Dr.eng Hebatalrahman,A*Consultant in materials sciences & materials
applications, Egypt(1)[email protected]
The invention has been transferred to industry The invention has been transferred to industry successfully in manufacturing of composite successfully in manufacturing of composite materials materials
Smart mold was designed, the mold absorb Smart mold was designed, the mold absorb energy and return to itenergy and return to it s original shape after s original shape after extraction of the sample , the inner surface was extraction of the sample , the inner surface was machined and polished . the inner surface is machined and polished . the inner surface is treated by irradiation to change the treated by irradiation to change the microstructure of the inner surface without any microstructure of the inner surface without any change in external surfaces, the oils is used in change in external surfaces, the oils is used in lubrication is analyzed into gases and contain lubrication is analyzed into gases and contain airbag system . it help the sample to extracted airbag system . it help the sample to extracted easily with very smooth surfaceeasily with very smooth surface..
The project is a complete industrial cycle. The project is a complete industrial cycle. The aims of the project areThe aims of the project are the production of new composite materials the production of new composite materials
with high quality and low cost, with high quality and low cost, development of a new method of development of a new method of
manufamanufacturingcturing recycling of the industrial wastes. recycling of the industrial wastes. The project produces more than 40 The project produces more than 40
compounds suitable for more than 120 compounds suitable for more than 120 industries.industries.
Laser irradiation used in surface treatmentLaser irradiation used in surface treatment
Idea
Experiments
Patents
PrototypeTransfer to Industry
SoftwareSemi Automatic production line
Steps of manufacturing
Manufacturing &
Machining
Laser treatmentAnd/or
Heat treatment
Lubrication
TREATMENT MECHANISMTREATMENT MECHANISM
Laser & heat treatedLaser & heat treated
The mold body and the lower The mold body and the lower punch are heated by IR laser punch are heated by IR laser source from room temperature to source from room temperature to 700:1000C and hold for time 700:1000C and hold for time depends on the size of the depends on the size of the specimen. The room temperature specimen. The room temperature structure is (pearlite+cementite structure is (pearlite+cementite Fe3C+ledeburite (pearlite+Fe3 C) Fe3C+ledeburite (pearlite+Fe3 C) which is changed to which is changed to (Austenite+cementite (Austenite+cementite Fe3C+ledeburite (austenite+Fe3 Fe3C+ledeburite (austenite+Fe3 C) and fast air cools leads to the C) and fast air cools leads to the formation offormation of
(Martensite+cementiteFe3C+lede(Martensite+cementiteFe3C+ledeburite (martensite+Fe3 C)burite (martensite+Fe3 C)
Martensite is hard and brittle Martensite is hard and brittle phase increases ability to resist phase increases ability to resist wear and friction and raises wear and friction and raises hardness while cementite hardness while cementite increases toughness. The high increases toughness. The high thermal conductivity of Iron thermal conductivity of Iron makes the air cool may be makes the air cool may be considered at fast cooling rateconsidered at fast cooling rate..
LubricationLubrication The lubrication of the The lubrication of the
mold by heavy mold by heavy petroleum oil which is petroleum oil which is dissociated by heat to dissociated by heat to gases Co,Co2 +other gases Co,Co2 +other gases and gases and hydrocarbon . hydrocarbon . Aldehydes and other Aldehydes and other aromatic compounds aromatic compounds on the inner surface of on the inner surface of the mold reduce the mold reduce friction and improve friction and improve surface finish.surface finish.
Mold designMold design
Laser technology has been Laser technology has been used to improve quality and used to improve quality and reduce cost, the specified reduce cost, the specified material has been exposed to material has been exposed to direct laser irradiation and a direct laser irradiation and a localized phase changes may localized phase changes may occur.occur.
المنفصلة السخانات ذات التصنيع المنفصلة قوالب السخانات ذات التصنيع قوالب
Molds
With
Separated
heaters
1-1-Good surface finish of final Good surface finish of final productsproducts
2-Easy machining and shaping2-Easy machining and shaping 3-High resistance to 3-High resistance to
environmental conditionsenvironmental conditions and and Wear Wear
4-L4-Long life moldsong life molds 5-Available in different shapes and 5-Available in different shapes and
colorscolors
Fabricated materialsFabricated materials
Manufacturing of composite Manufacturing of composite materialsmaterials
Final composite material products such Final composite material products such as (gears, nuts-----etc----).as (gears, nuts-----etc----).
Semi final products such as (disks, Semi final products such as (disks, cylinders------etc------).cylinders------etc------).
Powder MetallurgyPowder Metallurgy Waste recyclingWaste recycling..
The results of the project are income generation, job creation, and The results of the project are income generation, job creation, and vocational training.vocational training.
UNIQUE & INNOVATIVEUNIQUE & INNOVATIVE
**The project achieves two categories made and The project achieves two categories made and invented in Egypt.invented in Egypt.
*The composite material industry is a very *The composite material industry is a very complicated technology. complicated technology.
Our project changes these concepts completely.Our project changes these concepts completely. *The project makes the composite material *The project makes the composite material
manufacturing economic and suitable for small manufacturing economic and suitable for small industries scale. industries scale.
*The patents are transferred to industry, new *The patents are transferred to industry, new technology is created. technology is created.
All steps of the project are done in Egypt without All steps of the project are done in Egypt without any foreign experience. any foreign experience.
The future developments in the project will try to The future developments in the project will try to replace imported raw materials with Egyptian onereplace imported raw materials with Egyptian one
WeaknessNot suitable for very intricate shapesqualified team work (engineers and Technicians) are necessary for project operationTo over come weakness the following steps will be followed:-New Patents are developed for manufacturing of raw materials in EgyptTraining center will be established to prepare the required human resources.
StrengthOur products have good quality and low cost. Our product is really competitive. We can say that, the products meet the customer needs. !00% of raw materials and manufacturing utensils from local marketThe products have a wide range of applicationsOur production lines are suitable for small industries. The Egyptian market export similar products with about 700 million dollar every year.
SimpleDesign
Development
QualityPrice
Competition
Shoubra Company
N.I.L.E.S
Cairo university
Design & Research center
Al-ahram Science Club
Shoubra for Engineering industries
27factory
Social fund
Media
رب لله رب الحمد لله الحمدالعالمينالعالمين
رب لله رب الحمد لله الحمدالعالمينالعالمين
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