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Mian SH, Umer U, Moiduddin K, Alkhalefah H. Predicting Mechanical Properties of Polymer Materials Using Rate-Dependent Material Models: Finite Element Analysis of Bespoke Upper Limb Orthoses. Polymers (Basel) 2024; 16:1220. [PMID: 38732689 PMCID: PMC11085815 DOI: 10.3390/polym16091220] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/01/2024] [Revised: 04/22/2024] [Accepted: 04/24/2024] [Indexed: 05/13/2024] Open
Abstract
Three-dimensional printing-especially with fused deposition modeling (FDM)-is widely used in the medical field as it enables customization. FDM is versatile owing to the availability of various materials, but selecting the appropriate material for a certain application can be challenging. Understanding materials' mechanical behaviors, particularly those of polymeric materials, is vital to determining their suitability for a given application. Physical testing with universal testing machines is the most used method for determining the mechanical behaviors of polymers. This method is resource-intensive and requires cylinders for compression testing and unique dumbbell-shaped specimens for tensile testing. Thus, a specialized fixture must be designed to conduct mechanical testing for the customized orthosis, which is costly and time-consuming. Finite element (FE) analysis using an appropriate material model must be performed to identify the mechanical behaviors of a customized shape (e.g., an orthosis). This study analyzed three material models, namely the Bergström-Boyce (BB), three-network (TN), and three-network viscoplastic (TNV) models, to determine the mechanical behaviors of polymer materials for personalized upper limb orthoses and examined three polymer materials: PLA, ABS, and PETG. The models were first calibrated for each material using experimental data. Once the models were calibrated and found to fit the data appropriately, they were employed to examine the customized orthosis's mechanical behaviors through FE analysis. This approach is innovative in that it predicts the mechanical characteristics of a personalized orthosis by combining theoretical and experimental investigations.
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Affiliation(s)
- Syed Hammad Mian
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
- King Salman Center for Disability Research, Riyadh 11614, Saudi Arabia
| | - Usama Umer
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
- King Salman Center for Disability Research, Riyadh 11614, Saudi Arabia
| | - Khaja Moiduddin
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
- King Salman Center for Disability Research, Riyadh 11614, Saudi Arabia
| | - Hisham Alkhalefah
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
- King Salman Center for Disability Research, Riyadh 11614, Saudi Arabia
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Mian SH, Umer U, Moiduddin K, Alkhalefah H. Finite Element Analysis of Upper Limb Splint Designs and Materials for 3D Printing. Polymers (Basel) 2023; 15:2993. [PMID: 37514383 PMCID: PMC10383199 DOI: 10.3390/polym15142993] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/15/2023] [Revised: 06/28/2023] [Accepted: 07/06/2023] [Indexed: 07/30/2023] Open
Abstract
Three-dimensional (3D) printed splints must be lightweight and adequately ventilated to maximize the patient's convenience while maintaining requisite strength. The ensuing loss of strength has a substantial impact on the transformation of a solid splint model into a perforated or porous model. Thus, two methods for making perforations-standard approach and topological optimization-are investigated in this study. The objective of this research is to ascertain the impact of different perforation shapes and their distribution as well as topology optimization on the customized splint model. The solid splint models made of various materials have been transformed into porous designs to evaluate their strength by utilizing Finite Element (FE) simulation. This study will have a substantial effect on the designing concept for medical devices as well as other industries such as automobiles and aerospace. The novelty of the research refers to creating the perforations as well as applying topology optimization and 3D printing in practice. According to the comparison of the various materials, PLA had the least amount of deformation and the highest safety factor for all loading directions. Additionally, it was shown that all perforation shapes behave similarly, implying that the perforation shape's effect is not notably pronounced. However, square perforations seemed to perform the best out of all the perforation shape types. It was also obvious that the topology-optimized hand splint outperformed that with square perforations. The topology-optimized hand splint weighs 26% less than the solid splint, whereas the square-perforated hand splint weighs roughly 12% less. Nevertheless, the user must choose which strategy (standard perforations or topology optimization) to employ based on the available tools and prerequisites.
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Affiliation(s)
- Syed Hammad Mian
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
- King Salman Center for Disability Research, Riyadh 11614, Saudi Arabia
| | - Usama Umer
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
- King Salman Center for Disability Research, Riyadh 11614, Saudi Arabia
| | - Khaja Moiduddin
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
- King Salman Center for Disability Research, Riyadh 11614, Saudi Arabia
| | - Hisham Alkhalefah
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
- King Salman Center for Disability Research, Riyadh 11614, Saudi Arabia
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Moiduddin K, Mian SH, Umer U, Alkhalefah H, Ahmed F, Hashmi FH. Design, Analysis, and 3D Printing of a Patient-Specific Polyetheretherketone Implant for the Reconstruction of Zygomatic Deformities. Polymers (Basel) 2023; 15:polym15040886. [PMID: 36850170 PMCID: PMC9962529 DOI: 10.3390/polym15040886] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/29/2022] [Revised: 02/03/2023] [Accepted: 02/05/2023] [Indexed: 02/17/2023] Open
Abstract
The reconstruction of craniomaxillofacial deformities, especially zygomatic bone repair, can be exigent due to the complex anatomical structure and the sensitivity of the crucial organs involved. The need to reconstruct the zygomatic bone in the most precise way is of crucial importance for enhancing the patient outcomes and health care-related quality of life (HRQL). Autogenous bone grafts, despite being the gold standard, do not match bone forms, have limited donor sites and bone volume, and can induce substantial surgical site morbidity, which may lead to adverse outcomes. The goal of this study is to provide an integrated approach that includes various processes, from patient scanning to implant manufacture, for the restoration of zygomatic bone abnormalities utilizing Polyetheretherketone (PEEK) material, while retaining adequate aesthetic and facial symmetry. This study takes an integrated approach, including computer-aided implant design using the mirror reconstruction technique, investigating the biomechanical behavior of the implant under loading conditions, and carrying out a fitting accuracy analysis of the PEEK implant fabricated using state-of-the-art additive manufacturing technology. The findings of the biomechanical analysis results reveal the largest stress of approximately 0.89 MPa, which is relatively low in contrast to the material's yield strength and tensile strength. A high degree of sturdiness in the implant design is provided by the maximum value of strain and deformation, which is also relatively low at roughly 2.2 × 10-4 and 14 µm. This emphasizes the implant's capability for load resistance and safety under heavy loading. The 3D-printed PEEK implant observed a maximum deviation of 0.4810 mm in the outside direction, suggesting that the aesthetic result or the fitting precision is adequate. The 3D-printed PEEK implant has the potential to supplant the zygoma bone in cases of severe zygomatic reconstructive deformities, while improving the fit, stability, and strength of the implant.
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Affiliation(s)
- Khaja Moiduddin
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
- Correspondence: ; Tel.: +966-11-63287
| | - Syed Hammad Mian
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Usama Umer
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Hisham Alkhalefah
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Faraz Ahmed
- Department of Mechanical Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia
| | - Faraz Hussain Hashmi
- Department of Mechanical Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia
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Umer U, Mian SH, Mohammed MK, Abidi MH, Moiduddin K, Kishawy H. Self-Propelled Rotary Tools in Hard Turning: Analysis and Optimization via Finite Element Models. Materials (Basel) 2022; 15:8781. [PMID: 36556587 PMCID: PMC9782531 DOI: 10.3390/ma15248781] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/06/2022] [Revised: 12/04/2022] [Accepted: 12/06/2022] [Indexed: 06/17/2023]
Abstract
This study investigates self-propelled rotary tool (SPRT) performance in hard turning using 3D finite element (FE) models. The FE models developed in this study are based on coupled temperature-displacement analysis using an explicit time-integration scheme. The developed FE models can predict chip morphology, cutting forces, tool and workpiece stresses and temperatures. For model verification, hard turning experiments were conducted using an SPRT on AISI 4340 bars. Cutting forces and maximum tool-chip interface temperatures were recorded and compared with the model findings. The effects of different process parameters were analyzed and discussed using the developed FE models. The FE models were run with a central composite design (CCD-25) matrix with four input variables, i.e., the cutting speed, the feed rate, the depth of the cut and the inclination angle. Response surfaces based on the Gaussian process were generated for each performance variable in order to predict design points not available in the original design of the experiment matrix. An optimization study was carried out to minimize tool stress and temperature while setting limits for the material removal rate (MRR) and specific cutting energy for the process. Optimized processes were found with moderate cutting speeds and feed rates and high depths of cut and inclination angles.
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Affiliation(s)
- Usama Umer
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Syed Hammad Mian
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Muneer Khan Mohammed
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Mustufa Haider Abidi
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Khaja Moiduddin
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Hossam Kishawy
- Machining Research Laboratory, University of Ontario Institute of Technology, Oshawa, ON L1G 0C5, Canada
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Ahmed N, Naeem MA, Rehman AU, Rafaqat M, Umer U, Ragab AE. High Aspect Ratio Thin-Walled Structures in D2 Steel through Wire Electric Discharge Machining (EDM). Micromachines (Basel) 2020; 12:E1. [PMID: 33374907 PMCID: PMC7821946 DOI: 10.3390/mi12010001] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/24/2020] [Revised: 12/10/2020] [Accepted: 12/15/2020] [Indexed: 01/11/2023]
Abstract
Thin structures are often required for several engineering applications. Although thick sections are relatively easy to produce, the cutting of thin sections poses greater challenges, particularly in the case of thermal machining processes. The level of difficulty is increased if the thin sections are of larger lengths and heights. In this study, high-aspect-ratio thin structures of micrometer thickness (117-500 µm) were fabricated from D2 steel through wire electrical discharge machining. Machining conditions were kept constant, whereas the structure (fins) sizes were varied in terms of fin thickness (FT), fin height (FH), and fin length (FL). The effects of variation in FT, FH, and FL were assessed over the machining errors (FT and FL errors) and structure formation and its quality. Experiments were conducted in a phased manner (four phases) to determine the minimum possible FT and maximum possible FL that could be achieved without compromising the shape of the structure (straight and uniform cross-section). Thin structures of smaller lengths (1-2 mm long) can be fabricated easily, but, as the length exceeds 2 mm, the structure formation loses its shape integrity and the structure becomes broken, deflected, or deflected and merged at the apex point of the fins.
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Affiliation(s)
- Naveed Ahmed
- Industrial Engineering Department, College of Engineering and Architecture, Al-Yamamah University, Riyadh 11512, Saudi Arabia;
| | - Muhammad Ahmad Naeem
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, Pakistan; (M.A.N.); (M.R.)
| | - Ateekh Ur Rehman
- Department of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia;
| | - Madiha Rafaqat
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, Pakistan; (M.A.N.); (M.R.)
| | - Usama Umer
- Advanced Manufacturing Institute, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia;
| | - Adham E. Ragab
- Department of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia;
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Umer U, Kishawy H, Abidi MH, Mian SH, Moiduddin K. Evaluation of Self-Propelled Rotary Tool in the Machining of Hardened Steel Using Finite Element Models. Materials (Basel) 2020; 13:ma13225092. [PMID: 33187305 PMCID: PMC7697589 DOI: 10.3390/ma13225092] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/12/2020] [Revised: 11/02/2020] [Accepted: 11/09/2020] [Indexed: 11/16/2022]
Abstract
This paper presents a model for assessing the performance of self-propelled rotary tool during the processing of hardened steel. A finite element (FE) model has been proposed in this analysis to study the hard turning of AISI 51200 hardened steel using a self-propelled rotary cutting tool. The model is developed by utilizing the explicit coupled temperature displacement analysis in the presence of realistic boundary conditions. This model does not take into account any assumptions regarding the heat partitioning and the tool-workpiece contact area. The model can predict the cutting forces, chip flow, induced stresses, and the generated temperature on the cutting tool and the workpiece. The nodal temperatures and heat flux data from the chip formation analysis are used to achieve steady-state temperatures on the cutting tool in the heat transfer analysis. The model outcomes are compared with reported experimental data and a good agreement has been found.
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Affiliation(s)
- Usama Umer
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia; (M.H.A.); (S.H.M.); (K.M.)
- Correspondence:
| | - Hossam Kishawy
- Machining Research Laboratory, University of Ontario Institute of Technology, Oshawa, ON L1G 0C5, Canada;
| | - Mustufa Haider Abidi
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia; (M.H.A.); (S.H.M.); (K.M.)
| | - Syed Hammad Mian
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia; (M.H.A.); (S.H.M.); (K.M.)
| | - Khaja Moiduddin
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia; (M.H.A.); (S.H.M.); (K.M.)
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Ahmed N, Rehman AU, Ishfaq K, Naveed R, Moiduddin K, Umer U, E Ragab A, Al-Zabidi A. Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin. Materials (Basel) 2020; 13:ma13204523. [PMID: 33053899 PMCID: PMC7601468 DOI: 10.3390/ma13204523] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/13/2020] [Revised: 09/20/2020] [Accepted: 09/21/2020] [Indexed: 11/30/2022]
Abstract
Titanium-aluminium-vanadium (Ti 6Al 4V) alloys, nickel alloys (Inconel 718), and duraluminum alloys (AA 2000 series) are widely used materials in numerous engineering applications wherein machined features are required to having good surface finish. In this research, micro-impressions of 12 µm depth are milled on these materials though laser milling. Response surface methodology based design of experiment is followed resulting in 54 experiments per work material. Five laser parameters are considered naming lamp current intensity (I), pulse frequency (f), scanning speed (V), layer thickness (LT), and track displacement (TD). Process performance is evaluated and compared in terms of surface roughness through several statistical and microscopic analysis. The significance, strength, and direction of each of the five laser parametric effects are deeply investigated for the said alloys. Optimized laser parameters are proposed to achieve minimum surface roughness. For the optimized combination of laser parameters to achieve minimum surface roughness (Ra) in the titanium alloy, the said alloy consists of I = 85%, f = 20 kHz, V = 250 mm/s, TD = 11 µm, and LT = 3 µm. Similarly, optimized parameters for nickel alloy are as follows: I = 85%, f = 20 kHz, V = 256 mm/s, TD = 8 µm, and LT = 1 µm. Minimum roughness (Ra) on the surface of aluminum alloys can be achieved under the following optimized parameters: I = 75%, f = 20 kHz, V = 200 mm/s, TD = 12 µm, and LT = 3 µm. Micro-impressions produced under optimized parameters have surface roughness of 0.56 µm, 2.46 µm, and 0.54 µm on titanium alloy, nickel alloy, and duralumin, respectively. Some engineering applications need to have high surface roughness (e.g., in case of biomedical implants) or some desired level of roughness. Therefore, validated statistical models are presented to estimate the desired level of roughness against any laser parametric settings.
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Affiliation(s)
- Naveed Ahmed
- Department of Industrial Engineering, College of Engineering and Architecture, Al Yamamah University, Riyadh 11512, Saudi Arabia;
| | - Ateekh Ur Rehman
- Department of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (A.E.R.); (A.A.-Z.)
- Correspondence:
| | - Kashif Ishfaq
- Department of Industrial and Manufacturing Engineering, University of Engineering & Technology, Lahore 54890, Pakistan; (K.I.); (R.N.)
| | - Rakhshanda Naveed
- Department of Industrial and Manufacturing Engineering, University of Engineering & Technology, Lahore 54890, Pakistan; (K.I.); (R.N.)
| | - Khaja Moiduddin
- Advance Manufacturing Institute, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (K.M.); (U.U.)
| | - Usama Umer
- Advance Manufacturing Institute, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (K.M.); (U.U.)
| | - Adham E Ragab
- Department of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (A.E.R.); (A.A.-Z.)
| | - Ayoub Al-Zabidi
- Department of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (A.E.R.); (A.A.-Z.)
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Affiliation(s)
- Khaja Moiduddin
- Advanced Manufacturing Institute, King Saud University, Riyadh, Saudi Arabia
| | - Syed Hammad Mian
- Advanced Manufacturing Institute, King Saud University, Riyadh, Saudi Arabia
| | - Hisham Alkhalefah
- Advanced Manufacturing Institute, King Saud University, Riyadh, Saudi Arabia
| | - Usama Umer
- Advanced Manufacturing Institute, King Saud University, Riyadh, Saudi Arabia
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Mohammed MK, Umer U, Rehman AU, Al-Ahmari AM, El-Tamimi AM. Microchannels Fabrication in Alumina Ceramic Using Direct Nd:YAG Laser Writing. Micromachines (Basel) 2018; 9:mi9080371. [PMID: 30424304 PMCID: PMC6187727 DOI: 10.3390/mi9080371] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/08/2018] [Revised: 07/24/2018] [Accepted: 07/25/2018] [Indexed: 11/16/2022]
Abstract
Ceramic microchannels have important applications in different microscale systems like microreactors, microfluidic devices and microchemical systems. However, ceramics are considered difficult to manufacture owing to their wear and heat resistance capabilities. In this study, microchannels are developed in alumina ceramic using direct Nd:YAG laser writing. The laser beam with a characteristic pulse width of 10 µs and a beam spot diameter of 30 µm is used to make 200 µm width microchannels with different depths. The effects of laser beam intensity and pulse overlaps on dimensional accuracy and material removal rate have been investigated using different scanning patterns. It is found that beam intensity has a major influence on dimensional accuracy and material removal rate. Optimum parameter settings are found using grey relational grade analysis. It is concluded that low intensity and low to medium pulse overlap should be used for better dimensional accuracy. This study facilitates further understanding of laser material interaction for different process parameters and presents optimum laser process parameters for the fabrication of microchannel in alumina ceramic.
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Affiliation(s)
- Muneer Khan Mohammed
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia.
| | - Usama Umer
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia.
| | - Ateekh Ur Rehman
- Industrial Engineering Department, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia.
| | - Abdulrahman M Al-Ahmari
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia.
- Industrial Engineering Department, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia.
| | - Abdulaziz M El-Tamimi
- Industrial Engineering Department, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia.
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