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Kadhim Kamil

AL-Mustansiriyah University, Materials Engineering, Faculty Member

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PhD applied mechanics
international society of prosthetic and orthoses memeber
Head of materials engineering department (2011-2013)
Supervisors: Supervisor of 11 master students

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Ayad M. Takhakh

AL-Nahrain university

Ayad M. Takhakh

Al Nahrain University - IRAQ

Diyala Journal of Engineering Sciences

University of Diyala

TJPRC Publication

Jesuslives Peace

University of Manitoba

makhlouf M makhlouf

Mohammad Elahinia

AmirKabir University Of Technology

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Papers by Kadhim Kamil

Investigate the Microstructure and the Mechanical Properties of Ni-Ti-Cu Shape Memory Alloys

by Kadhim Kamil and Dania Fadhil

In this study a Nickel-Titanium-Cupper shape memory alloys was manufactured by powder metallurgy ... more In this study a Nickel-Titanium-Cupper shape memory alloys was manufactured by powder metallurgy (PM) technique, powder mixture of 50% Ti , 47% Ni and 3% Cu was prepared by mixing for two hours and compacted in a press machine using various compacting pressure (600, 700 and 800) MPa , sample was then sintered for 5 hrs in an electrical tube vacuum furnace using sintering temperature of (850˚C, 900˚C and 950˚C) .phase analysis of samples was conducted by X-ray diffraction test, the effect of different sintering temperature and compacting pressure on the porosity, microhardness ,compression strength and the shape memory effect (SME) was studied, the result showed decrease in the porosity and increasing in the shape recovery ,compression strength and microhardness with increasing compacting pressure and at lower sintering temperature and hence the best results was at 800MPa compacting pressure and 850˚C sintering temperature.

Optimization of Ni-Ti-Cu Shape Memory Effect Using Minitab Program

by Kadhim Kamil and Dania Fadhil

This study focus on the manufacturing of Nickel-Titanium-Cupper shape memory alloys using powder ... more This study focus on the manufacturing of Nickel-Titanium-Cupper shape memory alloys using powder metallurgy (PM) method, 50% Ti, 47% Ni and 3% Cu powder mixture was prepared by mixing in a ball mill for two hours and compacted in a press machine using various compacting pressure (600, 700 and 800) MPa , samples was then sintered in an electrical tube furnace using three sintering temperature of (850, 900 and 950)˚C. Optimization of the shape memory effect (SME) using Minitab program was conducted, the result showed increasing in the shape recovery with increasing of compacting pressure and reduction in sintering temperature. Shape memory alloys act as a very essential branch of clever or intelligence materials groups. It's a metallic material that can get back to their prior defined form and size when subjected to heat [1]. SMAs consist of two necessary phases called austenite and martensite; Austenite is the high temperature phase or called the parent phase, the crystal structure of austenite is (cubic).Martensite is the low-temperature phase which consist of (tetragonal or monoclinic) crystal structure [2]. There are four characteristic temperatures associated with the phase transformation of austenite and martensite phases expressed by; Ms, Mf, As, Af variables respectively [3]. The experimental research developed a range of the mechanical parameters that would be expected from shape memory alloy in its austenite and martensite phases and these mechanical properties are; pseudoelasticity or superelasticity effect and shape memory effect. Shape-memory effect (SME) is a phenomenon by which SMAs that have been permanently deformed can recover their original configuration after being heated above a certain transition temperature. Pseudoelasticity (also known as superelasticity) is the ability of the Ni-Ti SMA to return to its original shape upon unloading after substantial deformations, Ni-Ti alloy represents the most common shape memory alloy [4]. Shape memory alloys (SMA) provide high growth in aerospace, biomedical and mechanical engineering, the high success of these materials is due to their unusual properties, which makes them superior to conventional materials such as shape memory effects and superelastic effect [5]. Biological properties of the Ni-Ti SMAs can be improved by surface modification or by the addition of third element such as Cu. [6]. Ni-Ti-Cu shape memory alloys can be gained by the alteration of Ni by Cu atom in the equiatomic Ni-Ti alloy, copper placement as a third alloying element produce an increment in the characteristic temperatures of the martensitic transformation in contrast to a binary Ni-Ti alloy. Besides, copper addition result in good stability in the characteristic temperatures and increase the corrosion resistance, close transformation hysteresis and stop the Ti3Ni4 precipitation, the composition susceptibility of

"Study the mechanical properties and Numerical evaluation of Friction Stir Processing (FSP) for 7075-T73 aluminum alloys''

by Kadhim Kamil and Ayad M. Takhakh

Friction stir processing is a may be regarded as new method of changing the properties of a metal... more Friction stir processing is a may be regarded as new method of changing the properties of a metal through intense, localized plastic deformation ,this process mixes the material without changing the phase (by melting or otherwise) and creates a micro structure with fine, equiaxedgrains, It is used to improve the micro structural properties of metals. In this paper , studying the mechanical properties for 7075-T73 aluminum alloy of friction stir welding and friction stir processing methods at variable rotation speeds (1500,1700 and 1900 rpm) with constant feed speed(40 mm/min). The best results of the welding line at the parameter 40 mm/min weld speed and 1700 RPM rotation speed for the FSW and FSP where the efficiency reaches to 84.61% for FSW and 89.05% for FSP of the ultimate tensile strength of the parent metal .and it is involved a finite element simulation of friction stir processing (FSP) of 7075-T73 Aluminum alloy. Numerical simulations are developed for thermal conductivity, specific heat and density to know the relationship of these factors with peak temperature, The simulation model is tested with experimental results. The results of the simulation are in good comparison with the experimental results.

Effect of Friction Stir Processing (FSP) to the Mechanical properties of 6061-T6 Aluminum Alloys.

by Kadhim Kamil and Ayad M. Takhakh

1] Al-mustansiriyah University / college of Engineering / materials engineering department AlNahr... more

Enhancements of mechanical properties of friction stir welding for 6061 aluminum alloy by Friction Stir Processing (FSP) method

by Kadhim Kamil and Ayad M. Takhakh

Friction stir processing is a new method of changing the properties of a metal through intense, l... more Friction stir processing is a new method of changing the properties of a metal through intense, localized plastic deformation ,this process mixes the material without changing the phase (by melting or otherwise) and creates a microstructure with fine, equiaxedgrains, It is used to improve the microstructural properties of metals. In this paper , the enhancement of mechanical propertiesof friction stir welding specimens at variable rotation speeds (1100,1300 and 1500 rpm) with constant feed speed(60mm/min) for 6061-T6 aluminum alloy is studied by using the friction stir processing method at the same variable rotation speed and feed speed in order to transform a heterogeneous microstructure to a more homogeneous, refined microstructure. The best results of the welding line at the parameter 60 mm/min weld speed and 1300RPM rotation speed for the friction stir welding (FSW) and friction stir processing (FSP) where the efficiency reaches to 84.61% for FSW and 89.05% for FSP of the ultimate tensile strength of the parent metal.

Study the influence of stress relaxation on the below knee socket materials from creep test

by Kadhim Kamil and shireen hasan

ISPO world congress 2015

IMECE2015-52202 Design and Manufacturing of Fast Prosthetic Below Knee Socket

by Kadhim Kamil and ahmed mohammed

The large numbers terrorist attacks in Iraq led to the rise of the amputation numbers. However,ty... more The large numbers terrorist attacks in Iraq led to the rise of the amputation numbers. However,typically 80% of the amputations are trans-tibial(below knee lower limb amputations).This research included the fabrication of a new type of socket by a new method (modular socket system) that used direct lamination on residual limb of patients. Socket materials were subjected to tensile and creep (50 0 C) tests in order to determine their mechanical properties. Creep test data were analyzed in order to obtain the time dependent relaxation modulus using the Maxwell-Weichart model. The socket failure characteristics at room temperature and at high temperature were determined by fatigue testing .Interface pressure between the socket and the residual limb was calculated using F-Socket software. In addition,a numerical method was used to find the safety factor on socket by using AutoCAD software in 2014 and the program ANSYS 15.Finally the results of testing is compared with the results of traditional method (vacuum molding technique)in order to choose the best and comfortable method that used for socket manufactured.

Effect of Temperature on Buckling of Composite Material Column

by Mohammed Ali, Kadhim Kamil, and noor kadhm

Due to geometric (i.e., thin-walled shapes) and material (i.e., relatively low stiffness of polym... more Due to geometric (i.e., thin-walled shapes) and material (i.e., relatively low stiffness of polymer and high fiber strength), Fiber composite structures undergo a large deformation and are vulnerable to buckling before reaching the material strength failure under service loads. An experimental and numerical analyses pertaining to the buckling behavior of slender fiber reinforced column subjected to a concentric axial loading under varying temperatures (25 o C to 60 o C). In this study we have designed and manufactured a new buckling device with thermal chamber to take the effect of thermal parameter on buckling behavior of composite materials. Three groups of composite were fabricated by vacuum molding technique, the first and second consist of perlon fiber as a reinforcement and acrylic resin as a bonding matrix with different lay up for each and the third consists of a combination of perlon and carbon fibers as reinforcement. The results show that the temperature has considerable effect on different properties of FRC. (Perlon & Carbon reinforcement) composites gave optimum mechanical properties, which make them the best candidate to improve the buckling resistance characteristics of composite materials.

Stress Relaxation and Creep Effect on Polypropylene Below knee Prosthetic Socket

by shireen hasan and Kadhim Kamil

Prosthetic sockets serve as the interface between people with amputations and their prostheses an... more Prosthetic sockets serve as the interface between people with amputations and their prostheses and it is considered an element of major importance in the makeup of prosthesis. The effect of stress relaxation is evident in the material that makes them prosthetic socket, which causes sagging in the socket due to lower mechanical properties. Although most materials used to make prosthetic sockets have been used for many years, knowledge of these materials " properties is limited, especially after they are subjected to fabrication processes. This study evaluated the effect of stress relaxation on the materials that introduce in socket manufacturing.

Design and Manufacturing of Knee Ankle Foot Orthosis (KAFO

A gait analysis laboratory is an invaluable tool in quantitative analysis of orthotic systems and... more A gait analysis laboratory is an invaluable tool in quantitative analysis of orthotic systems and their effect on human locomotion , abnormal motion of knee ankle foot complex presents a major problem in the rehabilitation of stroke patients. In this study three types of KAFO (Aluminum , Polypropylene and composite materials) were analysis by using sensor Technique to measure the interface pressure between brace and skin , also the ground reaction forces was measured by force plate with gait cycle for normal and abnormal persons , three dimension acceleration was measured in three position (thigh , knee and ankle). For all the three types , S-N curves were tested then using the ANSYS program to determine the safety factor. From these results , the new KAFO was design , tested and manufacturing from composite materials depended on comfort ability , pressure and stress distribution , stability and life of materials .

Improving Fatigue Life of Bolt Adapter of Prosthetic SACH Foot

In this paper an analysis for improving the fatigue behavior (safety factor of fatigue) of non-ar... more In this paper an analysis for improving the fatigue behavior (safety factor of fatigue) of non-articular prosthetic foot (SACH) in the region (Bolt Adapter). The laser peening was carried to the fatigue specimens to improving the fatigue properties of bolt's material. The tests of mechanical properties and fatigue behavior were carried for material that the bolt manufacture from it, a region where the failure occur and inserted of these properties to the program of engineering analysis (Ansys) to calculate the safety factor of fatigue. The results showed that the safety factor after hardening by laser is increased by 42.8%.

STUDY OF CREEP-FATIGUE INTERACTION IN A PROSTHETIC SOCKET BELOW KNEE

The increasing numbers of amputees due to insurgence actions in Iraq urges the researches to cond... more The increasing numbers of amputees due to insurgence actions in Iraq urges the researches to conduct this study. Two stresses of fatigue and heat are generated as a result of limbs movement during extremely hot weather. The objective of this research is to Study the effect of temperature in hot climate countries on a socket made of composite materials during the gait. Where alternating pressures on the inner surface of the socket are generated and lead to variable stresses causing fatigue failure of material. It is evident that as temperature rises, the mechanical properties decrease over time due to creep which causes socket failure due to fatigue and creep interaction. The socket failure at room temperature is determined by fatigue test to obtain S-N curve. Also, stress distribution on the socket is studied at 50 C o .

Effect of Friction Stir Processing (FSP) to the Mechanical Properties of 7075-T73 Aluminum Alloys Plates Welded by Friction Stir Welding

Friction stir processing is a new method of changing the properties of a metal through intense, l... more Friction stir processing is a new method of changing the properties of a metal through intense, localized plastic deformation ,this process mixes the material without changing the phase (by melting or otherwise) and creates a microstructure with fine, equiaxedgrains , It is used to improve the microstructural properties of metals. In this paper , the enhancement of mechanical properties of friction stir welding specimens at variable rotation speeds (1500,1700 and 1900 rpm) with constant feed speed(40mm/min) for 7075-T73 aluminum alloy is studied by using the friction stir processing method at the same variable rotation speed and feed speed in order to transform a heterogeneous microstructure to a more homogeneous, refined microstructure. The best results of the weld gained at the parameter 40 mm/min weld speed and 1700RPM rotation speed for the friction stir welding (FSW) an d friction stir processing (FSP) where the efficiency reaches to 83.7% for FSW and 92.99% for FSP of the ultimate tensile strength of the parent metal.

Stress Relaxation on Prosthetic Laminated Socket Materials

by shireen hasan and Kadhim Kamil

The mechanical properties of socket materials are decreasing with time because they have a time d... more The mechanical properties of socket materials are decreasing with time because they have a time dependent nature. This research evaluated mechanical properties of the composite materials that used to fabricate prosthetic sockets. Stress relaxation, the time-dependent property, was evaluated from creep test by testing two types of socket materials at 50 o C and by using Burger viscoelastic model; the equation of stress relaxation modulus was obtained and it found that the stress relaxation modulus decreasing with time. In addition a pressure between the residual limb and the prosthetic below knee socket measured by using F-socket system. Besides this study include a numerical approach to find the deformation distribution on socket that resulting from decreasing in stress relaxation modulus by using ANSYS workbench 15, it found the socket materials were deformed with time, the deformation of material A was increased from (2.03 to 24.4 mm) during 150 minute, while material B increased from (5.2 to 31.2 mm). The difference in resistance to deformation in the socket materials due to the types and numbers of reinforcement used in these materials.

Improving Fatigue Life of Bolt Adapter of Prosthetic SACH Foot

In this research an analysis for improving the fatigue behavior (safety factor of fatigue) of non... more In this research an analysis for improving the fatigue behavior (safety factor of fatigue) of non-articular prosthetic foot (SACH) in the region (Bolt Adapter).The laser peening was carried to the fatigue specimens to improving the fatigue properties of bolt's material. The tests of mechanical properties and fatigue behavior were carried for material that the bolt manufacture from it, a region where the failure occur and inserted of these properties to the program of engineering analysis (Ansys) to calculate the safety factor of fatigue. The results showed that the safety factor after hardening by laser is increased by 42.8%.

Study and Analysis of Failure Mechanism of Bolt Adapter in Prosthetic SACH Foot

This paper presents is the study and analysis of failure mechanism of non-articular prosthetic fo... more This paper presents is the study and analysis of failure mechanism of non-articular prosthetic foot (SACH) in the region (Bolt Adapter). The tests of mechanical properties and fatigue behavior were carried for material of which the bolt manufacture from it is a region where the failure occurs out and inserted of these properties to the program of engineering analysis (Ansys) to calculate the safety factor of fatigue and stress equivalent (Von-Mises).The results that both, showed the maximum equivalent stress and the minimum safety factor of fatigue are located in bolt at interface region between the adapter and the foot at notch, however, in static case, the effect was on the ground reaction force at toe off phase more than heel strike phase.

Predict of residual stress behavior in aluminum friction stir welding by Leeb hardness method

The friction stir welding method it is a modern methods for non-welding material using a milling ... more The friction stir welding method it is a modern methods for non-welding material using a milling machine and rotary pin, as a result of heat generated due to rotation of the pin, it generates stresses inherent and it is necessary to know the behavior or the value of these stresses. In this research a new method were invented to predict the behavior of the residual stresses. Three models of friction welding samples are designed at different rotating speed (1500 rpm , 1000 rpm and 800 rpm) , then drawing a grid on each sample was drawn vertically and horizontally lines with spaces of 10 mm and 5 mm respectively for each line, Leeb hardness were measured in each node .It found that the hardness is low in the line of welding and then increased at 5-mm ,decreasing at 10 mm then another increase at 15 mm, these change in the value of hardness indicate a change of residual stresses value .

Design and Analysis of Knee Ankle Foot Orthosis (KAFO) for Paraplegia Person

Knee ankle foot orthoses (KAFOs) are prescribed to paraplegic patients with low level spinal cord... more Knee ankle foot orthoses (KAFOs) are prescribed to paraplegic patients with low level spinal cord injury and with good control of the trunk muscles. Three types of KAFOs were used in this work (plastic-metal, metal-metal and composite materials), the composite materials were depended on the number of perlon layers (13 layers & 9 layers) with one layer of carbon-fiber and (6 layers) without carbon-fiber. The mechanical properties of most of the KAFOs' materials were tested by tensile test and fatigue machines. The data of gait cycle (Ground Reaction Force (GRF), and pressure distribution) were collected from one patient with poliomyelitis (wearing brace type KAFO) and one normal subject. In this paper, the FEM (ANSYS) was used to compute the safety factor of fatigue for all types of KAFOs' models and the equivalent stress (Von-Mises). The interface pressure between the patient's leg and the brace was tested by using a piezoelectric sensor. The results obtained from ANSYS gave the profile of safety factor of fatigue, for metal-metal KAFO (3.69), plastic-metal model (0.88). While, the (13) layers for composite material was about (1.4), but (1.07) & (0.41) for (9) layers and (6) layers, respectively. The value of safety factor increased with the composite material for the suggested design.

DESIGN AND ANALYSIS OF A NEW PROSTHETIC FOOT FOR PEOPLE OF SPECIAL NEEDS

by Muslim Ali, Kadhim Kamil, and Ali Alhelli

Loss of the lower limb can cause loss of mobility .At all places and at all times, efforts have a... more Loss of the lower limb can cause loss of mobility .At all places and at all times, efforts have always been made to make up for such a loss. The basis of this investigation is to research current prosthetic in order to design and build a more human like prosthesis. Also this investigation aims at combining these characteristics in order to achieve a more multi functional prosthesis. In undertaking such a design, the new prosthesis will be exhibit a broader range of characteristics than those displayed in current prosthetic feet. In doing so, the new prosthesis will enable a closer representation of the functions inherent of a normal human foot. The characteristics involved in normal walking include dorsiflexion, impact absorption and fatigue foot test. The characteristics displayed in the manufactured new foot tested were compared to those of SACH foot. The characteristics exhibited by prostheses which compared favorably to those of a human foot were investigated further. A new prosthetic foot is designed and manufactured from polyethylene and a comparison study with SACH foot was used to determine if there are differences in the gait pattern while wearing the NEW foot and whether these differences would be problematic. The basis of the new prosthetic design combines current prosthetic design elements, such as materials and components. The analytical part presents the results of the static and fatigue analysis by methods; numerical methods (Finite Element method FEM) and experimental methods. The new foot was designed and the number of cycle, dorsiflexion and impact were measured. The new prosthetic foot has a good characteristic when compared with the SACH foot, such as good dorsiflexion (7.8 -6.4 o), force transmitted at impact heel (9.82N-9.50N) and life of foot (2,103,445-896,213) cycles respectively.

Design And Manufacturing Of A New Prosthetic Low Cost Pylon For Amputee

The Standard prosthetic pylon is manufacturing from aluminum-titanium alloys as a result of light... more The Standard prosthetic pylon is manufacturing from aluminum-titanium alloys as a result of light weight. In this study, a three prosthetic pylon are design and manufactured from different layers composite materials (6 layers ,9 layers and 12 layers). The mechanical properties such as σy and σ ult and σ e were measured for all type of pylon , Also , design pylon fatigue tester and impact pylon test then all pylon were tested by these device. All types of new prosthetic pylons are light and cheap comparing with the standard pylon Therefore, to choose the best pylon , the weighted method is preferred, this method depend on practical experience. From this method the optimum choice pylon (kp) , it explains that the Pylon II is good .

Investigate the Microstructure and the Mechanical Properties of Ni-Ti-Cu Shape Memory Alloys

by Kadhim Kamil and Dania Fadhil

In this study a Nickel-Titanium-Cupper shape memory alloys was manufactured by powder metallurgy ... more In this study a Nickel-Titanium-Cupper shape memory alloys was manufactured by powder metallurgy (PM) technique, powder mixture of 50% Ti , 47% Ni and 3% Cu was prepared by mixing for two hours and compacted in a press machine using various compacting pressure (600, 700 and 800) MPa , sample was then sintered for 5 hrs in an electrical tube vacuum furnace using sintering temperature of (850˚C, 900˚C and 950˚C) .phase analysis of samples was conducted by X-ray diffraction test, the effect of different sintering temperature and compacting pressure on the porosity, microhardness ,compression strength and the shape memory effect (SME) was studied, the result showed decrease in the porosity and increasing in the shape recovery ,compression strength and microhardness with increasing compacting pressure and at lower sintering temperature and hence the best results was at 800MPa compacting pressure and 850˚C sintering temperature.

Optimization of Ni-Ti-Cu Shape Memory Effect Using Minitab Program

by Kadhim Kamil and Dania Fadhil

This study focus on the manufacturing of Nickel-Titanium-Cupper shape memory alloys using powder ... more This study focus on the manufacturing of Nickel-Titanium-Cupper shape memory alloys using powder metallurgy (PM) method, 50% Ti, 47% Ni and 3% Cu powder mixture was prepared by mixing in a ball mill for two hours and compacted in a press machine using various compacting pressure (600, 700 and 800) MPa , samples was then sintered in an electrical tube furnace using three sintering temperature of (850, 900 and 950)˚C. Optimization of the shape memory effect (SME) using Minitab program was conducted, the result showed increasing in the shape recovery with increasing of compacting pressure and reduction in sintering temperature. Shape memory alloys act as a very essential branch of clever or intelligence materials groups. It's a metallic material that can get back to their prior defined form and size when subjected to heat [1]. SMAs consist of two necessary phases called austenite and martensite; Austenite is the high temperature phase or called the parent phase, the crystal structure of austenite is (cubic).Martensite is the low-temperature phase which consist of (tetragonal or monoclinic) crystal structure [2]. There are four characteristic temperatures associated with the phase transformation of austenite and martensite phases expressed by; Ms, Mf, As, Af variables respectively [3]. The experimental research developed a range of the mechanical parameters that would be expected from shape memory alloy in its austenite and martensite phases and these mechanical properties are; pseudoelasticity or superelasticity effect and shape memory effect. Shape-memory effect (SME) is a phenomenon by which SMAs that have been permanently deformed can recover their original configuration after being heated above a certain transition temperature. Pseudoelasticity (also known as superelasticity) is the ability of the Ni-Ti SMA to return to its original shape upon unloading after substantial deformations, Ni-Ti alloy represents the most common shape memory alloy [4]. Shape memory alloys (SMA) provide high growth in aerospace, biomedical and mechanical engineering, the high success of these materials is due to their unusual properties, which makes them superior to conventional materials such as shape memory effects and superelastic effect [5]. Biological properties of the Ni-Ti SMAs can be improved by surface modification or by the addition of third element such as Cu. [6]. Ni-Ti-Cu shape memory alloys can be gained by the alteration of Ni by Cu atom in the equiatomic Ni-Ti alloy, copper placement as a third alloying element produce an increment in the characteristic temperatures of the martensitic transformation in contrast to a binary Ni-Ti alloy. Besides, copper addition result in good stability in the characteristic temperatures and increase the corrosion resistance, close transformation hysteresis and stop the Ti3Ni4 precipitation, the composition susceptibility of

"Study the mechanical properties and Numerical evaluation of Friction Stir Processing (FSP) for 7075-T73 aluminum alloys''

by Kadhim Kamil and Ayad M. Takhakh

Friction stir processing is a may be regarded as new method of changing the properties of a metal... more Friction stir processing is a may be regarded as new method of changing the properties of a metal through intense, localized plastic deformation ,this process mixes the material without changing the phase (by melting or otherwise) and creates a micro structure with fine, equiaxedgrains, It is used to improve the micro structural properties of metals. In this paper , studying the mechanical properties for 7075-T73 aluminum alloy of friction stir welding and friction stir processing methods at variable rotation speeds (1500,1700 and 1900 rpm) with constant feed speed(40 mm/min). The best results of the welding line at the parameter 40 mm/min weld speed and 1700 RPM rotation speed for the FSW and FSP where the efficiency reaches to 84.61% for FSW and 89.05% for FSP of the ultimate tensile strength of the parent metal .and it is involved a finite element simulation of friction stir processing (FSP) of 7075-T73 Aluminum alloy. Numerical simulations are developed for thermal conductivity, specific heat and density to know the relationship of these factors with peak temperature, The simulation model is tested with experimental results. The results of the simulation are in good comparison with the experimental results.

Effect of Friction Stir Processing (FSP) to the Mechanical properties of 6061-T6 Aluminum Alloys.

by Kadhim Kamil and Ayad M. Takhakh

1] Al-mustansiriyah University / college of Engineering / materials engineering department AlNahr... more

Enhancements of mechanical properties of friction stir welding for 6061 aluminum alloy by Friction Stir Processing (FSP) method

by Kadhim Kamil and Ayad M. Takhakh

Friction stir processing is a new method of changing the properties of a metal through intense, l... more Friction stir processing is a new method of changing the properties of a metal through intense, localized plastic deformation ,this process mixes the material without changing the phase (by melting or otherwise) and creates a microstructure with fine, equiaxedgrains, It is used to improve the microstructural properties of metals. In this paper , the enhancement of mechanical propertiesof friction stir welding specimens at variable rotation speeds (1100,1300 and 1500 rpm) with constant feed speed(60mm/min) for 6061-T6 aluminum alloy is studied by using the friction stir processing method at the same variable rotation speed and feed speed in order to transform a heterogeneous microstructure to a more homogeneous, refined microstructure. The best results of the welding line at the parameter 60 mm/min weld speed and 1300RPM rotation speed for the friction stir welding (FSW) and friction stir processing (FSP) where the efficiency reaches to 84.61% for FSW and 89.05% for FSP of the ultimate tensile strength of the parent metal.

Study the influence of stress relaxation on the below knee socket materials from creep test

by Kadhim Kamil and shireen hasan

ISPO world congress 2015

IMECE2015-52202 Design and Manufacturing of Fast Prosthetic Below Knee Socket

by Kadhim Kamil and ahmed mohammed

The large numbers terrorist attacks in Iraq led to the rise of the amputation numbers. However,ty... more The large numbers terrorist attacks in Iraq led to the rise of the amputation numbers. However,typically 80% of the amputations are trans-tibial(below knee lower limb amputations).This research included the fabrication of a new type of socket by a new method (modular socket system) that used direct lamination on residual limb of patients. Socket materials were subjected to tensile and creep (50 0 C) tests in order to determine their mechanical properties. Creep test data were analyzed in order to obtain the time dependent relaxation modulus using the Maxwell-Weichart model. The socket failure characteristics at room temperature and at high temperature were determined by fatigue testing .Interface pressure between the socket and the residual limb was calculated using F-Socket software. In addition,a numerical method was used to find the safety factor on socket by using AutoCAD software in 2014 and the program ANSYS 15.Finally the results of testing is compared with the results of traditional method (vacuum molding technique)in order to choose the best and comfortable method that used for socket manufactured.

Effect of Temperature on Buckling of Composite Material Column

by Mohammed Ali, Kadhim Kamil, and noor kadhm

Due to geometric (i.e., thin-walled shapes) and material (i.e., relatively low stiffness of polym... more Due to geometric (i.e., thin-walled shapes) and material (i.e., relatively low stiffness of polymer and high fiber strength), Fiber composite structures undergo a large deformation and are vulnerable to buckling before reaching the material strength failure under service loads. An experimental and numerical analyses pertaining to the buckling behavior of slender fiber reinforced column subjected to a concentric axial loading under varying temperatures (25 o C to 60 o C). In this study we have designed and manufactured a new buckling device with thermal chamber to take the effect of thermal parameter on buckling behavior of composite materials. Three groups of composite were fabricated by vacuum molding technique, the first and second consist of perlon fiber as a reinforcement and acrylic resin as a bonding matrix with different lay up for each and the third consists of a combination of perlon and carbon fibers as reinforcement. The results show that the temperature has considerable effect on different properties of FRC. (Perlon & Carbon reinforcement) composites gave optimum mechanical properties, which make them the best candidate to improve the buckling resistance characteristics of composite materials.

Stress Relaxation and Creep Effect on Polypropylene Below knee Prosthetic Socket

by shireen hasan and Kadhim Kamil

Prosthetic sockets serve as the interface between people with amputations and their prostheses an... more Prosthetic sockets serve as the interface between people with amputations and their prostheses and it is considered an element of major importance in the makeup of prosthesis. The effect of stress relaxation is evident in the material that makes them prosthetic socket, which causes sagging in the socket due to lower mechanical properties. Although most materials used to make prosthetic sockets have been used for many years, knowledge of these materials " properties is limited, especially after they are subjected to fabrication processes. This study evaluated the effect of stress relaxation on the materials that introduce in socket manufacturing.

Design and Manufacturing of Knee Ankle Foot Orthosis (KAFO

A gait analysis laboratory is an invaluable tool in quantitative analysis of orthotic systems and... more A gait analysis laboratory is an invaluable tool in quantitative analysis of orthotic systems and their effect on human locomotion , abnormal motion of knee ankle foot complex presents a major problem in the rehabilitation of stroke patients. In this study three types of KAFO (Aluminum , Polypropylene and composite materials) were analysis by using sensor Technique to measure the interface pressure between brace and skin , also the ground reaction forces was measured by force plate with gait cycle for normal and abnormal persons , three dimension acceleration was measured in three position (thigh , knee and ankle). For all the three types , S-N curves were tested then using the ANSYS program to determine the safety factor. From these results , the new KAFO was design , tested and manufacturing from composite materials depended on comfort ability , pressure and stress distribution , stability and life of materials .

Improving Fatigue Life of Bolt Adapter of Prosthetic SACH Foot

In this paper an analysis for improving the fatigue behavior (safety factor of fatigue) of non-ar... more In this paper an analysis for improving the fatigue behavior (safety factor of fatigue) of non-articular prosthetic foot (SACH) in the region (Bolt Adapter). The laser peening was carried to the fatigue specimens to improving the fatigue properties of bolt's material. The tests of mechanical properties and fatigue behavior were carried for material that the bolt manufacture from it, a region where the failure occur and inserted of these properties to the program of engineering analysis (Ansys) to calculate the safety factor of fatigue. The results showed that the safety factor after hardening by laser is increased by 42.8%.

STUDY OF CREEP-FATIGUE INTERACTION IN A PROSTHETIC SOCKET BELOW KNEE

The increasing numbers of amputees due to insurgence actions in Iraq urges the researches to cond... more The increasing numbers of amputees due to insurgence actions in Iraq urges the researches to conduct this study. Two stresses of fatigue and heat are generated as a result of limbs movement during extremely hot weather. The objective of this research is to Study the effect of temperature in hot climate countries on a socket made of composite materials during the gait. Where alternating pressures on the inner surface of the socket are generated and lead to variable stresses causing fatigue failure of material. It is evident that as temperature rises, the mechanical properties decrease over time due to creep which causes socket failure due to fatigue and creep interaction. The socket failure at room temperature is determined by fatigue test to obtain S-N curve. Also, stress distribution on the socket is studied at 50 C o .

Effect of Friction Stir Processing (FSP) to the Mechanical Properties of 7075-T73 Aluminum Alloys Plates Welded by Friction Stir Welding

Friction stir processing is a new method of changing the properties of a metal through intense, l... more Friction stir processing is a new method of changing the properties of a metal through intense, localized plastic deformation ,this process mixes the material without changing the phase (by melting or otherwise) and creates a microstructure with fine, equiaxedgrains , It is used to improve the microstructural properties of metals. In this paper , the enhancement of mechanical properties of friction stir welding specimens at variable rotation speeds (1500,1700 and 1900 rpm) with constant feed speed(40mm/min) for 7075-T73 aluminum alloy is studied by using the friction stir processing method at the same variable rotation speed and feed speed in order to transform a heterogeneous microstructure to a more homogeneous, refined microstructure. The best results of the weld gained at the parameter 40 mm/min weld speed and 1700RPM rotation speed for the friction stir welding (FSW) an d friction stir processing (FSP) where the efficiency reaches to 83.7% for FSW and 92.99% for FSP of the ultimate tensile strength of the parent metal.

Stress Relaxation on Prosthetic Laminated Socket Materials

by shireen hasan and Kadhim Kamil

The mechanical properties of socket materials are decreasing with time because they have a time d... more The mechanical properties of socket materials are decreasing with time because they have a time dependent nature. This research evaluated mechanical properties of the composite materials that used to fabricate prosthetic sockets. Stress relaxation, the time-dependent property, was evaluated from creep test by testing two types of socket materials at 50 o C and by using Burger viscoelastic model; the equation of stress relaxation modulus was obtained and it found that the stress relaxation modulus decreasing with time. In addition a pressure between the residual limb and the prosthetic below knee socket measured by using F-socket system. Besides this study include a numerical approach to find the deformation distribution on socket that resulting from decreasing in stress relaxation modulus by using ANSYS workbench 15, it found the socket materials were deformed with time, the deformation of material A was increased from (2.03 to 24.4 mm) during 150 minute, while material B increased from (5.2 to 31.2 mm). The difference in resistance to deformation in the socket materials due to the types and numbers of reinforcement used in these materials.

Improving Fatigue Life of Bolt Adapter of Prosthetic SACH Foot

In this research an analysis for improving the fatigue behavior (safety factor of fatigue) of non... more In this research an analysis for improving the fatigue behavior (safety factor of fatigue) of non-articular prosthetic foot (SACH) in the region (Bolt Adapter).The laser peening was carried to the fatigue specimens to improving the fatigue properties of bolt's material. The tests of mechanical properties and fatigue behavior were carried for material that the bolt manufacture from it, a region where the failure occur and inserted of these properties to the program of engineering analysis (Ansys) to calculate the safety factor of fatigue. The results showed that the safety factor after hardening by laser is increased by 42.8%.

Study and Analysis of Failure Mechanism of Bolt Adapter in Prosthetic SACH Foot

This paper presents is the study and analysis of failure mechanism of non-articular prosthetic fo... more This paper presents is the study and analysis of failure mechanism of non-articular prosthetic foot (SACH) in the region (Bolt Adapter). The tests of mechanical properties and fatigue behavior were carried for material of which the bolt manufacture from it is a region where the failure occurs out and inserted of these properties to the program of engineering analysis (Ansys) to calculate the safety factor of fatigue and stress equivalent (Von-Mises).The results that both, showed the maximum equivalent stress and the minimum safety factor of fatigue are located in bolt at interface region between the adapter and the foot at notch, however, in static case, the effect was on the ground reaction force at toe off phase more than heel strike phase.

Predict of residual stress behavior in aluminum friction stir welding by Leeb hardness method

The friction stir welding method it is a modern methods for non-welding material using a milling ... more The friction stir welding method it is a modern methods for non-welding material using a milling machine and rotary pin, as a result of heat generated due to rotation of the pin, it generates stresses inherent and it is necessary to know the behavior or the value of these stresses. In this research a new method were invented to predict the behavior of the residual stresses. Three models of friction welding samples are designed at different rotating speed (1500 rpm , 1000 rpm and 800 rpm) , then drawing a grid on each sample was drawn vertically and horizontally lines with spaces of 10 mm and 5 mm respectively for each line, Leeb hardness were measured in each node .It found that the hardness is low in the line of welding and then increased at 5-mm ,decreasing at 10 mm then another increase at 15 mm, these change in the value of hardness indicate a change of residual stresses value .

Design and Analysis of Knee Ankle Foot Orthosis (KAFO) for Paraplegia Person

Knee ankle foot orthoses (KAFOs) are prescribed to paraplegic patients with low level spinal cord... more Knee ankle foot orthoses (KAFOs) are prescribed to paraplegic patients with low level spinal cord injury and with good control of the trunk muscles. Three types of KAFOs were used in this work (plastic-metal, metal-metal and composite materials), the composite materials were depended on the number of perlon layers (13 layers & 9 layers) with one layer of carbon-fiber and (6 layers) without carbon-fiber. The mechanical properties of most of the KAFOs' materials were tested by tensile test and fatigue machines. The data of gait cycle (Ground Reaction Force (GRF), and pressure distribution) were collected from one patient with poliomyelitis (wearing brace type KAFO) and one normal subject. In this paper, the FEM (ANSYS) was used to compute the safety factor of fatigue for all types of KAFOs' models and the equivalent stress (Von-Mises). The interface pressure between the patient's leg and the brace was tested by using a piezoelectric sensor. The results obtained from ANSYS gave the profile of safety factor of fatigue, for metal-metal KAFO (3.69), plastic-metal model (0.88). While, the (13) layers for composite material was about (1.4), but (1.07) & (0.41) for (9) layers and (6) layers, respectively. The value of safety factor increased with the composite material for the suggested design.

DESIGN AND ANALYSIS OF A NEW PROSTHETIC FOOT FOR PEOPLE OF SPECIAL NEEDS

by Muslim Ali, Kadhim Kamil, and Ali Alhelli

Loss of the lower limb can cause loss of mobility .At all places and at all times, efforts have a... more Loss of the lower limb can cause loss of mobility .At all places and at all times, efforts have always been made to make up for such a loss. The basis of this investigation is to research current prosthetic in order to design and build a more human like prosthesis. Also this investigation aims at combining these characteristics in order to achieve a more multi functional prosthesis. In undertaking such a design, the new prosthesis will be exhibit a broader range of characteristics than those displayed in current prosthetic feet. In doing so, the new prosthesis will enable a closer representation of the functions inherent of a normal human foot. The characteristics involved in normal walking include dorsiflexion, impact absorption and fatigue foot test. The characteristics displayed in the manufactured new foot tested were compared to those of SACH foot. The characteristics exhibited by prostheses which compared favorably to those of a human foot were investigated further. A new prosthetic foot is designed and manufactured from polyethylene and a comparison study with SACH foot was used to determine if there are differences in the gait pattern while wearing the NEW foot and whether these differences would be problematic. The basis of the new prosthetic design combines current prosthetic design elements, such as materials and components. The analytical part presents the results of the static and fatigue analysis by methods; numerical methods (Finite Element method FEM) and experimental methods. The new foot was designed and the number of cycle, dorsiflexion and impact were measured. The new prosthetic foot has a good characteristic when compared with the SACH foot, such as good dorsiflexion (7.8 -6.4 o), force transmitted at impact heel (9.82N-9.50N) and life of foot (2,103,445-896,213) cycles respectively.

Design And Manufacturing Of A New Prosthetic Low Cost Pylon For Amputee

The Standard prosthetic pylon is manufacturing from aluminum-titanium alloys as a result of light... more The Standard prosthetic pylon is manufacturing from aluminum-titanium alloys as a result of light weight. In this study, a three prosthetic pylon are design and manufactured from different layers composite materials (6 layers ,9 layers and 12 layers). The mechanical properties such as σy and σ ult and σ e were measured for all type of pylon , Also , design pylon fatigue tester and impact pylon test then all pylon were tested by these device. All types of new prosthetic pylons are light and cheap comparing with the standard pylon Therefore, to choose the best pylon , the weighted method is preferred, this method depend on practical experience. From this method the optimum choice pylon (kp) , it explains that the Pylon II is good .