Mohamed EL Mansori

Mohamed EL Mansori
Ecole Nationale Supérieure d'Arts et Métiers | ENSAM · Laboratoire Mécanique, Surfaces, Matériaux et Procédés (MSMP)

PhD, HDR

About

302
Publications
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Publications

Publications (302)
Book
Full-text available
New materials are constantly being developed which may improve or transform many aspects of our lives, and nowhere is this more exciting than in the fields of vehicle and machinery technology. This book presents the proceedings of the 2022 International Conference on New Materials, Machinery and Vehicle Engineering (NMMVE 2022), held as a virtual...
Article
Full-text available
4D printing of shape memory polymers (SMPs) with the Fused Deposition Modeling (FDM) technique is still a dominant challenge, especially those SMPs having lower glass transition temperatures are prone to higher thermal strains during the FDM printing process. Cross-layer reheating events primarily affect the degree of residual stresses causing warp...
Article
Full-text available
The filling stage is a critical phenomenon in sand casting for making reliable castings. Latest research has demonstrated that for most liquid engineering alloys, the critical meniscus velocity of the melt at the ingate is in the range of 0.4–0.6 m s−1. The work described in this research paper is to use neural network (NN) technology to propose di...
Article
Full-text available
Natural fiber reinforced polymers (NFRPs) are environmentally friendly and are receiving growing attention in the industry. However, the multi-scale structure of natural fibers and the random distribution of the fibers in the matrix material severely impede the machinability of NFRPs, and real-time monitoring is essential for quality assurance. Thi...
Article
Carbon fiber-reinforced polymer composites have been mainly used for several applications owing to their thermo-mechanical properties. Fused deposition modeling is a rapidly growing additive manufacturing technology owing to its ability to create a functional part with complex geometries. The tensile properties of polyamide-6 and carbon fiber-reinf...
Article
This work investigates the defects (pore and lack of fusion), microstructure, and fatigue properties of Sc and Zr-modified Al–Mg alloy on different building directions fabricated by laser powder bed fusion (LPBF). The results showed that transversely deposited (TD) samples exhibited a superior fatigue strength (100.5 MPa) compared to that (57 MPa)...
Article
Concrete walls are constructed by pouring fresh concrete in-between formworks. The lifespan of these formworks is limited due to the abrasive nature of concrete. The present work investigates the wear of metallic and polymeric-coated plates in contact with fresh concrete. Two formulations were studied: standard concrete and self-consolidating concr...
Article
Sintering is a comprehensive process that involves the complex evolution of material microstructures and properties, being recognized as a critical factor to improve the machinability of ceramics. The present work aims to address the evolution of the material removal mechanisms of the 3 mol% yttria-stabilized tetragonal zirconia polycrystal (3Y-TZP...
Research Proposal
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The topics of interest include but are not limited to: Fabrication and characterization of advanced coating materials; Evaluation of cutting performances of coated tools; Modeling and simulation of machining operations using coated tools; Machinability assessment of hard-to-cut materials; Thermal and frictional behaviors of coating materials; Wear...
Article
Sintering is a comprehensive process that involves complex evolution of material microstructures and properties, being recognized as a key factor to improve the machinability of ceramics. The present study aims to address the densification mechanisms of 3 mol% yttria-stabilized tetragonal zirconia polycrystal (3Y-TZP) based on the properly designed...
Article
The use of machine vision systems for Quality Control (QC) of reflective metal surfaces has increased over the years with new systems that combine higher resolution cameras and better illumination of inspected objects. With the advances in Artificial Intelligence (AI) pattern recognition of images, the integration of a machine vision systems in a m...
Article
Full-text available
Tribo-peening is a unique derivative process of shot peening to produce functional surface with fully localized or distributed deformation induced by the impact and friction of activated formed and dispersed shot particles. This research paper discusses a methodology to develop a smart tribo-peening of surface functionalization with the aim of cont...
Article
Full-text available
This paper reports an intelligent approach for modeling and optimisation of filling system design (FSD) in the case of sand casting process of aluminium alloy. In order to achieve this purpose, physics-based process modeling using finite element method (FEM) has been integrated with artificial neural networks (ANN) and genetic algorithm (GA) soft c...
Article
Full-text available
The present work addresses the printed sand mold thickness effect on the solidification process of a eutectic aluminum-silicon alloy (AlSi13). Several sand mold thicknesses (varying from 3 to 30 mm) are numerically studied using Quikcast® software. The study shows that the solidification time decreases when the sand thickness of mold increases. It...
Preprint
Full-text available
Natural fiber reinforced polymers (NFRPs) are environmentally friendly and are receiving growing attention in the industry. However, the multi-scale structure of natural fibers and the random distribution of the fibers in the matrix material severely impede the machinability of NFRPs, and real-time monitoring is essential for quality assurance. Thi...
Article
The wear of aluminum alloy may be decreased by its reinforcement with quasicrystals (QCs) prepared by melt, which in itself has good wear-resisting properties. This research paper considers the part played by a dense Al-Fe-Cr QC reinforced Al matrix composite fabricated by the directed energy deposition (DED) in reducing wear between sliding surfac...
Article
Full-text available
This paper aims to investigate the frictional and wear performances of natural flax fibers reinforced polypropylene composites subjected to lubricated mechanical polishing. Particularly, the interactions between the biocomposite surfaces and two different liquids (oil and water) are considered using a rotary tribometer where the counter-face is fed...
Article
Machining of biocomposites using traditional techniques has shown some limitations due to the multiscale complex cellulosic structure of natural fibrous reinforcement. This paper aims to demonstrate the feasibility of the cryogenic nitrogen jet, which is a novel cutting process that combines sustainable resources and cryogenic temperatures from -15...
Article
The current work aims to investigate the effectiveness of surface textures on improving the wear performance of 3Y-TZP zirconia restorations and the operating mechanisms of surface texture under different lubrication conditions and with different counter bodies. A series of sliding wear tests against Si3N4 ceramics and 304 stainless steel were cond...
Article
3D sand mould printing through binder jetting can solve many technical issues in casting including part consolidation, design of parts to optimise the consumption of materials and hazardous chemicals, and on-demand and any size part manufacturing near the customer. Incorporating artificial intelligence in optimising the design of moulds, printing p...
Article
Mechanical drilling of carbon fiber reinforced polymers (CFRPs) has been notoriously difficult due to the high abrasiveness of reinforcing fibers and the anisotropic behavior of the constituents leading to poor hole quality and rapid tool wear. Special drill bits featured by novel geometrical designs have been proved as a promising alternative to c...
Article
Full-text available
This paper aims to investigate the effect of water absorption on the cutting behavior of biocomposites using flax fiber reinforced polylactic-acid (PLA) and the orthogonal cutting process. Different immersion times have been considered from 1 to 150 days in order to investigate both transient and saturated hygrometric regimes. Machining forces are...
Article
In the course of the selective laser melting (SLM) process, the part is built layer by layer involving partial re-melting/heating of the previous layer, called as intrinsic heat treatment. Therefore, superficial properties of as-built parts are somewhat different from that of the inside of the part. In this work, the nano-tribological behavior of c...
Chapter
Full-text available
The use of natural fibers in composite industry requires a deep understanding of their complex mechanical behavior related to their multiscale cellulosic structure. This article aims to investigate the tribo-mechanical properties of flax fiber reinforced polypropylene composites using nanoindentation and scratch-test techniques in order to analyze...
Chapter
Full-text available
Machinability qualification of natural fiber composites requires a specific approach that involves the multiscale structure of natural fibers. This article addresses the machining qualification issues for natural fiber composites and proposes a new multiscale approach to analyze the topography of the machined surfaces. Results show that machining o...
Chapter
Full-text available
The machinability of thermoplastic natural fiber composites is investigated in this article. An exploratory study is performed to investigate the effect of natural fiber type, fiber reinforcement structure, tool geometry, and process parameters on the cutting behavior of natural fibers under the usual machining processes. Results show how the cutti...
Chapter
Full-text available
This article presents a 2D micromechanical model developed to predict the machining behavior of natural fiber composites using the finite element (FE) method. Natural fibers are modeled using an elasto-plastic behavior and a ductile criterion for failure. The FE model has been performed for the orthogonal cutting of flax fiber reinforced polymer co...
Research Proposal
Full-text available
CALL FOR PAPERS: The emergence of fibre-reinforced composites can be regarded as a significant breakthrough in the development era of new materials in human society. This can be seen by their huge impacts on the material distributions in diverse industrial fields due to their superior mechanical/physical properties and flexible structural functiona...
Article
Full-text available
A relatively new methodology bridging FEM and Artificial Neural Network (ANN) is proposed and validated in this study to optimize the gating system design for smart 3D sand casting. This methodology was applied on the case of 3D sand casting of a simple plate with aluminum alloy (EN AC-44200). Several mold-filling simulations are performed with the...
Article
Concrete, a commonly used material in the construction industry, interacts with metallic surfaces such as formwork during pouring and reinforced bar during lifespan. Formworks are designed to minimize hardened concrete adherence in order to avoid wall defects after formwork removal. In opposite, reinforced bar designs aim at maximizing their adhere...
Article
Full-text available
Ti6Al4V alloys are often employed in conjunction with carbon fiber–reinforced polymers (CFRPs) to create hybrid structures for aerospace applications. The introduction of the fibrous composites brings significant challenges to the titanium alloys with extremely poor machinability. Since the minimum quantity lubrication (MQL) is reported as a techno...
Article
3D printed sand molds for the casting industry play a vital role in manufacturing intricate parts using a computer model. The possibility of producing fairly significant structural castings using a small job-box 3D sand mold printer is another advantage compared to the direct metal 3D printing processes. It is important to identify the relationship...
Article
In this work, a novel tungsten steel was in-situ prepared using selective laser melting (SLM) and hot isotropic pressing (HIPing). The sample is firstly prepared by SLM from powder mixture of maraging steel and WC for the net-shaped manufacturing requirement. Then, the effects of HIPing on microstructure evolution and mechanical properties of SLMed...
Article
Binder jet 3D printing of ceramic materials is an additive manufacturing technology that enables the production of complex and multi-functional parts through the selective jet binding of precursor powder beds. The present study makes use of the 3D Sand Printing (3DSP) process to create moulds and cores in the casting industry. The use of the 3DSP c...
Article
Full-text available
This paper aims to enhance the predictiveness of a finite element (FE) model for machining of natural fiber composites through a tribological approach based on the micro-friction phenomenon between the cutting tool and the components of the composite structure. A 2D micromechanical model for orthogonal cutting of flax fibers reinforced polylactic-a...
Article
Full-text available
Manufacturing processes of natural fiber reinforced polymer (NFRP) composites are becoming the interest of industrials and scientists because these eco-friendly materials are emerging in automotive and aerospace industries. In this context, machining processes of NFRP composites present significant issues related to the complex structure of natural...
Article
Natural fiber reinforced plastic (NFRP) composites are eliciting an increased interest across industrial sectors, as they combine a high degree of biodegradability and recyclability with unique structural properties. The heterogeneous structure of these materials—resulting from different fiber orientations and their complex multi-scale structure –i...
Chapter
The present study aims at enhancing the comprehension of the interactions between shot and target during shot-peening process, with focus on the energy transmitted and roughness generation. A single impact approach was developed in order to establish relations between the process parameters, media and target properties, and the generated surface st...
Article
Full-text available
As the current trend in the manufacturing industry is moving toward cleaner production and sustainable manufacturing, selecting a proper cooling method is of vital importance to reduce the environmental and economical impacts of machining processes. Thus, one of the biggest challenges a manufacturer faces when machining titanium-composite stacks is...
Article
Full-text available
In this paper, we have studied the effect of the degree of asymmetry and peakedness on the performances of a rough contact. A numerical model is proposed to evaluate the real area, the number of contacting asperities and the normal stiffness. The contact between two rough surfaces was modeled as a contact between a rigid flat and an elastic–plastic...
Article
This paper introduces a hybrid model that incorporates a convolutional neural network (CNN) with a stacked bi-directional and uni-directional LSTM (SBULSTM) network, named CNN-SBULSTM, to address sequence data in the task of tool remaining useful life (RUL) prediction. In the CNN-SBULSTM network, CNN is firstly utilized for local feature extraction...
Article
Although minimum quantity lubrication (MQL) has been proved beneficial for the machinability improvement of metallic materials, it is still not well understood whether or not to use the MQL when machining the composite-titanium stacks and whether the MQL can achieve a comparable effect as it operates in the metal cutting processes. The current work...
Article
Full-text available
This paper aims to develop a 2D finite element (FE) model at microscale for numerical simulation of the machining behavior of natural fiber-reinforced polymer (NFRP) composites. The main objective of this study is to reproduce the experimentally observed specific cutting behavior of natural fibers within the composite material. Flax fibers reinforc...
Article
Full-text available
Accurate characterization of the mass transport properties of additively processed sand molds is essential in order to achieve reproducibility of the produced castings and control of gas defects in foundry industries. The present work highlights the potential use of X-ray micro-computed tomography (µ-CT) to characterize the evolution of permeabilit...
Article
In drilling CFRP/Ti6Al4V stacks, the cutting sequence strategy, which determines the coupling effects of each phase machining, affects significantly the machinability of the sandwiched material as well as the tool wear characteristics. The present paper contributes to a scientific understanding of the effects of different cutting sequence strategie...
Article
Zirconia ceramics are promising restorative materials that are being extensively used in clinical dental prosthodontics such as inlays, implant crowns and fixed bridges due to their high strength, high toughness, high corrosion resistance and excellent esthetical effects. However, in addition to the superior mechanical and physical properties, the...
Article
In this work, almost dense (over 99.8 %) Ti-Mo alloy samples were manufactured by directed energy deposition (DED) from a mixture of pure Ti and pure Mo (7.5 wt.%) powders. As a consequence of thermal accumulation and in-situ heat treating during the DED process, as-deposited samples present a graded microstructure along the building direction alon...
Conference Paper
Full-text available
a. Laboratoire MSMP-EA 7351, Ecole nationale supérieure d'arts et métiers ParisTech, 2cours des arts et métiers, 13617 Aix-en-Provence, France Résumé : La présente étude porte sur le procédé d'impression 3D au sable habituellement utilisé pour la création de pièces et moules dans l'industrie de la fonderie. L'utilisation des pièces obtenues par ce...
Article
In aluminum low-pressure sand casting process, filling oscillations are observed when the metal front reaches a section change in a part. The effect of geometry on the filling oscillations is primary considered experimentally, including both mold cavity and filling system geometries. To highlight the geometric parameters impacting the oscillations,...
Article
Full-text available
Machining of high-strength carbon fiber reinforced polymers (CFRPs) has faced great challenges in quality control and tool wear management due to their inherent heterogeneity and high abrasiveness leading to serious workpiece damage and rapid tool wear. The present paper contributes to an experimental investigation of evaluating the machinability o...
Article
Full-text available
The enhanced mechanical/physical properties and improved functionalities have made the carbon fiber–reinforced polymer/titanium alloy (CFRP/Ti6Al4V) stacks very attractive to the modern aerospace industry. However, the current knowledge of machining CFRP/Ti6Al4V stacks remains insufficient to guide their industrial applications. The main contributi...
Article
The present paper aims to utilize the orthogonal cutting method to offer an enhanced interpretation of the drilling process on CFRP/Ti6Al4V stacks. It contributes to relating the chip separation modes of the orthogonal cutting of multilayer CFRP/Ti6Al4V stacks with their drilling characteristics. A particular focus was made to identify the effect o...
Conference Paper
Full-text available
One of the major concerns in sand molding using Three-Dimensional Printing (3DP) technology is the proper characterization of the local density and permeability of the mold for quality assessment without destruction. Molding sand compaction and liquid binder jetting bonding plays a crucial role on the mold quality and hence the quality of casting....
Article
Full-text available
This paper aims to explore the thermal influence on the micro-tribo-mechanical behavior of natural fiber composites. Nanoindentation and scratch-test are used to characterize flax fibers reinforced polypropylene (PP) composites. Results show a different thermo-mechanical behavior between flax fibers and PP matrix. While the stiffness of PP matrix d...
Article
Full-text available
3D printing sand mold technology offers an opportunity for the foundry industry to rethink old casting approaches and to revive the manufacturing approach using computer models. One of the major concerns in sand molding using 3D printing is the functional characterization of the 3D printed molds as its mechanical and mass transport properties. This...
Article
Full-text available
Tribological mechanisms that control machining of natural fiber reinforced plastic (NFRP) composites are different from those of synthetic fiber composites in terms of cutting forces, tool wear, and surface finish. The aim of this paper is to investigate the cutting performances of NFRP composites using improved milling tool geometry with doublecro...
Article
Multiple parallel scratches are often analyzed to understand the material removal mechanisms due to abrasion. However, successive scratches with different orientations may represent better the conditions found in machining processes, such as honing and belt finishing. The objective of this work was to analyze the cutting forces and the phenomena of...
Article
Metal-matrix composites with solid lubricant reinforcements may present a suitable alternative to improve the tribological behavior of sintered components. Besides the performance during the application, the presence of solid lubricants may also modify component manufacture, for example, during machining operations to achieve complex shapes not dir...
Article
In this work, the tribological behaviour of selective laser melting (SLM)processed hypereutectic Al-Si alloy is investigated by the ball on disc test with focus on the effect of silicon content (18 and 50 wt %). Different from the conventional casted sample, the SLM processed sample shows an ultra-fine microstructure with silicon size inferior to 5...
Article
Drilling CFRP/Ti6Al4V stacks in one-shot time becomes essential in the modern aerospace manufacturing sectors in order to guarantee the productivity due to the demands of riveting and fastening assembly. In the present study, a novel integrated system of low frequency vibration assisted drilling (LFVAD) coupled with the forced air-cooling was desig...
Article
Metals remain the essential structural material for many demanding engineering applications requiring high strength at elevated temperatures and good performance in environments subjected to high thermal fluctuations such as often encountered in the automotive, rail and aircraft industries. The sand-casting process is one of the most preferred meth...
Article
In Low Pressure Casting (LPC), the counter gravity filling at low velocity and the protective gas atmosphere above the metal can potentially reduce gas and oxides entrapment in the metal. However, the relationship between the imposed gas pressure evolution and the melt filling dynamics cannot be analytically determined as it is geometry-dependent....
Article
Full-text available
High-strength carbon fiber reinforced polymer (CFRP) composites have become popular materials to be utilized in the aerospace and automotive industries, due to their unique and superior mechanical properties. An understanding of cutting temperatures is rather important when dealing with high-strength CFRPs, since machining defects are likely to occ...
Article
Full-text available
The sticking of the concrete on metallic formworks during building construction generates many concrete wall defects. Several solutions have been proposed, among which surface lubrication and polymeric coatings are commonly applied. In this paper, the main functional signatures of a steel formwork skin and a polymeric coating were determined to und...