Sasan Sattarpanah Karganroudi

Sasan Sattarpanah Karganroudi
University of Quebec at Trois-Rivieres · Département de Génie Mécanique

PhD
Smart manufacturing, 3D geometric inspection, GD&T, FEA, Laser manufacturing process, Optimization, DoE, AI

About

69
Publications
22,828
Reads
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758
Citations
Introduction
Smart 3D geometrical inspection using laser scanners; Geometric dimensioning and tolerancing (GD&T); Smart manufacturing; Laser welding, surface and heat treatment; Induction heating; FEA; Additive manufacturing (SLM, FDM 3D printing)
Additional affiliations
September 2020 - present
Université du Québec à Rimouski UQAR
Position
  • Lecturer
Description
  • smart inspection using laser scanners, geometric dimensioning and tolerancing (GD&T), smart manufacturing using laser welding, steel heat treatment using induction heating method, spot welding, additive manufacturing (3D printing) SLM FDM
September 2018 - April 2021
Institut Technologique de Maintenance Industrielle (ITMI)
Position
  • Head of Department
Description
  • Industry 4.0; FEA; computer-aided design manufacturing and inspection; predictive-preventive maintenance and condition monitoring; computerized maintenance management (CMMS); smart manufacturing and inspection
August 2017 - present
Université de Sherbrooke
Position
  • PostDoc Position
Description
  • vibration and structural analysis of aeolian cables for electrical energy transport
Education
January 2013 - August 2017
University of Quebec at Trois-Rivieres
Field of study
  • Mechanical engineering

Publications

Publications (69)
Article
Computer-aided inspection (CAI) of non-rigid parts significantly contributes to improving performance of products, reducing assembly time and decreasing production costs. CAI methods use scanners to measure point clouds on parts and compare them with the nominal computer-aided design (CAD) model. Due to the compliance of non-rigid parts and for ins...
Conference Paper
This paper introduces a novel approach for inspecting non-rigid structures, which are difficult to assess using traditional methods due to their flexibility and susceptibility to deformation. Our method enables comprehensive geometric inspection by integrating mobile robotics and 3D laser scanning. The system autonomously navigates around the struc...
Article
Full-text available
This bibliographic analysis explores the evolving landscape of additive manufacturing (AM) in the context of Industry 4.0 and the emerging paradigms of Industry 5.0. This research critically examines the key literature and scholarly works to clarify the evolution, challenges, and opportunities presented by integrating AM technologies with digital t...
Article
Full-text available
This study explores the impact of transfer learning on enhancing deep learning models for detecting defects in aero-engine components. We focused on metrics such as accuracy, precision, recall, and loss to compare the performance of models VGG19 and DeiT (data-efficient image transformer). RandomSearchCV was used for hyperparameter optimization, an...
Article
Full-text available
Infrastructure maintenance is critical to ensuring public safety and the longevity of essential structures. Nondestructive Evaluation (NDE) techniques allow for infrastructure inspection without causing damage. Computer vision has emerged as a powerful tool in this domain, providing automated, efficient, and accurate solutions for defect detection,...
Article
The accurate prediction of remaining useful life (RUL) can serve as a reliable foundation for equipment maintenance, thereby effectively reducing the incidence of failure and maintenance costs. In this study, a novel deep learning (DL) framework that incorporates functional principal component analysis (FPCA) and enhanced temporal convolutional net...
Article
Full-text available
The Applied Sciences Editorial Office retracts the article, “Laser Welding of UNS S33207 Hyper-Duplex Stainless Steel to 6061 Aluminum Alloy Using High Entropy Alloy as a Filler Material” [...]
Article
Selective laser melting (SLM) is an advanced additive manufacturing technology that creates complex geometries that were previously impossible to produce. However, for industrial applications that require the highest standards, the performance of SLM-manufactured metal components still needs to be improved. Therefore, post-processing heat treatment...
Article
In the context of global efforts to mitigate climate change by pursuing sustainable energy sources, wind energy has emerged as a critical contributor. However, the wind energy industry faces substantial challenges in maintaining and preserving the integrity of wind turbine blades. Timely and accurate detection and classification of blade faults, en...
Article
This investigation delves into the residual stresses that arise during the deep drawing process of laser-welded blanks (LWBs) using a combination of experimental and numerical methods. While LWBs are preferred for their low distortion and high-quality welds, they are subjected to detrimental residual stresses during forming operations that can adve...
Preprint
Full-text available
Accurate condition monitoring has been a major challenge among railroad management authorities as they work to minimize collisions that lead to fatalities or damage to railroads infrastructure. Hence, research and technological developments in railroad maintenance and inspection are vital. Several research studies, on the inspection and defect dete...
Article
Accurate condition monitoring has been a major challenge among railroad management authorities as they work to minimize collisions that lead to fatalities or damage to railroads infrastructure. Hence, research and technological developments in railroad maintenance and inspection are vital. Several research studies, on the inspection and defect dete...
Article
Metal additive manufacturing is revolutionizing how we produce and use materials. Selective Laser Melting (SLM) is one of the most popular additive manufacturing techniques for creating high-performance metal components. Stainless Steel is preferred for additive manufacturing due to its powder form availability, low cost, mechanical properties, and...
Article
Full-text available
Selective laser melting (SLM) process produces high-performance metal parts using a layer-by-layer technique involving various influential factors. Nevertheless, there is a research gap in predictive models for the performance of SLM-processed 316L stainless steel, specifically concerning the effect of process parameters and their interactions. To...
Article
Full-text available
Wind energy has emerged as a critical source of renewable energy worldwide, and the performance of wind turbines relies heavily on the quality and design of their blades. However, the manual manufacturing process of wind turbine blades using polymeric matrix composite materials makes them susceptible to irregular and complex loading damage. This da...
Preprint
Full-text available
Many contributory factors can influence the quality of the deep drawing process, among which Blank Holder Force (BHF) plays a decisive role. Therefore, controlling the BHF during the deep drawing process can bring many advantages and act as a deterrent against process failures, including tearing, wrinkling, and fatigue due to excessive residual str...
Article
Full-text available
In an increasingly competitive industrial world, the need to adapt to any change at any time has become a major necessity for every industry to remain competitive and survive in their environments. Industries are undergoing rapid and perpetual changes on several levels. Indeed, the latter requires companies to be more reactive and involved in their...
Chapter
Nowadays, computer-aided inspection (CAI) is used to cope with increasing complexity in part manufacturing and the difficulty of physical access to certain workplaces. Therefore, manufacturing companies adopt automated CAI methods to increase the efficiency of the control quality activities. This study aims to capture the current state of the art o...
Chapter
In modern Industrial and manufacturing systems, digitalization and sustainability are significant areas which are affecting all equipment of the manufacturing chain. In the fourth industrial revolution era (industry 4.0), maintains play a key role in sustainable manufacturing and production system. Meanwhile, maintenance 4.0 as a part of industry 4...
Article
In this research, forming limit diagram (FLD) of aluminum alloy 1050 (AA 1050) sheet produced by Accumulative Roll Bonding (ARB) is investigated numerically and experimentally. The Gurson-Tvergaard-Needleman (GTN) ductile damage model is used to predict sheet failure and obtain its FLD using numerical simulation in Abaqus/Explicit. Nucleation and g...
Article
Full-text available
In this study, a novel approach for residual stress (RS) distribution on forged AA7175 is considered to replace and simplify the manufacturing process, based on the lean manufacturing concept. AA7175 alloy is a quench-sensitive material applied in the aeronautics industry, which is subjected to vibration and cyclic loads leading to fatigue failure....
Article
Full-text available
Wind turbines are known to be the most efficient method of green energy production, and wind turbine blades (WTBs) are known as a key component of the wind turbine system, with a major influence on the efficiency of the entire system. Wind turbine blades have a quite manual production process of composite materials, which induces various types of d...
Article
Full-text available
Inspection methods, also known as non-destructive evaluation (NDE), is a process for inspecting materials, products, and facilities to identify flaws, imperfections, and malfunctions without destruction or changing the integrity of materials, structures, and mechanisms. However, detecting those defects requires test conducting and results inferring...
Article
Full-text available
The coronavirus disease 2019 (COVID-19) rapidly spread to over 180 countries and abruptly disrupted production rates and supply chains worldwide. Since then, 3D printing, also recognized as additive manufacturing (AM) and known to be a novel technique that uses layer-by-layer deposition of material to produce intricate 3D geometry, has been engaged...
Article
Full-text available
The increase in the maturity level and the competitiveness of renewable energy systems, such as wind or solar-powered systems, is modifying the energy production market. Due to the possibility of decentralizing energy sources, standalone hybrid energy systems are those with the most promising potential. They generate a whole new electricity distrib...
Article
Full-text available
In the present paper, continuous Ytterbium Laser Systems (YLS) fiber laser hardening of cylindrical AISI 4340 steel specimens was studied using experimental and statistical analyses. Three laser parameters, namely laser power, laser feed speed, and sample rotation speed were selected to evaluate their influence on the depth of the hardened zone and...
Article
Full-text available
Coordinate measuring machines (CMMs) are massively exploited as measuring tools in the modern manufacturing industry. The performance of these machines, in terms of accuracy, has been considerably improved in recent years by using quasi-static errors compensation. Considering the shorter cycle times required during measurement tasks, CMMs are to be...
Preprint
Full-text available
The Coronavirus disease 2019 (COVID-19) rapidly spread to over 180 countries and abruptly disrupted the production rates and supply chains worldwide. Since then, 3D printing also recognized as additive manufacturing (AM) and known to be a novel technique that uses layer-by-layer deposition of material to produce the intricate 3D geometry, has been...
Article
Full-text available
In the era of the fourth industrial revolution, several concepts have arisen in parallel with this new revolution, such as predictive maintenance, which today plays a key role in sustainable manufacturing and production systems by introducing a digital version of machine maintenance. The data extracted from production processes have increased expon...
Article
Full-text available
In the present paper, continuous Ytterbium Laser Systems (YLS) fiber laser hardening of cylindrical AISI 4340 steel specimens was studied using experimental and statistical analyses. Three laser parameters, namely laser power, laser feed speed, and sample rotation speed were selected to evaluate their influence on the depth of the hardened zone and...
Article
Full-text available
Nowadays, productivity challenges in modern manufacturing systems have been the driving force in generating energy-efficient technologies in every industry, including diesel–electric locomotives. The diesel–electric locomotive is one of the most widely used methods in rail transportation, especially in North America. More precisely, the evolution o...
Article
Full-text available
The benefits of laser welding include higher production values, deeper penetration, higher welding speeds, adaptability, and higher power density. These characteristics make laser welding a superior process. Many industries are aware of the benefits of switching to lasers. For example, metal-joining is migrating to modern industrial laser technolog...
Article
Full-text available
This paper aims at investigating the effect of laser welding parameters on the hardness profile, using hardness mapping analyses, and welding geometry of galvanized steel plates. Hardness distribution and geometry deflection of galvanized welded thin plates are commonly applied in fields where weld quality is of utmost importance. Due to the weldin...
Preprint
Full-text available
In the present paper, continuous Nd:YAG laser hardening of cylindrical AISI 4340 steel specimens was studied using experimental and statistical analyses. Three Laser parameters namely laser power, laser feed speed, and sample rotation speed were selected to evaluate their influence on the depth of the hardened zone, and the maximum surface hardness...
Article
Full-text available
Rail transport, specifically diesel-electric trains, faces fundamental challenges in reducing fuel consumption to improve financial performance and reduce GHG emissions. One solution to improve energy efficiency is the electric brake regenerative technique. This technique was first applied on electric trains several years ago, but it is still consi...
Article
Full-text available
The manufacturing industry has undergone numerous revolutions over the years, with a unanimous acceptance of the greater benefits of being sustainable. The present industrial wave—Industry 4.0—by using its enabling technologies and principles holds great potential to develop sustainable manufacturing paradigms which require balancing out the three...
Article
Full-text available
In this article, the forming limit diagram (FLD) for aluminum 6061 sheets of thicknesses of 1 mm and 3 mm was determined numerically and experimentally, considering different punch velocities. The punch velocity was adjusted in the range of 20 mm/min to 200 mm/min during the Nakazima test. A finite element (FE) simulation was carried out by applyin...
Article
Full-text available
In this study, Al1050 sheets were fabricated in five passes using the accumulative roll bonding (ARB) technique. For a more accurate and complete investigation, different tests were used, including a uniaxial tensile test. The results show that elongation increases about 50% for the annealed sample, which is 2.5 times that of the fifth pass (20%)....
Article
Full-text available
In this study, welding and forming defects in a deep drawing process of laser-welded blanks (LWBs) are investigated both experimentally and numerically. LWB is used to achieve minimum distortion and desirable weld quality. However, some unfavorable residual stresses are added throughout the forming operations, which decrease the lifetime of LWBs. T...
Article
The set covering problem is a fundamental model which comprises a wide range of important applications such as crew scheduling problems that need to cover a set of trips. It is one of the most common issues in the facility location problem, which requires further investigations, particularly in emergency and service facilities. As such, the objecti...
Article
Nowadays, laser-welded blanks (LWBs) are an advanced approach for automobile companies to reduce the weight of their products using sheets with different thicknesses, materials, strengths, and coatings, joined by different welding methods. In this current study, experimental and numerical approaches are used to tune the parameter effects and optimi...
Article
Full-text available
This study involves the validating of thermal analysis during TIG Arc welding of 1.4418 steel using finite element analyses (FEA) with experimental approaches. 3D heat transfer simulation of 1.4418 stainless steel TIG arc welding is implemented using ABAQUS software (6.14, ABAQUS Inc., Johnston, RI, USA), based on non-uniform Goldak’s Gaussian heat...
Article
Full-text available
Residual stresses on aluminum parts can be modified during heat treatments. During solution heat treatment, quenching, and aging, metallurgical transformations combined with thermal gradients lead to a modification of parts properties. Quench and aging treatments sensitivity of AA 7175 aluminum alloy components is addressed in this work. Samples ha...
Article
Full-text available
Induction hardening serves as one of the best mass production processes used recently due to its ability to quickly generate high-intensity heat in a well-defined location of the part. Numerous advantages of this method make it a reliable technique to produce a thin martensite layer on the part surface that has compressive residual stresses. In thi...
Article
Full-text available
Moisture and temperature are the most important environmental factors that affect the degradation of wind turbine blades, and their influence must be considered in the design process. They will first affect the resin matrix and then, possibly, the interface with the fibers. This work is the first to use a series of metaheuristic approaches to analy...
Article
As medical equipment has become more complex and expensive, the maintenance of this equipment requires special attention to improve outcomes and reduce costs notably in the Small Hospital and Health Care Organizations (SHHOC). This research explores how SHHOC can improve maintenance management according to the maintenance employees’ views, and what...
Poster
Following the industrial revolutions and with the arrival of Industry 4.0, maintenance methods have been improved over time to increase the reliability of industrial processes and improve their performance and profitability. Design methods have evolved to better serve maintenance needs. This project provides a root cause analysis of defective equip...
Article
In this study, distortion mapping (deformation or warping) of aluminum Laser Welded Blanks (LWBs) is investigated during an automated forming process. Here, a novel approach of automated and real-time inspection is presented which enhances final product quality, reduces lead time, and increases manufacturing cadence while reducing product cost. As...
Preprint
Full-text available
This paper aims at investigating the effect of laser welding parameters on the hardness profile, using hardness mapping analyses, and welding geometry of galvanized steel plates. Hardness distribution and geometry deflection of galvanized welded thin plates are commonly applied in fields where the weld quality is of utmost importance. Due to the we...
Preprint
Full-text available
Induction hardening serves as one of the best mass production processes used recently due to its ability to quickly generating high-intensity heat in a well-defined location of the part. Numerous advantages of this method make it a reliable technique to produce a thin martensite layer on the part surface that has compressive residual stresses. In t...
Article
Full-text available
The fatigue life of overhead conductors is usually evaluated through experimental tests on clamp/conductor assemblies. Some recent studies aim to estimate the fatigue life of conductors using uniaxial tests on individual strands. This paper presents an innovative method for assessing the fretting fatigue life of overhead conductors combining the ef...
Article
Full-text available
Induction hardening, a promising approach for selective hardening of metal parts, is widely used for surface hardening, where a hard surface is required alongside a tough core. Regarding the complexity of this process, parts’ geometry deeply affects the temperature distribution and hardness profile accordingly. In this study, two magnetic flux conc...
Article
Sheet metal components capitalizing on the advantages of laser-welded blanks (LWBs) are widely used in automotive industries. In the current study, residual stresses are estimated in a deep drawing process of LWBs both experimentally (hole drilling) and numerically (using SIMUFACT™ and ABAQUS™). This study aims at predicting residual stresses durin...
Article
Galvanized steel welded joints are susceptible to porosities since their protective zinc layer may be evaporated and trapped during welding. In this study, a novel approach of identifying voids and porosities is developed by performing a pattern matrix of micro-indentation hardness tests in the cross-section of welds. The hardness grid is then visu...
Article
Full-text available
This study displays the effect of laser surface hardening parameters on the hardness profile (case depth) of a splined shaft made of AISI 4340 steel. The approach is mainly based on experimental tests wherein the hardness profile of laser hardened splines is acquired using micro-hardness measurements. These results are then evaluated with statistic...
Article
Full-text available
This paper presents a biaxial fretting fatigue test bench which provides the capability of performing fretting fatigue experiments on individual wires of a conductor combining the effect of both alternating tension and bending loadings to represent a more realistic state of a conductor individual strand under periodic loading caused by aeolian vibr...
Article
Full-text available
Recent developments in the fixtureless inspection of non-rigid parts based on computer-aided inspection (CAI) methods significantly contribute to diminishing the time and cost of geometrical dimensioning and inspection. Generally, CAI methods aim to compare scan meshes, which are acquired using scanners as point clouds from non-rigid manufactured p...
Research
 Numerical simulation and vibration analyses of overhead conductors (electric power transmission lines) and dampers using finite element analyses.  Numerical simulation of inter-wire fretting behavior for electric power transmission conductors.  Experimental estimation of the residual tensile strength of corroded conductors.
Article
Full-text available
Dimensional inspection is an important element in the quality control of mechanical parts that have deviations from their nominal (CAD) model resulting from the manufacturing process. The focus of this research is on the profile inspection of non-rigid parts which are broadly used in the aeronautic and automotive industries. In a free-state conditi...
Thesis
The competitive industrial market demands manufacturing companies to provide the markets with a higher quality of production. The quality control department in industrial sectors verifies geometrical requirements of products with consistent tolerances. These requirements are presented in Geometric Dimensioning and Tolerancing (GD&T) standards. Howe...
Article
Full-text available
Computer-aided inspection (CAI) of non-rigid parts significantly contributes to improving performance of products, reducing assembly time and decreasing production costs. CAI methods use scanners to measure point clouds on parts and compare them with the nominal computer-aided design (CAD) model. Due to the compliance of non-rigid parts and for ins...
Conference Paper
Full-text available
Geometric inspection of non-rigid (flexible) parts in free-state can aid manufacturers to automatically and inexpensively improve quality by detecting defects on manufactured parts. Non-contact optic data acquisition devices (scanners) are used to measure point clouds on the boundary of manufactured part in free-state and compare it with its nomina...
Conference Paper
Full-text available
L’inspection géométrique des pièces flexibles à l’état libre est susceptible de diminuer considérablement le coût et la rapidité de détection de défauts sur des pièces manufacturées. Ces défauts peuvent être mesurés en comparant le modèle scanné de la pièce à l’état libre avec le modèle géométrique provenant de la conception assistée par ordinateur...
Thesis
Full-text available
Fatigue study of the fillet weld waving on weld toe and the penetration in the weld root based on the effective notch stress approach
Conference Paper
This study proves the possibility of predicting the existence of a cavity inside a homogenous body based on the geometrical parameters and the position of cavity by means of the boundary element method. Regarding the extensive use of steel plates in heavy and huge industries, this project focuses on two-dimensional plates and studies the thermal ef...

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