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Production Technology

Description

This course provides a comprehensive introduction to manufacturing processes and workshop practices essential for all engineers in general, and mechanical and production engineers in particular. It covers the fundamental techniques used in shaping, joining, and finishing engineering materials, along with practical knowledge required for industrial applications.

Students will begin by understanding the properties and classifications of engineering materials, followed by an in-depth study of metal casting processes such as sand casting, die casting, centrifugal casting, and investment (lost-wax) casting. The course then transitions to metal forming operations—including forging, rolling, extrusion, deep drawing, and spinning—emphasizing how deformation and material flow influence final product characteristics.

Further modules address welding processes and machining operations, with focused discussions on turning and milling, where students gain both theoretical and practical exposure to machine tools and cutting principles. The importance of engineering metrology for precision measurement and workshop planning for process optimization are also highlighted toward the end of the course.

By the end of this course, students will be able to:

  • Identify and describe the major manufacturing processes.

  • Understand process selection based on material and design requirements.

  • Apply measurement and quality control principles in workshop settings.

  • Demonstrate safe and efficient workshop practices.

A Comprehensive and Comparative Investigation of Maximum Power Point Tracking Algorithms for Photovoltaic Systems

Research Abstract

This paper presents a detailed comparative analysis of conventional and AI-driven Maximum Power Point Tracking (MPPT) techniques utilized in photovoltaic (PV) systems. The study evaluates Fuzzy Logic Control (FLC) methods, the incremental conductance (INC) method, Perturb and Observe (P&O) methods with both fixed and variable step sizes, and the Simplified Model-Based State Estimation (SMSE-based) method. All simulations were rigorously conducted in the MATLAB/SIMULINK for ensuring consistent application of each technique, enabling a comprehensive comparison of their performance across various solar irradiance conditions. Results show that despite initial high oscillations, the SMSE-based method efficiently reaches the Maximum Power Point (MPP) with efficiency values of up to 99.9%. Fuzzy Logic Control Set-2 demonstrates exceptional performance with minimal oscillations and high …

Research Authors
Husam A Ramadan, Abdalla I Elrefaei, Hamdy Ziedan, Ahmed A Zaki Diab
Research Date
Research Department
Research Journal
2024 25th International Middle East Power System Conference (MEPCON)
Research Member
Research Pages
1-8
Research Publisher
IEEE
Research Rank
1
Research Vol
25
Research Year
2024

Electrical grid linked to PV/wind system based fuzzy controller and PID controller tuned by PSO for improving LVRT

Research Abstract

This paper presents the use of a static synchronous compensators (STATCOM) device to improve the low voltage ride through (LVRT) ability of an electrical network consisting of wind farms that produce 9 MW and 1 MW PV stations during grid faults. A hybrid energy model is connected with 100 MVAR STATCOM at the point of common coupling (PCC) through line to line fault occurs on the grid. STATCOM control is used to detect the voltage at the PCC bus through occurring line to line (LL) faults by compensating reactive energy. A method of particle swarm optimization (PSO) is utilized for adjusting the optimum value of proportional—integral—derivative (PID) STATCOM control. STATCOM is controlled by (PID) and is compared with STATCOM controlled by fuzzy logic control (FLC). The proposed system has been performed utilizing Matlab/Simulink. Results of the simulation clear effectiveness and the ability of …

Research Authors
Noura G El Sayed, Ali M Yousef, Gaber El-Saady, Meshari D Alanazi, Hamdy A Ziedan, Montaser Abdelsattar
Research Date
Research Department
Research Journal
Scientific Reports
Research Member
Research Pages
7698
Research Publisher
Nature Publishing Group UK
Research Rank
1
Research Vol
15
Research Website
https://www.nature.com/articles/s41598-025-87208-z
Research Year
2025

CNN-LSTM-AM approach for outdoor wireless optical communication systems

Research Abstract

This paper introduces the enhancement of Visible Light Communications (VLC) for V2V using artificial intelligence models. Different V2V scenarios are simulated. The first scenario considers a specific longitudinal separation and a variable lateral shift between vehicles. The second scenario assumes random longitudinal separation and a specific lateral shift between vehicles. Significant obstacles that impair performance and dependability in V2V communication systems include bit errors, high power consumption, and interference. By combining Convolutional Neural Networks (CNNs), Generative Adversarial Network (GAN), Gated Recurrent Unit (GRU), and Deep Denoising Autoencoder (DDAE), this paper suggests a deep learning-based system to address these issues. The framework comprises four modules, a power reduction module that uses a GAN to generate low-power signals while maintaining signal …

Research Authors
Montaser Abdelsattar, Eman S Amer, Hamdy A Ziedan, Wessam M Salama
Research Date
Research Department
Research Journal
Scientific Reports
Research Member
Research Pages
32178
Research Publisher
Nature Publishing Group UK
Research Rank
1
Research Vol
15
Research Website
https://www.nature.com/articles/s41598-025-16828-2
Research Year
2025

A comprehensive review of power converter topologies and control techniques for welding power supply applications

Research Abstract

rc welding power supplies play a critical role in the welding process by providing the necessary electrical power, control, and stability required to produce high-quality welds efficiently and safely. Investing in a high-quality welding power supply is essential for achieving optimal welding results and maximizing productivity in various welding applications. By incorporating these control techniques into arc welding power circuits, manufacturers can deliver versatile, efficient, and user-friendly power supplies that meet the diverse needs of welders across different industries and applications. These control techniques play a crucial role in achieving consistent weld quality, optimizing productivity, and ensuring operator safety in the welding process. A detailed overview of power circuit topologies and control techniques specifically tailored for welding power supply application was provided. It delves into the intricate design …

Research Authors
Islam Hassan, Khairy Sayed, Meshari D Alanazi, Hamdy A Ziedan, Montaser Abdelsattar
Research Date
Research Department
Research Journal
Discover Applied Sciences
Research Member
Research Pages
1036
Research Publisher
Springer International Publishing
Research Rank
9
Research Vol
7
Research Year
2025

Integrated Techno-Economic, Environmental, and Sensitivity Analysis of Hybrid PV/Wind Energy Systems for Powering a 3.5 MVA Tourist Resort in Ras Al-Hekma City, Egypt

Research Abstract

This study presents an integrated techno-economic, environmental, and sensitivity analysis of hybrid photovoltaic (PV) and wind energy systems designed to supply a peak load of 3.5 MVA to a remote tourist resort in Ras Al-Hekma City, Egypt. Multiple configurations; PV- and wind-based; were examined, each incorporating combinations of battery storage (BS), fuel cells (FC), and hybrid FC/BS systems under off-grid conditions. The assessment evaluates system performance, cost of energy (COE), capital and operational expenditures, and resilience across different scenarios using real-site solar and wind resource data. Among PV-based systems, the PV/BS configuration demonstrated the lowest COE at $0.076/kWh, offering simplicity and economic efficiency, while the PV/FC/BS setup provided a balanced trade-off between reliability and cost. For wind-based systems, Wind/BS achieved the lowest COE at $0.067/kWh, making it the most cost-effective, whereas Wind/FC/BS offered the highest resilience at a higher cost. A comprehensive sensitivity analysis identified solar irradiance, wind speed, and component costs as the most influential parameters affecting system performance and COE. The findings underscore the feasibility of deploying hybrid renewable energy systems in coastal, off-grid locations and contribute to Egypt’s strategic goals for renewable energy integration and sustainable development.

Research Authors
Hamdy A Ziedan, Ali M Yousef, Toka Ezzat El-Taweel
Research Date
Research Department
Research Journal
Pharos Engineering Science Journal
Research Member
Research Pages
335-344
Research Publisher
Pharos University, Faculty of Engineering
Research Rank
2
Research Vol
2
Research Year
2025

Cost-Effective Analysis of a Hybrid PV/Fuel Cell/Battery System for Sustainable Seawater Desalination in a Tourist Resort in Ras Al-Hekma City, Egypt

Research Abstract

The increasing global demand for clean water and sustainable energy solutions has driven the exploration of hybrid renewable energy systems for desalination applications. This study investigates the optimal sizing of a stand-alone hybrid energy system comprising photovoltaic (PV) panels, fuel cells (FC), and battery storage (BS) to power a seawater desalination (SD) plant and meet the electrical load of a tourist resort in Ras Al-Hekma City, Egypt. The resort's total electrical demand of 3.5 MVA includes a reverse osmosis (RO) desalination plant, lighting, air conditioning, and a wastewater treatment facility. Three system configurations; PV/BS, PV/FC, and PV/FC/BS; were analyzed to determine the most cost-effective and reliable solution. The performance of each system was evaluated based on energy production, storage requirements, and economic metrics such as the cost of energy (COE) and net present cost (NPC). Results indicate that the PV/FC/BS hybrid system offers a balanced solution with a COE of 0.081 $/kWh, combining the reliability of fuel cells with the sustainability of solar energy and battery storage. This research highlights the potential of hybrid renewable energy systems to address water scarcity and energy challenges in remote coastal regions while contributing to Egypt's renewable energy goals.

Research Authors
Hamdy A Ziedan, Ali M Yousef, Toka Ezzat M El-Taweel
Research Date
Research Department
Research Journal
SVU-International Journal of Engineering Sciences and Applications
Research Member
Research Pages
90-103
Research Publisher
South Valley University, Faculty of Engineering
Research Rank
2
Research Vol
6
Research Year
2025

Control and Modeling Framework for Balanced Operation and Electro-Thermal Analysis in Three-Level T-Type Neutral Point Clamped Inverters

Research Abstract

Reliable multilevel inverter IGBT modules require precise loss and heat management, particularly in severe traction applications. This paper presents a comprehensive modeling framework for three-level T-type neutral-point clamped (TNPC) inverters using a high-power Insulated Gate Bipolar Transistor (IGBT) module that combines model predictive control (MPC) with space vector pulse width modulation (SVPWM). The particle swarm optimization (PSO) algorithm is used to methodically tune the MPC cost function weights for minimization, while achieving a balance between output current tracking, stabilization of the neutral-point voltage, and, consequently, a uniform distribution of thermal stress. The proposed SVPWM-MPC algorithm selects optimal switching states, which are then utilized in a chip-level loss model coupled with a Cauer RC thermal network to predict transient chip-level junction temperatures dynamically. The proposed framework is executed in MATLAB R2024b and validated with experiments, and the SemiSel industrial thermal simulation tool, demonstrating both control effectiveness and accuracy of the electro-thermal model. The results demonstrate that the proposed control method can sustain neutral-point voltage imbalance of less than 0.45% when operating at 25% load and approximately 1% under full load working conditions, while accomplishing a uniform junction temperature profile in all inverter legs across different working conditions. Moreover, the results indicate that the proposed control and modeling structure is an effective and common-sense way to perform coordinated electrical and thermal management, effectively allowing for predesign and reliability testing of high-power TNPC inverters.

Research Authors
Ahmed H Okilly, Cheolgyu Kim, Do-Wan Kim, Jeihoon Baek
Research Date
Research Department
Research File
Research Journal
Energies
Research Member
Research Publisher
MDPI
Research Rank
International journal (SCIE)
Research Vol
18
Research Website
https://www.mdpi.com/1996-1073/18/21/5587
Research Year
2025

Performance study of building cooling system composed of photovoltaic panels, phase change material, and thermoelectric cooler: impact of its orientation

Research Authors
Hossam A Ahmed, Sameh Nada, Hamdy Hassan
Research Date
Research Journal
International Journal of Air-Conditioning and Refrigeration
Research Pages
3
Research Publisher
Springer Nature
Research Vol
33
Research Year
2025

Impact of modules number of thermoelectric cooler coupled with PV panels and phase change material on building air conditioning

Research Authors
Hossam A Ahmed, Tamer F Megahed, Sameh Nada, Shinsuke Mori, Hamdy Hassan
Research Date
Research Journal
Journal of Building Engineering
Research Pages
108914
Research Publisher
Elsevier
Research Vol
86
Research Year
2024
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