PROJECTS OF FRP COMPOSITESTITLE: “Key Technologies and Application Foundation for Ultrasonic Processing of Soft and Brittle Composites Structure with Large-Scale Complex Profile”A joint project with Tsinghua University, China (2018-2023)ROLE: Co-PICOST: US$ 30,000BRIEF DESCRIPTION:Collaborated with the Chinese team led by Dr. Jianfu Zhang (Beijing Key Laboratory of Precision/Ultra-Precision Manufacturing Equipment and Control, Department of Mechanical Engineering, Tsinghua University) in successful integration of rotary ultrasonic machining system with the CNC machine at UET Lahore. Supervised research on design optimization of some novel types of ultrasonic horns, straight knife cutters and circular disc cutters through Finite Element Analysis (harmonic and modal).Supervised research on ultrasonic machining of soft and brittle honeycomb structures made of aramid fiber reinforced polymer composites. Parameters investigated included material removal mechanism, chip formation, the surface generation mechanism.Project deliverables included various MSc theses, one PhD dissertation, presentations in symposia/conferences, and research papers in journals.TITLE: “Supply of Machinery and Transfer of Technical Know-How for Composites Based Sports Goods at Product Development Centre (PDC) For Composites Based Sports Goods, Sialkot”A project of Small and Medium Enterprises Development Authority (SMEDA), Pakistan (2021-22)ROLE: Technological ConsultantCOST: US$ 1 millionBRIEF DESCRIPTION:Sports goods (rackets, bats, hockey sticks, fishing tackles, ski poles, billiard cues golf sticks) comprise a major export category of the country. This project is vital in transforming conventional sports goods manufacturers/exporters from wooden materials to CRRP composites. Provided consultancy on finalizing technical specs and cost estimates of the complete project through correspondence with Chinese suppliers.

TITLE: “Design of Manufacturing Process for Engineered Polymer Composite (EPC) Railroad Ties”ROLE: Consultant / DesignerSTATUS: Funding AwaitedBRIEF DESCRIPTION:Federal Railroad Authority of United Stated of America (FRA-USA) recommends replacement of wooden railroad ties by EPC ties owing to their high strength-to-weight ratio, portability, corrosion free properties and high intended service life (EPC: 50 years VS Wood: 15/20 years)However, manufacturing EPC Ties is a tough technological challenge. Only a few companies are specialized in it, but they don’t share their manufacturing process.Prior attempts made by researchers to manufacture EPC railroad ties by joining multiple segments did not prove to be successful because (1) manufacturing time was too high (2) seam-failure took place due to fatigue effect of loads VARTM results in no seam failure since it is one-shot operation. An innovative process of manufacturing railroad ties has been designed which is capable of:Manufacturing EPC tie as a single piece, eliminating seam failure Achieving a good production rate ( 30 minutes/tie)Incorporating any kind of variation in the fiber architecture.

TITLE: “Evaluation of the Hole Quality and Tool Wear in CFRP Composites Using Different Drill-Bits”M.Sc. Manufacturing Engineering Project (2015-16)ROLE: SupervisorBRIEF DESCRIPTION:Investigated the drilling characteristics of CFRP composites: Samples (quadriaxial, 8-ply, 4mm thick) were prepared in lab.Drilling was done at variable speeds and feeds using HSS and AlCrN coated tools.Hole quality was determined in terms of delamination, roundness, burr and chip formation, in addition to tool wear.

Supervisor: Hota GangaRao, Wadsworth Professor and Director of Constructed Facilities CenterTITLE: “Failure Behavior of Pultruded GFRP Members under Combined Bending and Torsion”ROLE: PhD Research Project (2009-2012)BRIEF DESCRIPTION: Designed, fabricated and instrumented a rig for testing the full length pultruded GFRP composite sections under torsion and combined torsion and bending.Devised appropriate methods to test the full length specimens to failurePerformed a wide range of tests on coupons and short span beams on Universal Testing MachinesPerformed burnout tests, optical microscopy and Scanning Electron MicroscopyExplained the experimental behavior in the light of Classical Laminate Theory and Simplified Classical Laminate TheorySupported the experimental and theoretical behavior with Finite Element Analysis for selected casesTITLE: “GFRP Composite Railroad Ties Project”Funded by Federal Railroad Authority, USA (2007-2009)ROLE: Graduate Research AssistantBRIEF DESCRIPTION:Manufactured the ties through compression molding processTested and evaluated the behavior under heavy fatigue loads. Such loads simulate the train loadsInvestigated the aging behavior by subjecting the ties to freeze-thaw cycles in an environmental chamber for more than a year.TITLE: “FRP Composite Structures Design Projects (2007-2012)”ROLE: Graduate Research AssistantBRIEF DESCRIPTION:Design of pultruded GFRP Composite sections (columns, joists, girts) Rehabilitation of deteriorated beams and columns by Carbon Fiber Reinforced Polymer (CFRP) Composite External Wrapping TechniqueRehabilitation of bridge substructural elements (wing walls and abutments) by Glass Fiber Reinforced Polymer (GFRP) Composite External Wrapping Technique