Salman Pervaiz

Salman Pervaiz
Rochester Institute of Technology | RIT · Department of Mechanical Engineering

BSc MSc Tech-licentiate Doctor of Philosophy, Production Engineering from KTH Royal Institute of Technology , Sweden

About

100
Publications
43,321
Reads
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1,100
Citations
Introduction
My current research interests include sustainable manufacturing, material process modeling (FEM), minimum quantity lubrication (MQL), machinability of difficult to cut materials, & material damage analysis. The research is beneficial for the aerospace, automotive, industrial machinery, and oil& gas industries. Specialties: - Metal Cutting, Sustainable Manufacturing, Finite Element Based Machining Simulations, CFD for machining applications, FSW, Damage characterization and material testing
Additional affiliations
August 2016 - August 2021
Rochester Institute of Technology
Position
  • Professor (Assistant)
February 2009 - January 2016
American University of Sharjah
Position
  • Laboratory Instructor

Publications

Publications (100)
Article
The multi jet fusion (MJF) additive manufacturing techniques enable producing different complex geometries quickly with a relatively inexpensive product development process, using a thermoplastic powder, specifically polyamide 12 (PA 12). The multi jet fusion additive manufacturing technology aims to enhance the quality of parts quickly and inexpen...
Article
Full-text available
Aluminum closed cell syntactic foams possess reduced density, higher peak compression strength, and lower coefficient of thermal expansion and thermal conductivity compared to metal alloys. However, the industrial mass production of these complex material systems presents a significant problem in the form of poor machinability. In order to address...
Article
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In the recent times, with higher demand on the functionality of engineering materials, single crystal-based products start gaining a good reputation because of many different advantages. Single-crystal materials provide a uniform set of properties with fewer defects, such as traditional casting process facilitates polycrystalline formation which ha...
Article
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Inconel 718 is famous for its applications in the aerospace industry due to its inherent properties of corrosion resistance, wear resistance, high creep strength, and high hot hardness. Despite the favorable properties, it has poor machinability due to low thermal conductivity and high hot hardness. To limit the influence of high cutting temperatur...
Article
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The cutting tool heats up during the cutting of high-performance super alloys and it negatively affects the life of the cutting tool. Improved tool life can enhance both the machinability and sustainability of the cutting process. To improve the tool life preferably cutting fluids are utilized. However, the majority of cutting fluids are non-biodeg...
Article
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As machining processes are complex in nature due to the involvement of large plastic strains occurring at higher strain rates, and simultaneous thermal softening of material, it is necessary for manufacturers to have some manner of determining whether the inputs will achieve the desired outputs within the limitations of available resources. However...
Conference Paper
Additive manufacturing has been of interest in the recent years due to its popularity in small scale production and rapid prototyping. There is a wide variety of additive manufacturing processes that are practiced today such as Material Extrusion, Material Jetting, Binder Jetting and more. Although, quite a few of these processes generally offer lo...
Conference Paper
The different additive manufacturing (AM) technologies are showing a higher flexibility and process capabilities over the years, these technologies are not limited to produce a prototype only, but also to produce a valuable and cost-effective large near net parts. The Wire Arc Additive Manufacturing (WAAM) technique is regarded as one of the most i...
Conference Paper
In this paper, an extensive literature review of sustainable machining using different minimum quantity lubrication (MQL) variants is presented. Nowadays, sustainable development (SD) is referred as a common global issue. Sustainability concept in machining is linked with two major goals. The first goal is to reduce the environmental impact by redu...
Conference Paper
Metallic alloys with convex curved surfaces have large scale applications in several industries such as in the automotive, marine and aerospace industries. These curved surfaces are used in the applications where surface integrity is extremely important. A large amount of research has been conducted related to the finishing processes, such as surfa...
Article
Sheet metal forming operations are widely used in the industry because of their ability to produce complex shapes at higher production rates. These operations utilize high stresses to plastically deform workpiece in the desired geometry. For reliable performance, punch design and operating parameters can play significant role. To investigate the to...
Article
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Composite materials are a combination of two or more types of materials used to enhance the mechanical and structural properties of engineering products. When fibers are mixed in the polymeric matrix, the composite material is known as fiber-reinforced polymer (FRP). FRP materials are widely used in structural applications related to defense, autom...
Article
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In drilling operations, cutting forces are one of the major machinability indicators that contribute significantly towards the deviations in workpiece form and surface tolerances. The ability to predict and model forces in such operations is also essential as the cutting forces play a key role in the induced vibrations and wear on the cutting tool....
Article
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Wire electric discharge machining (WEDM) is a thermoelectrical process wherein workpiece surface integrity still remains a concern due to process-generated thermal damage. Recent developments in WEDM, such as the use of novel coated wires and multi-pass strategy, present opportunity for reducing this thermal damage and improve surface integrity. Av...
Article
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Cryogenic cooling is attributed as a green option to counter the high temperatures developed in machining process. The parameters specific to the cryogenic cooling such as jet radius and jet location have controlling influence on the machining performance. Inconel 718 is one of the most prominent aeronautic alloys, mainly used in the aerospace indu...
Article
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Key composite made aerostructures such as fuselage inner walls, flap support fairings, empennage ribs, and the vertical fin ribs are comprised of non-vertical inclined and radial holes that join with other key metallic and non-metallic structures. Carbon fiber reinforced plastics (CFRP) are also used in the aerospace, automotive, marine, and sports...
Conference Paper
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Minimum quantity lubrication (MQL) with nanocomposite particles is among the new areas of study and has proven to provide very good cooling and lubrication in the machining of difficult to cut materials, such as titanium, Inconel and ADI. It is therefore imperative to understand their effects on the environment in the early stages of investigation,...
Conference Paper
Because of the flexible nature of 3D printing and additive manufacturing technology, manufacturing sector has been revolutionized. There is a possibility to manufacture different intricate geometrics that cannot be produced through conventional processes previously. The conventional design concepts such as design for manufacture (DFM) and design fo...
Conference Paper
Finite element (FE) assisted numerical modeling approach is known as a popular approach to predict the machining performance of different machining operations. Tapping operation is a well-known manufacturing process that is used to cut threads efficiently. In the automotive and aerospace applications, precisely machined tapped holes are required in...
Article
Machining of novel light weight 7075 aluminum alloy reinforced with thin-walled hollow ceramic bubbles present a significant challenge to the manufacturing industry. The presence of hollow bubble phase causes poor surface finish and high machining cost. In this paper, an effort has been made to elucidate the mechanics of machining new grade AA7075...
Article
Full-text available
Machined surface quality and integrity affect the corrosion performance of AZ31 magnesium composites. These novel materials are preferred for temporary orthopedic and vascular implants. In this paper, the drilling performance of AZ31-magnesium reinforced with hollow alumina microsphere syntactic foam under LN2 cryogenic, dry, and Almag ® Oil is pre...
Article
Metal syntactic foams are a novel grade of materials that find potential applications in the manufacture of lightweight structural components and biomedical applications. For these materials to be inducted into industrial applications, it becomes imperative to study their machining behavior. In this paper, for the first time in the literature, mach...
Article
Full-text available
Nickel-based superalloys are famous in the demanding applications. Inconel 718 is one of the most commonly used nickel-based superalloys due to its extraordinary inherent properties. Inconel 718 is a suitable material for high temperature applications due to the properties such as anti-oxidization, high hot hardness, high creep, and fatigue strengt...
Article
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The role played by hollow ceramic thin-walled aluminium oxide microballoons on the shear deformation characteristics of AZ31 Magnesium syntactic foam is studied through high-speed machining. The ceramic microballoons embedded in the AZ31 matrix provides the necessary stiffness for these novel foams. The effect of hollow ceramic microballoon propert...
Article
Manufacture of modern aircraft components involve production of high value near net-shape carbon fiber reinforced polymer (CFRP) parts, which requires drilling holes for rivets and bolts at acute inclinations. The study explores the surface morphology of the inclined holes (30 ͦ, 60 ͦ, and 90 ͦ) drilled in CFRP under cryogenic cooling using coated...
Cover Page
Full-text available
There is a continuous growing concern in the machining of difficult-to-cut advanced engineering materials. These difficult-to-cut advanced engineering materials are favored for use in demanding applications due to their unique metallurgical properties, ability to operate at higher temperatures, resistance to corrosion and fatigue, etc. These materi...
Article
Electron beam melting (EBM) is one of the promising technologies with the capability of producing complex near-net shapes from difficult to process materials such as titanium alloys. However, the parts produced from the EBM process suffer from the poor surface quality and machining is required to finish the EBM parts to achieve the necessary surfac...
Conference Paper
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Compliant mechanisms are flexible devices that can produce useful work through elastic deformations. Compliance is a relatively novel approach, that contrasts with the conventional rigid body approach common in most mechanisms. The advantages of compliant mechanisms over conventional rigid body mechanisms include reduced parts, lower costs due to r...
Article
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Achieving the maximum material removal rate (MRRmax) is not always desired in machining especially during laser milling. Actual volume of the material removed during laser beam machining (LBM) is not always precisely equal to the designed volume. Dimensional accuracy of the laser milled feature requires the controlled layer of the substrate removal...
Conference Paper
Minimum quantity lubrication (MQL) assisted techniques are gaining popularity because of their lower environmental impact and cost effectiveness. Fibre reinforced polymers (FRP) are mainly utilized in the aerospace and automotive sectors, because of their high strength-to-weight ratio, low coefficient of thermal expansion, high corrosion resistance...
Conference Paper
Energy efficiency is an important aspect of all industrial processes. Sustainability in manufacturing sector can be improved by reducing and optimizing the energy requirements of the machine tool during the machining process. Growing energy demand and shortages in conventional energy sources have prompted research into energy conservation and susta...
Conference Paper
Drilling is one of most executed manufacturing operations to assist the assembling of different engineering components. In orbital drilling process, a milling tool is rotating along its own axis in combination with the spiral rotational movement. The rotation of tool about its own axis is with high rotational speed, but the spiral movement of tool...
Article
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Metal-cutting process deals with the removal of material using the shearing operation with the help of hard cutting tools. Machining operations are famous in the manufacturing sector due to their capability to manufacture tight tolerances and high dimensional accuracy while simultaneously maintaining the cost-effectiveness for higher production lev...
Conference Paper
Full-text available
Metal syntactic foams are a new grade of novel composites in which hollow ceramic microspheres are dispersed through the magnesium metal matrix. For a spectrum of applications, in the industries of interest and applicability, the chosen material needs to have good corrosion resistance, mechanical strength and energy absorption capabilities under co...
Article
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Cladded materials are heterogenous in nature and considered as difficult-to-cut especially via conventional machining operations. Gas and/or plasma cutting are common in practice to cut clad materials. However, these processes induce deeper heat-affected zones and provide very rough surface integrity. Wire electric discharge machining (WEDM) is a c...
Article
Nickel alloys including Inconel 718 are considered as challenging materials for machining. Laser beam machining could be a promising choice to deal with such materials for simple to complex machining features. The machining accuracy is mainly dependent on the rate of material removal per laser scan. Because of the involvement of many laser paramete...
Article
Titanium and its alloys especially Ti-6Al-4V are being widely used numerous application areas. In addition to have iconic properties, Ti-6Al-4V is considered as challenging material in machining perspective that is why it has captured global research focus. In this research, electric discharge machining of Ti-6Al-4V has been carried out by employin...
Article
Nontraditional machining processes are frequently used in product manufacturing when either the material is difficult to machine, or a very precise geometry is required. Electrical discharge machining (EDM) is considered as a popular nontraditional machining process. EDM process is used to machine a diverse range of engineering materials such as ha...
Article
Titanium alloys are generally known as difficult-to-machine materials because of their low machinability ratings. Their usage is favored for demanding sectors because of their high strength to weight ratio, high corrosion resistance and ability to operate at elevated temperatures. Machining of titanium alloys results in higher environmental burden,...
Chapter
Impact testing is commonly utilized to determine the fracture characteristics of engineering materials under dynamic loading. Materials have the tendency to behave differently under dynamic high rate loading as compared to their quasi static response. Additionally, impact testing can also reveal information about (i) a material’s resisting behavior...
Conference Paper
In machining operation, cutting tool performs a central role towards the overall machining performance. A user from metal cutting community always look for better cutting tools that can enhance productivity by reducing tool wear and cost. Modification in the micro-geometry of cutting edge is termed as edge preparation, and it is performed to improv...
Conference Paper
Energy security and resource depletion have been emerged as major threats when sustainability of manufacturing sector is considered. The rapid growth and development in the manufacturing sector also requires manufacturing companies to improve their performance towards energy and resource consumption. As manufacturing system deals with different inp...
Article
Gas/plasma cutting of cladded materials provides inferior cut quality that demands subsequent finishing processes. Abrasive waterjet cutting could be a proficient alternate in terms of cut quality. However, the inherent problem of kerf taper and low material removal rate in comparison to the said thermal cutting processes limit its application. The...
Chapter
Titanium alloys are mainly utilized in the aerospace, biomedical, power generation, automotive and marine sectors due to their high hot hardness, ability to operate at higher operating temperatures and resistance against corrosion. Alpha-beta titanium alloy (Ti6Al4V) is the most frequently used titanium alloy, mainly preferred for the applications...
Article
Full-text available
Electron beam melting (EBM) is one of the growing processes of additive manufacturing technology (AMT) to fabricate 3D parts from various difficult-to-process materials such as titanium alloys. A major limitation of the EBM process is the poor surface finish of the produced parts which ultimately demands a subsequent subtractive method (secondary f...
Article
Machining processes consume natural resources as input streams and generate intense heat during the cutting process due to excessive shearing caused by plastic deformation and friction. The excessive amount of heat generation in the cutting zone can impair the machining performance and service life of the product by reducing the tool life, disturbi...
Article
Full-text available
Titanium and its alloys e.g. Ti6Al4V have widespread applications in aerospace, automotive and medical industry. At the same time titanium and its alloys are regarded as difficult to machine materials due to their high strength and low thermal conductivity. Significant efforts have been dispensed to improve the accuracy of the machining processes f...
Article
Full-text available
Ti6Al4V is known as difficult-to-cut material due to its inherent properties such as high hot hardness, low thermal conductivity and high chemical reactivity. Though, Ti6Al4V is utilized by industrial sectors such as aeronautics, energy generation, petrochemical and bio-medical etc. For the metal cutting community, competent and cost-effective mach...
Conference Paper
Carbon Fiber Reinforced Polymer (CFRP) is favoured in the aerospace, automotive, structural and sports-based industries due to its high strength-to-weight ratio, rigidity and comparatively higher stiffness. CFRP is termed as a difficult-to-machine material due to the problems associated with its machined quality, surface integrity and tooling cost....
Conference Paper
Machining operations such as reaming, boring or milling create undesirable extruded sharp edges at the entry and exit side of the machined holes. These sharp burrs / extruded edges act as stress concentration regions for fatigue crack propagation in safety critical aerospace components. In this paper, results of an experimental investigation carrie...
Article
Full-text available
Nickel based super alloys manufactured through powder metallurgy (PM) route are required to increase the operational efficiency of gas turbine engines. They are material of choice for high pressure components due to their superior high temperature strength, excellent corrosion, oxidation and creep resistance. This unique combination of mechanical a...
Article
Full-text available
During the metal cutting operation, heat generation at the cutting interface and the resulting heat distribution among tool, chip, workpiece, and cutting environment has a significant impact on the overall cutting process. Tool life, rate of tool wear, and dimensional accuracy of the machined surface are linked with the heat transfer. In order to d...
Article
Full-text available
BK7 glass is an important engineering material with extensive applications in high-quality and precision transmissive optical components. However, BK7 glass is considered to be a difficult-to-cut material due to its high brittleness and nonconductivity. This article presents the use of rotary ultrasonic machining process for drilling holes in BK7 g...
Article
Full-text available
Electron beam melting (EBM), an additive method and rotary ultrasonic machining (RUM), a subtractive technique have been in great demand owing to their innumerable benefits. These techniques can manufacture components from titanium alloys (such as Ti-6Al-4 V) for industries such as aerospace, medical, and automotive, etc. However, these techniques...
Article
Full-text available
Sustainable development has been recognized globally as one of the major driving forces towards the current technological innovations. To achieve sustainable development and attain its associated goals, it is very important to properly address its concerns in different aspects of technological innovations. Several industrial sectors have enjoyed pr...
Article
Full-text available
Shielded metal arc welding (SMAW) process is one of the most commonly employed material joining processes utilized in the various industrial sectors such as marine, ship-building, automotive, aerospace, construction and petrochemicals etc. The increasing pressure on manufacturing sector wants the welding process to be sustainable in nature. The SMA...
Conference Paper
Sustainable development has been recognized globally as one of the major driving forces towards the current technological innovations. To achieve sustainable development and attain its associated goals, it is very important to properly address its concerns in different aspects of technological innovations. Several industrial sectors have enjoyed pr...
Conference Paper
Shielded metal arc welding (SMAW) process is one of the most commonly employed material joining processes utilized in the various industrial sectors such as marine, ship-building, automotive, aerospace, construction and petrochemicals etc. The increasing pressure on manufacturing sector wants the welding process to be sustainable in nature. The SMA...
Conference Paper
Composite sandwich structures are constructed by adding a light weight thick core material surrounded by thin rigid sheets as skins or faces. These structures mainly offer high specific strength-to-weight ratio due to which they are mainly employed in construction, automotive, marine and aerospace sectors. In most of the applications it is importan...
Article
Full-text available
In the last many decades, the usage of cutting fluid is a common technique for improving the machinability of metals. The application of cutting fluid during the machining phase significantly influences the environmental burden of the process. The disposal of these cutting fluids imposes threat to the environment due to their high noxiousness and n...
Conference Paper
The major global drivers affecting our societies are listed ‎as human population, food based ‎security, energy based ‎security, resource depletion, emissions and associated ‎climate ‎change, community safety, transportation and ‎economic globalization. Out of these global ‎drivers, the most ‎important global driver is identified to be the human ‎po...
Article
Full-text available
During the machining operation, elevated temperatures are achieved at the cutting interface due to the presence of high plastic deformation and friction in between the tool and chip contacting area. Efficient heat dissipation from the cutting interface is required to achieve better machining performance. Elevated temperature in the cutting area res...
Article
This study investigates the energy consumption involved in the machining of AISI 1045 steel using uncoated carbide tools. Energy utilised in the machining operation is termed as an important machining performance indicator that has direct influence on the greenhouse gas (GHG) emissions. The present study utilised finite element modelling (FEM) tech...