Hazim El-Mounayri

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https://hdl.handle.net/1805/6690

Hazim El-Mounayri has translated his research into practical technology that brings virtual training to tomorrow's manufacturing workforce. The Advanced Virtual Manufacturing Laboratory (AVML), developed with industrial partner Advanced Science and Automation Corp., provides virtual training and education on high-tech Computer Numerically Controlled (CNC) machines. It enables colleges to easily and inexpensively provide students with effective, safe, and highly accessible web-based training on advanced machining tools, equipment and processes.

AVML is a valuable tool for training the local workforce in advanced manufacturing. The system can be used by machine tool manufacturers to provide online training, reducing or eliminating the need for on-site, live training classes for their customers. The system can also be used for machining process verification and optimization. The AVML is so versatile it can run on desktop or laptop personal computers as well as on more sophisticated 3D and fully immersive systems.

The new technology opens the door for effective distance education in disciplines that were traditionally confined to live teaching, including engineering, physics, and science. It is expected to be a major tool for training of Indiana's workforce in advanced manufacturing and attracting talented students to engineering and technology directly from high schools.

Professor El-Mounaryi's use of technology to expand the reach of teaching and training in advanced manufacturing is another practical example of how IUPUI's faculty members are TRANSLATING their RESEARCH INTO PRACTICE.

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Nanotechnology Research, Education, and Outreach by the Integrated Nanosystems Development Institute (INDI)
(Office of the Vice Chancellor for Research, 2014-04-11) Agarwal, Mangilal; Rizkalla, Maher; Naumann, Christoph A.; Decca, Ricardo; El-Mounayri, Hazim; Witzmann, Frank
Through multidisciplinary research and novel educational programing, the Integrated Nanosystems Development Institute (INDI) is sponsored under IUPUI’s Signature Center Initiative to advance nanotechnology-based systems research and spark student interest in this emerging STEM field. Innovation in the field of nanotechnology arises from interdisciplinary approaches and INDI draws on the expertise of faculty across departments and schools (including the School of Engineering and Technology, School of Science, School of Dentistry, and School of Medicine) in order to fuel research collaborations and offer nanosystems coursework to both science and engineering students. Current research efforts are focused in INDI’s thrust areas of bionanotechnology and sustainable nanoenergy, which build on the existing strengths of participating schools and span a range of critical issues in nanomaterials, nanodevices, nanosystems, energy, physics, and nanomedicine. Examples of research include the development of artificial biomaterials, nanosensor arrays for disease detection, and the development of nanomanufacturing techniques and educational tools. INDI facilitates research efforts by identifying funding opportunities, establishing research teams, offering seed funding, and providing a cluster of analytical equipment, characterization tools, and lab resources that support the work of faculty and student researchers. INDI continues to expand its shared resources through the acquisition on new cutting edge instrumentation, including a new field emission scanning electron microscopy facility, which is now open to researchers across campus. Aside from research, INDI plays a vital role in nanotechnology curriculum development on campus, in particular, the design and implementation of coursework offered within IUPUI’s newly developed Nanotechnology Track and Energy Engineering degree program. This academic track provides students with both theory and hands-on experiences involving the fabrication, characterization, and applications of nanomaterials, nanodevices and nanomedicine. Moreover, INDI’s community outreach activities, including its nanotechnology summer camps for K-12 students and teachers, aim to provide early student exposure and educate teachers in applying nanotechnology modules within their classrooms. These student experiences are designed to encourage higher education in an effort to generate the advanced nanotechnology workforce needed by Indiana and the nation.
EFFECTS OF COATING ON DIE COMPONENTS DURING ALUMINUM EXTRUSION PROCESS
(Office of the Vice Chancellor for Research, 2014-04-11) Bakhtiani, Tushar; Zhang, Jing; El-Mounayri, Hazim
In aluminum extrusion the life of the die tooling components are mainly limited by wear and fatigue. Therefore reliable predictions of the amount of wear and its distribution in dies are important factors for the die manufacturer[1]. In this study the stress location and wear depth of the tooling components were calculated with the help of Archards wear model which is implemented into Deform 3D finite element code for large scale plastic deformation. Using Deform 3D a comparative study was conducted on the modular die design mandrel and die plate made out of powder metal (PM) tool steel without coating and Bilayer chemical vapor deposition (CVD) coating of (TiCN + Al2O3) to locate to maximum stress locations and to calculate the amount of wear that occurs during hot aluminum extrusion. The results generated from the simulation would help predict the service life of the components, would also help in optimizing the right amount of thickness needed for the coating to improve die life and would also help in understanding the effects of coating on die stress and wear.
AFM-Based Fabrication of Nanofluidic Device for Medical Application
(Office of the Vice Chancellor for Research, 2014-04-11) Promyoo, Rapeepan; El-Mounayri, Hazim; Karingula, Varun Kumar
Recent developments in science and engineering have advanced the atomic manufacture of nanoscale structures, allowing for improved high-performance technologies. Among them, AFM-based nanomachining is considered a potential manufacturing tool for operations including machining, patterning, and assembling with in situ metrology and visualization. In this work, atomic force microscope (AFM) is employed in the fabrication of nanofluidic device for DNA stretching application. Nanofluidic channels with various depths and widths are fabricated using AFM indentation and scratching techniques. To introduce the fluid inside the nanochannels, microchannels are made on both sides of the nanochannels. Photolithography technique is used to fabricate microfluidic channels on silicon wafers. A 3D Molecular Dynamics (MD) model is used to guide the design and fabrication of nanodevices through nanoscratching. The correlation between the scratching conditions, including applied force, scratching depth, and distant between any two scratched grooves and the defect mechanism in the substrate/workpiece is investigated. The MD model allows proper process parameter identification resulting in more accurate nanochannel size.
Numerical simulation of aluminum extrusion using coated die
(2014) Bakhtiani, Tushar; El-Mounayri, Hazim; Zhang, Jing
In aluminium extrusion, the life of the die tooling components is mainly limited by wear and fatigue. Therefore reliable predictions of the amount of wear and its distribution in dies are important factors for the die design. In this study the stress location and wear depth of the tooling components were calculated using finite element models incorporating the Archards wear model. A comparative study was conducted on an extrusion die without coating and with a bilayer (TiCN + Al2O3) chemical vapor deposition (CVD) coating. Stress distribution and the amount of wear were calculated. The results generated from the simulation would help predict the service life of the components through optimizing coating thickness.
AFM-Based Nanofabrication: Modeling, Simulation, and Experimental Verification
(Office of the Vice Chancellor for Research, 2013-04-05) Promyoo, Rapeepan; El-Mounayri, Hazim; Karingula, Varun Kumar; Varahramyan, Kody
Recent developments in science and engineering have advanced the fabrication techniques for micro/ nanodevices. Among them, atomic force microscope (AFM) has already been used for nanomachining and fabrication of micro/nanodevices. In this paper, a computational model for AFM-based nanofabrication processes is being developed. Molecular Dynamics (MD) technique is used to model and simulate mechanical indentation and scratching at the nanoscale. The effects of AFM-tip radius and crystal orientation are investigated. The simulation is also used to study the effect of the AFM tip speed on the indentation force at the interface between the tip and the substrate/workpiece. The material deformation and indentation geometry are extracted from the final locations of atoms, which are displaced by the rigid indenter. Material properties including modulus of elasticity and hardness are estimated. It is found that properties vary significantly at the nanoscale. AFM is used to conduct actual nanoindentation and scratching, to validate the MD simulation. Qualitative agreement is found. Finally, AFM-based fabrication of nanochannels/nanofluidic devices is conducted using different applied forces, scratching length, and feed rate.
Nanotechnology Research, Education, and Outreach by the Integrated Nanosystems Development Institute (INDI)
(Office of the Vice Chancellor for Research, 2013-04-05) Naumann, Christoph A.; Rizkalla, Maher; Decca, Ricardo; El-Mounayri, Hazim; Witzmann, Frank; Agarwal, Mangilal
Through multidisciplinary research and novel educational programing, the Integrated Nanosystems Development Institute (INDI) is sponsored under IUPUI’s Signature Center Initiative to advance nanotechnology-based systems research and spark student interest in this emerging STEM field. Innovation in the field of nanotechnology arises from interdisciplinary approaches and INDI draws on the expertise of faculty across departments and schools (including the School of Engineering and Technology, School of Science, School of Dentistry, and School of Medicine) in order to fuel research collaborations and offer nanosystems coursework to both science and engineering students. Current research efforts are focused in INDI’s thrust areas of bionanotechnology and sustainable nanoenergy, which build on the existing strengths of participating schools and span a range of critical issues in nanomaterials, nanodevices, nanosystems, energy, physics, and nanomedicine. Examples of research include the development of artificial biomaterials, toxicology of nanomaterials, and the development of nanomanufacturing techniques and educational tools. INDI facilitates research efforts by identifying funding opportunities, establishing research teams, offering seed funding, and providing a cluster of analytical equipment, characterization tools, and lab resources that support the work of faculty and student researchers. Aside from research, INDI plays a vital role in nanotechnology curriculum development on campus, in particular, the design and implementation of coursework offered within IUPUI’s newly developed Nanotechnology Track and Energy Engineering degree program. This academic track provides students with both theory and hands-on experiences involving the fabrication, characterization, and applications of nanomaterials, nanodevices and nanomedicine. Moreover, INDI’s community outreach activities, including its nanotechnology summer camps for K-12 students and teachers, aim to provide early student exposure and educate teachers in applying nanotechnology modules within their classrooms. These student experiences are designed to encourage higher education in an effort to generate the advanced nanotechnology workforce needed by Indiana and the nation.
Simulate Turning Process using ANN, Predict Optimum Control Factors to achieve Minimum Surface Roughness
(Office of the Vice Chancellor for Research, 2012-04-13) Kulkarni, Ruturaj; El-Mounayri, Hazim
Abstract Turning is a material removal process, a subtractive form of machining which is used to create parts of circular or rotational form of desired geometry/shape by removing unwanted material. Accuracy of any process depends on involvement of operational variables. The operating parameters that contribute to turning process are Cutting speed, Feed rate, Depth of cut. Vibrations, tool wear, tool life, surface finish and cutting forces etc are also in direct relation with values selected for process parameters. Hence to improve the efficiency of process and quality of the product it is necessary to control the process parameters. Surface roughness is the parameters with main focus, as it dictates the aesthetics and sometimes ergonomical characteristics of the product. The tests were carried out on AISI 4140 steel. 12 speed Jones and Lamson Lathe model was used for turning operation. The specimen with a diameter of 60mm, 500mm length and hardened 35 HRC is used. The tool used for this is one that is most commonly used for turning process DTGNR 163 C 0° Lead Angle 60° Triangle insert. It is product of Kennametal. Statistical Design of Experiments was used to reduce the total number of trials in order to save the time and resources without compromising the accuracy of prediction. These readings are used to train and validate the Neural Network. ANN is found to be very useful with simulations tasks which have complex and explicit relation between control factors and result of process. Neural Network was created using feed forward back propagation technique for simulation of the process using the Matlab Neural network toolbox. With assurance of accuracy of the predictive capabilities of the neural network, it was then used for optimization. Particle Swarm Optimization Algorithm, an evolutionary computation technique is used find out the optimum values of the input parameters to achieve the minimum surface roughness. The objective function used here is to minimize the surface roughness. Limits of the operational variables are used as constraints for developing the code for optimization algorithm. Keywords: Turning process, Surface roughness, Artificial Neural Network, Particle swarm optimization.
Nanotechnology Research, Education, and Outreach by the Integrated Nanosystems Development Institute (INDI)
(Office of the Vice Chancellor for Research, 2012-04-13) Naumann, Christoph; Rizkalla, Maher; Decca, Ricardo; El-Mounayri, Hazim; Witzmann, Frank; Agarwal, Mangilal
Abstract: The Integrated Nanosystems Development Institute (INDI), sponsored under the IUPUI Signature Centers Initiative, with a vision of becoming a world-recognized resource for the realization of nanotechnology-based systems, is advancing both nanotechnology research and education on campus. Innovation in nanotechnology requires multidisciplinary approaches and INDI, a collective group of faculty members across departments and schools (including the School of Engineering and Technology, School of Science, School of Dentistry, and School of Medicine), enables interdisciplinary research collaborations and offers nanosystems coursework to students in science and engineering disciplines. Current research efforts span a range of critical issues in nanomaterials, nanodevices, nanosystems, energy, physics, and nanomedicine, and include projects such as the design and characterization of nanoarchitectures for biomedical applications, advancing fuel cell and energy storage technologies, and investigating nanoparticle toxicology. Several members of INDI have externally funded research and outreach projects. The nanotechnology research capabilities within INDI, including of a cluster of analytical equipment and lab resources for nanosystems development and characterization, support local industry needs as well as the research interests of over 30 faculty members and over 100 students (undergraduate, graduate and postdoctoral) on the IUPUI campus. INDI also provides, through the newly developed courses, students with both theory and hands-on experiences involving the fabrication, characterization, and applications of nanosystems. These courses are also part of IUPUI’s newly developed Nanotechnology Track in Mechanical Engineering and Electrical and Computer Engineering degree programs, and the Energy Engineering degree program. In addition, INDI’s active community outreach activities, including its nanotechnology summer camps for K-12 students and teachers, provide early exposure to nanofabrication techniques and research. These classroom and lab-based experiences are designed to encourage higher education and involvement in academic research in an effort to generate the advanced workforce needed by Indiana and the nation.
AFM-Based Nanofabrication: Modeling, Simulation, and Experimental Verification
(Office of the Vice Chancellor for Research, 2012-04-13) Promyoo, Rapeepan; El-Mounayri, Hazim; Varahramyan, Kody
Recent developments in science and engineering have advanced the fabrication techniques for micro/nanodevices. Among them, atomic force microscope (AFM) has already been used for nanomachining and fabrication of micro/nanodevices. In this research, a multi-scale computational model for AFM-based nanofabrication processes is being developed. Molecular Dynamics (MD) technique was used to model and simulate mechanical indentation and scratching at the nanoscale. MD simulation represents itself as a viable alternative to the expensive traditional experimental approach, which can be used to study the effects of various indentation variables in a much more cost effective way. The effects of workpiece materials, AFM-tip materials, AFM-tip radius, as well as crystal ori entations were investigated. The simulation allows for prediction of the indentation forces at the interface between an indenter and a workpiece. Also, the MD simulation was used to study the effects of speed on the indentation force. The material deformation and indentation geometry are extracted based on the final locations of atoms, which are displaced by the rigid indenter. Material properties including modulus of elasticity and friction coefficient are presented. AFM was used to conduct actual indentation and scratching at the nanoscale, and provide measurements to validate the predictions from the MD simulation. Qualitative agreement was found between the simulation and actual AFM-based nanomachining.
Design Optimization of Injection Molds with Conformal Cooling for Additive Manufacturing
(Office of the Vice Chancellor for Research, 2015-04-17) Wu, Tong; Jahan, Suchana A.; Kumaar, Praveen; Tovar, Andres; El-Mounayri, Hazim; Zhang, Yi; Zhang, Jing; Acheson, Doug; Nalim, M. Razi
Abstract This is a framework for optimizing additive manufacturing of plastic injection molds. The proposed system consists of three modules, namely process and material modeling, multi-scale topology optimization, and experimental testing, calibration and validation. Advanced numerical simulation is implemented for a typical die with conformal cooling channels to predict cycle time, part quality and tooling life. A thermo-mechanical topology optimization algorithm is being developed to minimize the die weight and enhance its thermal performance. The technique is implemented for simple shapes for validation before it is applied to dies with conformal cooling in future work. A method for designing a die with porous material which can be produced in additive manufacturing is developed. Also a comprehensive set of systemic design rules are developed and to be integrated with CAD modeling to automate the process of obtaining viable plastic injection dies with conformal cooling channels. Finally, material modeling using simulation as well as design of experiments is underway for obtaining the material properties and their variations.

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