Research interests and practical activities
- Deep drawing and stretch forming:
- I started my graduate research on theoretical and experimental analyses of nontraditional deep drawing process in 1985. Since then most of my research has been involved in this area in particular instability, wrinkling and effects of anisotropy in deep drawing and stretching processes. I have used FEM codes (such as NISA, ANSYS, ABAQUS and FORGE) for my process simulations and CAD courses.
- I have also supervised one PhD student and one Master students who developed an FEM program for the 3D simulation of planar anisotropic sheet metals, which was also capable of the prediction of a general 3D instability mode. In this program a rigid nonlinear hardening material and large deformation theory has been used and rotation of principal directions of anisotropy were also taken into account.
- I have also been involved in practical aspects of the deep drawing process in the design and manufacture of multistage circular and noncircular deep drawing dies for various precision parts. Examples include: stators of DC motors and large irregular deep drawn parts like automotive fuel tanks.
- Cold roll forming (CRF):
- I have supervised three Masters and two PhD students in this field (one PhD student is currently active). We have been able to develop computer codes for the analyses of circular (tube) and noncircular sections.
- I have also cooperated with industries in the CRF field. The main purpose of these activities was computer-aided design and manufacture of rolls at different stages of the CRF process required at more flexible manufacturing lines.
- I have also cooperated in establishing an Iranian CRF scientific committee for arranging technical courses, scientific seminars and establishing a library for the CRF community in Iran.
- Die design and manufacture:
- Supervision of a die-making workshop, for three years in I.U.T. specialized in making dies for difficult-to-form parts for three years. In this workshop I supervised more than ten engineers and skilled die makers. I was responsible for the management of the personnel and also financial and technical problems of the workshop. Analysis, design and manufacture of different dies mostly for deep drawn or fine blanked parts were performed. Based on more than ten years consultation with industry and supervision of this workshop, I can accept responsibility for detail die design for sheet metal parts including tool material selection, force calculations, determination of clearances, die tests, adjustment of working conditions on a press, trouble shooting of a die, etc.
- Design and manufacture of progressive dies. I have also had long-term consultation experience in die design activities with different factories. I have been able to help various companies, by consulting, correcting and improving their proposed designs, detecting and predicting unwanted problems, design errors, weak areas or ideas. A few examples are: cooler blower, burner of gas heaters, automotive door and hood locks and DC motor laminations.
- Design and manufacture of progressive and compound fine blanking dies. I am a specialist in the design of fine blanking dies. I have successfully made fine blanking dies and have taught fine blanking technology for more than eight years. I have also been able to equip mechanical presses with extra hydraulic cylinders and control circuits for the manufacture of fine blanked parts.
- Machine design:
- Design and manufacture of a hydraulic CNC sheet metal testing press (in cooperating with a team of professional engineers), capable of performing up to ten standard sheet metal tests such as Erichsen Cupping Test, Hole Expansion Test, Fukui Test, Forming Limit Diagram Test, Swift Deep Drawing Test, Engelhardt Test, Limiting Dome Height Test, Bulge Test, etc.
- Design and manufacture of rotary forging equipment. This machine was used for a precise and repeatable riveting process.
- Die casting and injection molding:
- I have translated a Die Casting Handbook from English to Persian. Also I have supervised the design and manufacture of die-casting dies for aluminum and zinc alloy parts. An example is a die-casting die for an aluminum wiper base with a 3D parting surface and two cam operated slides. The part had a tolerance of 0.05 mm between power axes and a no-void limitation.
- Design and manufacture of injection molding dies. Besides designing injection-molding dies, I have also designed and made a continuous high-pressure injection machine for continuous injection of solid slabs and cylindrical polymer parts.
- Cold extrusion of steel:
- Design and manufacture of a cold backward extrusion die for manufacturing hollow cylindrical steel parts. My master student was elected as the best master student of the year, between mechanical engineering departments of Iran.
- I had a Master student and currently have a PhD student who developed an FEM program for the simulation of bulk metal forming processes. In this code a flow formulation approach has been used. We have been able to improve prediction of hydrostatic stresses in bulk forming processes.
- I have also designed and made cold forward and backward extrusion dies for manufacturing a steel starter gear and a housing part. This is one of the most difficult processes that I have been involved with. I have a patent on cold Forward extrusion of steel gears.
Tube hydro-forming (THF):
At the Ohio State University, IWSE department, CEFT group, I have activated a new research area in the field of THF aiming at:
- Development of next generation of tubes for tube hydro-forming processes. These activities can include FEM modeling and experimental study of tubes made of lightweight materials such as aluminum, titanium alloys, combination of different material types and thickness, dual wall ribbed tubes, effects of anisotropy on tube hydro-forming process and analysis of failure modes and instability.
- Development of tools for tube hydro-forming process. These activities can include FEM modeling and experimental study of lubrication and surface coating, design of low weight and low cost tooling, design of tooling for warm tube hydro-forming, design and improvement of sealing systems, bending and preparation of preformed tubes, computer aided process control for better and improved formability, material selection for THF tools, secondary THF operations such as high pressure calibrating, hydro-piercing and improvement of fastening and/or joint methods. I have currently designed a tube hydro-forming apparatus to investigate experimentally different lubrication conditions and surface coatings, which is also extendable to warm THF.
At the Ohio State University, IWSE department, CEFT group, I have been involved in micro-forming and particularly micro-piercing of sheet metal parts.
- One objective of this investigation is feasibility study of micro-hydro-piercing process for the elimination of micro punches and other problems related to the punch such as its manufacture, assembly, and its guidance.
- The second objective is feasibility study of micro-piercing with solid punches by investigating new methods for manufacture of punch, die and their appropriate alignment and assembly problems.