. More specifically, high-volume silicon carbide particles reinforce aluminum-based metal matrix composite (SiCp/Al 50% vol:) are difficult to cut materials due to their exc...

This study utilized a 3D printer that employed the photopolymer extrusion (PPE) technique with ultraviolet (UV) lasers to solidify a liquid-photosensitive polymer material. The research focused on studying fumed silica nanoparticles reinforced fillers with PPE, aiming for improved surface finish while maintaining desired rheological and mechanical...

Metal-organic frameworks (MOFs), as lubricant additives, have remarkable potential in super lubrication performance because of their big surface area, tunable chemistry, load bearing capacity, corrosion protection and environmental friendliness. However, only a small number of MOFs are capable of melting. In this paper, Zeolitic Imidazolate Framewo...

Biodiesel is an eco-friendly source of energy that is synthesized from plant or animal-based oils and fats. However, the commercial use of biodiesel is limited due to its drawbacks such as auto-oxidation and moisture absorption, leading to accelerated corrosion of the metallic parts and degradation of wear resistance. In this work, a novel amorphou...

The development of hard coating layers emerges as a promising avenue to promote surface properties such as hardness, wear resistance, and, hence, lifetime. Metal nitrides, especially Cr-based, are among the array of available coating materials that stand out for their exceptional tribological performance and chemical stability, particularly at elev...

Metal matrix composites (MMCs) have gained great recognition in recent decades in a wide range of applications, including aerospace, automobiles, engine cylinders, and other sectors. MMCs possess excellent properties including being light in weight, high corrosion resistance, stiffness, and strength. However, they are categorized as difficult-to-cu...

The present article investigates the performance of powder-mixed die sink electrical discharge machining (PMEDM) under the influence of micro-flakes graphite (Gr) powder additive in dielectric (1.25 and 2.5 g/l of concentrations) during machining two workpiece materials of D2 steel and mild steel that are extensively employed alloys in the die and...

Nickel-based superalloys have gained widespread use in various industries like aerospace, power generation, chemical processing, and marine engineering due to their exceptional mechanical properties. However, machining these superalloys poses significant challenges due to their hardness. To address these issues and improve machining performance, se...

Metallic glasses are a new class of metallic alloys that attract increasing attention in bone implants due to their ultrahigh wear resistance and hardness, high toughness and superior strength. However, their cytotoxicity and biocorrosion resistance are still under investigation. In this research, the cytotoxicity and biocorrosion resistance of iro...

The commonly used metallic biomaterials fail to prove durability for orthopedics due to their lack of biocompatibility and poor bioactivity which weakens the bonding to bones. Metallic glasses (MGs) have attracted attention as an alternative biomaterial for orthopedics owing to their superior mechanical properties and acceptable biocompatibility. N...

Wire electrical discharge machining, commonly known as Wire-EDM (or WEDM), is a nonconventional process of machining complicated, precise parts of hard conductive materials without using costly grinding or forming tools. Efficient utilization of available wire electrodes for computer integrated-Wire-EDM is an important aspect of production economic...

Titanium (Ti) alloys are produced with the combination of titanium and alloying elements. Titanium and titanium alloys are lightweight materials with high toughness, corrosion resistance and tensile strength at high temperatures. Titanium and its alloys have been widely used in several industrial applications, such as marine, biomedicine, chemical,...

This paper presents the analytical and experimental investigations on different factors such as surface integrity, flexural strength and grinding energy and cost of Alumina through the use of various diamond grinding wheels. For obtaining the analytical model for single-grit grinding, the effect of strain rate and grinding temperature are also incl...

In the present paper, the impact of grinding on the surface integrity of the PSZ is investigated through analytical, numerical, and experimental studies. The analytical model of the single grit grinding of the PSZ was developed by taking into consideration the strain rate, the grinding temperature, and the phase transformation of the zirconia. Nume...

The aim of this study is to evaluate the effect of various grinding parameters on the phase transformation, surface roughness, G-ratio, grinding cost, and specific grinding energy of partially stabilized zirconia (PSZ) using different diamond grinding wheels. The use of PSZ ceramic in dental applications has significantly increased in recent years...

Zirconia has been used in medical applications since last few years and an optimum and cost-effective condition in grinding zirconia has drawn industrial attention. This paper aimed to improve and control the surface integrity, flexural strength and grinding cost in grinding partially stabilized zirconia (PSZ) using a diamond grinding wheel. The ph...

In the current research work undertaken, an oxide film was grown by performing hard anodizing process on a pure aluminum layer deposited by PVD magnetron sputtering process on AA7075-T6 alloy. The corresponding tribo-mechanical properties were evaluated and compared with those of the base alloy. The dry sliding wear experiments were carried out to...

Amorphous metals – or Metallic Glass (MG) – have a great potential in bone implant applications because of their exceptional mechanical properties, excellent tribological and corrosion resistance characteristics, and good biocompatibility. An upcoming trend is to develop an amorphous metallic coating on different metallic alloys to promote the hard...

Tubular ultrasonic motors are one of the simplest yet effective methods to realize rotational ultrasonic motors. In this paper, electromechanical modeling of a tubular ultrasonic motor is achieved using assumed-modes method, Euler-Bernoulli beam theory, and constitutive equations of piezoelectricity. Upon validating the analytical model using finit...

Recently, there has been increased need for alternative lubrication techniques in grinding of advanced engineering ceramics. Literatures have indicated that the minimum quantity lubrication (MQL) method is a viable option for lubrication during grinding operations. The MQL technique was found to be non-hazardous, sustainable, eco-friendly, inexpens...

The use of nanofluid in lubrication during machining of advanced engineering ceramics has been found to be highly efficient and eco‐friendly. This work involves experimental investigation of grinding Alumina (Al2O3) ceramic to determine the effect of the grinding variables. The grinding variables considered include depth of cut, feed rate, type of...

Al-Mg2Si in situ composite is a new metal matrix composite (MMC) with numerous applications in different engineering fields. MMCs are considered difficult-to-cut materials due to the abrasive nature of the reinforcement (e.g., Mg2Si), hardness, and built-up edge. Hence, electrical discharge machining (EDM) is one of the alternative ways to machine...

This research proposes the development of amorphous-crystalline FeCrMoCB layer as a promising biomaterial for bone-implant applications. The FeCrMoCB amorphous powder was laser cladded on nickel-free stainless-steel (Cronidur30) using three laser specific energies (E s ) levels (31.8, 27.5 and 23.4 J/mm ² ) to attain different amorphous contents. T...

In this research work, the electrodeposition of Nickel-Phosphorous (Ni-P) coating on carbon steel alloy for higher surface hardness has been investigated. Nickel phosphorus (Ni–P) with 11–12 wt% phosphorous was electrodeposited onto AISI 1045 steel substrate with direct current and solutions of phosphorous and phosphoric acid, nickel sulphate and n...

Additive manufacturing (AM) is the process of building 3D objects by layer-upon-layer. AM became a promising technique in various applications as automotive, aerospace and biomedical applications. The AM provides a flexible and versatile technique to produce complex shapes in short time using vast materials in a cost-effective way. So, AM has been...

Fused deposition modelling (FDM) is a type of additive manufacturing technology which is being used to manufacture prototypes and functional parts. However, the volumetric shrinkage limits the functionality of the manufactured prototypes. Accurately predicting the volumetric shrinkage will diversify the applicability of this manufacturing technolog...

Purpose Optimisation of grinding processes involves enhancing the surface quality and reducing the cost of manufacturing through reduction of power consumptions. Recent research works have indicated the minimum quantity lubrication (MQL) system is used to achieve near dry machining of alloys and hard materials. This study aims to provide an experi...

In this research work, a novel investigation of the substrate surface roughness effects on the geometry, the phase transformation, and the hardness of a single laser-cladded track on nickel-free high nitrogen stainless steel used for biomedical applications. First, two samples were sandblasted using 40- and 100-grit Al2O3 abrasive and two other sam...

The effect of various amounts of copper oxide (CuO) up to 1 wt% on the densification behaviour and mechanical properties of 3 mol% yttria-tetragonal zirconia polycrystal (Y-TZP) were studied by using microwave (MW) sintering method. The MW sintering was performed at temperatures between 1100 °C and 1400 °C, with a heating rate of 30 °C/min. and hol...

Silicon nitride (Si3N4) ceramic is highly desired in various engineering applications due to its exceptional properties. However, machining the Si3N4 ceramic suffers setbacks due to various degrees of damage inflicted on the ceramic during machining. Studies have shown that the minimum quantity lubrication (MQL) process is a better alternative to t...

Especially with increased cutting forces using complex-shape tools such as long end milling tools, deflection in machining significantly affects the dimensions and geometry. This kind of error in end milling may be efficiently reduced by controlling the cutting parameters and properly selecting a suitable lubrication mode. The target of this resear...

Corrosion and wear are common problems encountered in the oil and gas industry. These entail the gradual destruction of materials by mechanical action on the opposite surface, and the chemical and/or electrochemical reaction with their environment. In this research, Al8Si20BN ceramic powder with specific properties against corrosion and wear was se...

Polymers are recently utilized in numerous tribological applications because of the excellent characteristics, for example, accommodating shock loading and shaft misalignment. High surface finish is required to ensure consistently good performance and extended service life of manufactured polymeric components. Burnishing is the best choice as finis...

In this work, the viability of producing biogenic hydroxyapatite from bio-waste animal bones, namely bovine (cow), caprine (goat) and galline (chicken), through a heat treatment process has been investigated. The animal bones were locally sourced, cleaned to remove collagen and subsequently heat treated in air atmosphere at different temperatures r...

In this research, the comparison between microwave sintering and conventional sintering on the mechanical properties and microstructural evolution of 3 mol% yttria-stabilised zirconia were studied. Green bodies were compacted and sintered at various temperatures ranging from 1200 °C to 1500 °C. The results showed that microwave assisted sintering w...

As is recognized widely, tool wear is a major problem in the machining of difficult-to-cut titanium alloys. Therefore, it is of significant interest and importance to understand and determine quantitatively and qualitatively tool wear evolution and the underlying wear mechanisms. The main aim of this paper is to investigate and analyse wear, wear m...

Corrosion is the deterioration of materials by chemical interaction with their environment. In the oil and gas industry, corrosion of the pipelines and other equipment is one of the leading causes of failure and the corrosion-related costs are very high. Hence, corrosion protection is an essential requirement. In this study, the objective is to ana...

In this study, an experimentally validated numerical analysis was performed toward optimization of stacking sequence in multidirectional laminated composites subjected to low-velocity impact. For this purpose, an optimization program was developed by integrating finite element method and Multi Objective Genetic Algorithm using modeFRONTIER. In this...

Metallic glasses (MG) have great potential in biomedical applications because of their superior mechanical properties, excellent wear and corrosion resistance, and good biocompatibility. A strategy to overcome the limitations in size and low elongation percentage is to develop MG on different metallic alloys. In this research, Fe-based MG coating w...

This paper presents a review on ultrasonic-assisted grinding (UAG) of advanced materials, specifically investigating the effects of ultrasonication on material removal rates (MRR), grinding forces and energy, tool wears, wheel loading, residual stress and surface/subsurface damages. It compares the performance of UAG of ceramics and super alloys fo...

Conventional methods of building CNC machine tools involve using linear motors and ball screw drives to obtain table motion. The double opposite sync motion design is an improvement over traditional CNC machines. In this work, an enhanced CNC gantry machine design is proposed, which exhibits a double motion mechanism. The new design is based on a r...

Micro-dies, molds and miniaturized products can be manufactured using micro EDM process. In this research, EDM machine and on-machine fabricated CuW micro-electrode were utilized to produce the micro holes in WC-16%Co. The effects of voltage, current, pulse ON time, pulse OFF time, capacitor and rotating speed on Material removal rate (MRR) during...

Thermal Spray Coating, Plasma, HVOF The common manufacturing processing method for improving the surface of piping and accessories is overlay welding or cladding. This method has some limitations, such as its limitation for choosing materials. In addition, the high temperature of welding causes the final surface has some defects such as, thermal re...

A simplified 2D axisymmetric meshfree model of transient metal laser drilling is proposed for continuous laser beam of Gaussian distribution. The penetration depth is predicted over the whole ablation time. Meshless Local Petrov-Galerkin (MLPG) collocation method is used for discretizing the governing equation. Moving Least Square (MLS) and Weighte...

Teleoperation systems have been developed in order to manipulate objects in environments where the presence of humans is impossible, dangerous or less effective. The presence of force signals plus position signals in the control scheme could effectively improve transparency. However, the main restriction is force measurement in some applications. A...

In this research work, Adaptive Neuro-Fuzzy Inference System (ANFIS) modeling is implemented to predict the friction force in the CNC linear guideways and servomotor current in the feed drive system in dry lubrication condition. Initially, the friction forces in the CNC linear guideways are calculated from the cutting force analysis during cutting...

Electrical discharge machining (EDM) is a non-conventional machining technique that is well-known for use in fabricating dies and molds owing to machinability of high hardness materials. Although the electro-thermal mechanism of EDM offers many advantages over other available machining methods, its sluggish nature limits the wide application of suc...

Wire electrical discharge machining (WEDM) is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). WEDM demands high cutting rate and high quality to improve machining performance for manufacturing hard materials. The machining performance of computer-controlled WEDM is directly dependent on spark energy...

These days, miniaturized products have a lot of applications in biotechnology, information technology, environmental and medical industries, electric devices, miniaturized machines, and so on. Micro-electrical discharge machining (micro-EDM) is one the most efficient technologies among the nonconventional machining technologies for producing micro-...

Ultrasonic motor working with coupled in-plane and out-of-plane vibration modes of rectangular plate is proposed and experimentally investigated. Thanks to its unique configuration, proposed motor provides large contact area between stator and rotor of motor which can reduce wear and enhance motor life-time. The proposed motor is designed using fin...

Prediction of penetration depth in metal laser drilling is done through a simple meshfree numerical model. 2D axisymmetric simplified model of transient metal laser drilling is proposed for continuous laser beam of Gaussian distribution with strong form of Radial Point Interpolation Method (RPIM) used for approximating the temperature field. The co...

Recently, there has been an increasing trend in researches focusing on improving the performance of the biomedical implants. The clinicians used metallic implants to treat bone imperfections and fractures. The commonly used metals (Stainless steel, Ti-alloys and Co-alloy) failed to prove long-term durability and did not build sufficient bond with h...

The effects of two-step sintering (TSS) on the mechanical properties and hydrothermal ageing resistance of yttria-stabilized tetragonal zirconia polycrystals (Y-TZP) were investigated. In TSS, the first step involved heating the samples up to 1400 °C at a heating rate of 10 °C/min and holding the samples at this temperature for 1 minute. The second...

A simple numerical model is proposed for predicting the penetration depth of metal laser drilling. A simplified 2D axisymmetric model for transient metal laser drilling is introduced. Strong-form of symmetric smoothed particle hydrodynamics (SSPH) method is used to harness its significant reduction in computational time. The 2D axisymmetric domain...

Wire electrical discharge machining (WEDM) is one of the most important nontraditional machining process that is well-known for cutting difficult to machine materials. The wire electrode along with machining parameters control the WEDM process. This research work focuses on optimizing WEDM parameters using Taguchi technique to minimize wire rupture...

The current work investigates the effects of sintering additives, particularly focused on 0.5 wt% manganese oxide (MnO2) and 0.1 wt% alumina (Al2O3), and co-doping both additives together (i.e. MnO2 + Al2O3), on the microstructure and mechanical properties of 3 mol% Y-TZP. The doped powders were prepared by attrition milling and subsequently green...

One of the major requirements of wire electrical discharge machining (WEDM) is to develop suitable technology for producing smooth surfaces. The main characteristic of WEDM is the development of the white layer. To ensure good surface quality, the white layer thickness (WLT) must be as thin as possible, homogeneous, and crack-free. Spark energy and...

Electrical discharge machining (EDM) is a powerful, nonconventional machining technique with the ability to machine any conductive material regardless of mechanical property. However, the sluggish nature of EDM stands out when the target is in mass production in industrial plants. Poor surface quality, residual stress, and heat-affected zone are am...

These days, the miniaturized products have a lot of applications. This work describes electrical discharge machining (EDM) and micro EDM comprehensively and compares the types of pulse generators, electrodes and methods for calculating material removal rate (MRR), electrode wear ratio (EWR), overcut and surface roughness for these methods. Various...

A precise and compact tubular ultrasonic motor driven by a single-phase source is proposed and tested in this study. The motor is designed by modeling a motor stator in FEM software. The motor fabricated according to the design is tested experimentally and its working characteristics including speed and torque are measured and presented. The maximu...

Micro-electrodes are used for micro holes EDM drilling in miniaturized products. This study represents novel fabricating and measuring processes of high aspect ratio micro-electrodes based on horizontal moving block electrical discharge grinding (horizontal moving BEDG [HM-BEDG]) and gage block with a typical EDM machine, as well as solving the pro...

Wire cutting electrical discharge machining (WEDM) is a non-traditional technique by which the required profile is acquired using spark energy. Concerning wire cutting, precision machining is necessary to achieve high product quality. White layer thickness (WLT) is one of the most important factors for evaluating surface quality. Furthermore, WLT i...

This paper establishes a novel control strategy for a nonlinear bilateral macro–micro teleoperation system with time delay. Besides position and velocity signals, force signals are additionally utilized in the control scheme. This modification significantly improves the poor transparency during contact with the environment. To eliminate external fo...

Electrical discharge machining (EDM) is a non-conventional machining technique for removing material based on the thermal impact of a series of repetitive sparks occurring between the tool and workpiece in the presence of dielectric fluid. Since the machining characteristics are highly dependent on the dielectric’s performance, significant attentio...

The tool electrode has a significant role in electrical discharge machining (EDM) performance, as it affects machining efficiency, surface quality and the geometrical accuracy of the machined component. This study presents a new approach for developing a pure copper electrode using severe plastic deformation (SPD) to enhance the machining character...

Residual stresses are usually imposed on a machined component due to thermal and mechanical loading. Tensile residual stresses are detrimental as it could shorten the fatigue life of the component; meanwhile, compressive residual stresses are beneficial as it could prolong the fatigue life. Thermal and mechanical loading significantly affect the be...

Linear guideways are widely applied in advanced machinery industries worldwide for different types of CNC machine (e.g., turning, milling, grinding, and gantry). All of these machines require accuracy and precision in the machining operations to manufacture quality products. The cutting operation in product manufacturing occurs with the displacemen...

In industry, the capability to predict tool wear is an essential matter as the quality and performance of a cutting tool directly affect the product quality. Developing a model to predict tool wear can help control tool wear and maximize tool utilization. Therefore, this study presents a method of predicting tool flank wear of coated carbide insert...

Wire-cut electric discharge machining is a nontraditional technique by which the required profile is acquired using sparks energy. Concerning wire-cut electric discharge machining, high cutting rates and precision machining is necessary to improve productivity and achieve high quality of machined work-pieces. In this research work, an experimental...

Carbon steel is the most commonly used material in the petroleum industry owing to its high performance and relatively low cost compared with highly alloyed materials. The corrosion resistance of carbon steel in aqueous solutions is dependent on the surface layer created on carbon steel. This layer often consists of siderite (FeCO3) and cementite (...

Wire Electric Discharge Machining (WEDM) is a nontraditional technique by which the required profile is acquired using spark energy. Regarding wire cutting, precision machining is necessary to achieve high product quality. White Layer Thickness (WLT) is one of the most important factors for assessing superior surface finish. In this research, Adapt...

Surface roughness is one of the key measures in manufacturing that describes machined surface integrity. In this research work, the effect of silicon morphology on surface roughness when turning Al-11%Si-1.8%Cu alloy and Sr-containing alloys was investigated. The experiments are carried out under oblique dry cutting conditions using a PVD TIN-coate...

Manufacturing geometrically complex components with high strength and high wear resistance is an essential requirement in fabricating heavy-duty industrial components. Electrical Discharge Machining (EDM) is a non-conventional machining technique with the potential to machine any conductive material regardless of hardness property. This experiment...

The capability of CNC gantry milling machines in manufacturing long components has caused the expanded use of such machines. On the other hand, the machines' gantry rigidity can reduce under severe loads or vibration during operation. Indeed, the quality of machining is dependent on the machine's dynamic behavior throughout the operating process. F...

Piezoelectric cantilever actuators are widely used in micro/nano-positioning applications due to their relatively accurate response and large operating bandwidth. One of the main obstacles in the way of implementing high-accuracy position tracking in high frequencies is the piezoelectric hysteresis phenomenon. It is known from previous research tha...

Ti6Al4V alloy is highly used in the automotive and aerospace industry due to its good machining characteristics. Micro EDM drilling is commonly used to drill micro hole on extremely hard material with very high depth to diameter ratio. In this study, the parameters of micro-electrical discharge machining (EDM) in drilling of Ti6Al4V alloy is optimi...

Milling is a machining process that removes any desired material from the surface by using relative motion between a work piece and a rotating cutter where the cutting tool intermittently enters and leaves the work piece. The milling process operates in two modes, namely, conventional (up) mode and climb (down) mode. Both modes are known for their...

Ceramic composite Cr3C2–25%NiCr with high corrosion resistivity (up to 900 °C) is applied on carbon steel (SC45) pipes by two different thermal spray-coating techniques: HVOF and Plasma. These techniques can create dense and homogenously deposited layers without affecting the materials’ properties. The corrosion behavior of coated samples is invest...

Thermal energy storage plays a key role in improving the efficiency of solar applications. In this study, the energy storage behavior (melting or charging) and energy removal process (solidification or discharging) are investigated in the presence of paraffin wax as a phase-change material (PCM) in a horizontal shell-and-finned tube. The horizontal...