New smart molds for composite materials manufacturing

2. * Dr.eng Hebatalrahman,A
Consultant in materials sciences & materials
( applications, Egypt(1
hebatalrahman11@yahoo.com
hebatalrahman@naseej.com

3. 

The invention has been transferred to industry
successfully in manufacturing of composite
materials
Smart mold was designed, the mold absorb
energy and return to it s original shape after
extraction of the sample , the inner surface was
machined and polished . the inner surface is
treated by irradiation to change the
microstructure of the inner surface without any
change in external surfaces, the oils is used in
lubrication is analyzed into gases and contain
airbag system . it help the sample to extracted
easily with very smooth surface.

4. The project is a complete industrial cycle.
The aims of the project are
 the production of new composite materials
with high quality and low cost,
 development of a new method of
manufacturing
 recycling of the industrial wastes.
 The project produces more than 40
compounds suitable for more than 120
industries.
 Laser irradiation used in surface treatment

5. Idea
Experiments
Patents
Prototype
Transfer to Industry
Software
Semi Automatic production line

6. Steps of manufacturing
Manufacturing
&
Machining
Laser treatment
And/or
Heat treatment
Lubrication

7. TREATMENT MECHANISM




Laser & heat treated
The mold body and the lower
punch are heated by IR laser
source from room temperature to
700:1000C and hold for time
depends on the size of the
specimen. The room temperature
structure is (pearlite+cementite
Fe3C+ledeburite (pearlite+Fe3 C)
which is changed to
(Austenite+cementite
Fe3C+ledeburite (austenite+Fe3
C) and fast air cools leads to the
formation of
(Martensite+cementiteFe3C+ledeb
urite (martensite+Fe3 C)
Martensite is hard and brittle
phase increases ability to resist
wear and friction and raises
hardness while cementite
increases toughness. The high
thermal conductivity of Iron
makes the air cool may be
considered at fast cooling rate.
Lubrication
The lubrication of the
mold by heavy
petroleum oil which is
dissociated by heat to
gases Co,Co2 +other
gases and
hydrocarbon .
Aldehydes and other
aromatic compounds
on the inner surface of
the mold reduce
friction and improve
surface finish.



8. Mold design

9. 
Laser technology has been
used to improve quality and
reduce cost, the specified
material has been exposed to
direct laser irradiation and a
localized phase changes may
occur.

10. ‫‪Molds‬‬
‫‪With‬‬
‫‪Separated‬‬
‫‪heaters‬‬
‫‪‬‬
‫قوالب التصنيع ذات السخانات المنفصلة‬

12.  1-Good
surface finish of final
products
 2-Easy machining and shaping
 3-High resistance to
environmental conditions and
Wear
 4-Long life molds
 5-Available in different shapes
and colors

13. Fabricated materials

14. Manufacturing of composite
materials
Final composite material products such
as (gears, nuts-----etc----).
Semi final products such as (disks,
cylinders------etc------).
 Powder Metallurgy
 Waste recycling.


16. The results of the project are income generation, job creation,
and vocational training.
UNIQUE & INNOVATIVE
*The project achieves two categories made
and invented in Egypt.
*The composite material industry is a very
complicated technology.
Our project changes these concepts
completely.
*The project makes the composite material
manufacturing economic and suitable for
small industries scale.
*The patents are transferred to industry, new
technology is created.
All steps of the project are done in Egypt
without any foreign experience.

17. Weakness Strength
Not suitable for very intricate shapes
qualified team work (engineers and
Technicians) are necessary for project
operation
To over come weakness the following
steps will be followed:New Patents are developed for
manufacturing of raw materials in
Egypt
Training center will be established to
prepare the required human resources.
Our 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
market
The products have a wide range of
applications
Our production lines are suitable for
small industries.
The Egyptian market export similar
products with about 700 million dollar
every year.

18. Quality
Price
Competition
Simple
Design
Development

19. Shoubra Company
Media
N.I.L.E.S
Social fund
Cairo university
Shoubra for
Engineering industries
27factory
Design & Research center
Al-ahram Science Club

20. ‫الحمد ل رب العالمين‬