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Research Interests
Research Interests
Additive Manufacturing, Selective Laser Melting
Heat Transfer and Computational Fluid Dynamics
Molecular Dynamics
Control System and Optimization
Machine Learning, Deep Learning, Large Language Models
Research Experience
Research Experience
Undergraduate Thesis, Dept. of Mechanical Engineering, BUET Apr 2025– Jun 2026
Supervisor: Dr. Shahereen Chowdhury
Developed a computationally efficient numerical-analytical framework, based on Rosenthal’s moving heat source solution, implemented in Python to predict temperature fields and melt pool geometry in Selective Laser Melting (SLM) of Ti-6Al-4V and Inconel-718.
Investigated steady-state and transient formulations using effective-property and iterative-property update approaches to handle temperature-dependent material properties.
Validated model predictions against experimentally reported melt pool dimensions from the literature; found the effective-property method gave the better overall agreement.
Showed the transient formulation converges rapidly to a stable thermal regime, closely matching the steady state formulation at significantly lower computational cost under single-track scanning conditions.
Abstract
Abstract
Selective Laser Melting (SLM) is a relatively new additive manufacturing process in which metal powder is selectively melted by laser beams followed by rapid solidification, and parts are built layer-by-layer. Accurate prediction of temperature distribution and melt pool geometry is essential for process optimization and defect reduction, since experiments are instrument intensive as well as costly. High-fidelity numerical approaches provide detailed predictions, but they are often computationally expensive. In this study, a computationally efficient numerical-analytical framework based on Rosenthal’s moving heat source solution was developed and implemented in Python to predict temperature fields and melt pool geometry during SLM of Ti-6Al-4V and Inconel-718 alloys. Both steady-state and transient formulations were investigated using effective-property and iterative-property update approaches for handling temperature dependent material properties. Model predictions were validated against experimentally reported melt pool dimensions from the literature. The results showed that under the scope of the current study, the effective-property method provided better overall agreement with experimental data than the iterative approach, while both demonstrated reasonable predictive capability. The transient formulation rapidly converged to a stable thermal regime and produced results nearly identical to the steady-state formulation, indicating that the latter can achieve comparable accuracy at significantly lower computational cost under single-track scanning conditions. A parametric study further revealed a strong logarithmic relationship between melt pool geometry and linear energy density. Overall, the proposed framework offers an efficient and reasonably accurate approach for predicting melt pool behavior in SLM while maintaining low computational expense.
Optimization of Tension Control Systems: P, PI, and PID Controller Comparison Jul 2025
Supervisor: Dr. Sumon Saha
Designed and simulated a closed-loop wire tension control system using DC motor dynamics in MATLAB/Simulink.
Compared P, PI, and PID controllers via MATLAB PID Tuner (Ziegler–Nichols method); the tuned PI controller gave the most stable and efficient response.
Abstract
Abstract
Maintaining consistent tension is crucial in industries such as packaging, wire manufacturing, textiles, printing press, among others. Irregularities in tension may compromise the quality of final products, affect dimensional accuracy, and reduce the efficiency of the system. Constant tension in these industries can assist in bringing down material waste and operational cost. A closed-loop feedback tension control system has been modeled to address this tension fluctuation issue. The model includes a DC motor that drives an adjustable slider, lying on a linear motion platform, which updates its position to regulate the tension in real-time. The dynamic behaviour of this system was mathematically represented as a transfer function. The system was analyzed without controllers and then compared to P, PI, and PID controllers to test for steady-state error, rise time, settling time, and system overshoot to ultimately check for stability under such dynamic conditions. The controllers were tuned using the Ziegler-Nichols method and PID Tuner App’s Autotuning feature to determine values of the proportional coefficient Kp, integral coefficient Ki, and derivative coefficient Kd on the transient response characteristics of the system. The performance of the controller parameters was simulated and evaluated using SIMULINK. The results highlighted the effective ness of each controller in regulating tension in the system.
Conference Proceedings
Conference Proceedings
Abstract submitted (based on undergraduate thesis work), 7th International Conference on Mechanical, Industrial and Materials Engineering (ICMIME 2026), Rajshahi University of Engineering & Technology (RUET), Bangladesh; scheduled 9–11 December 2026. [Status: abstract accepted; full paper and acceptance pending.]
Paper Validations
Paper Validations
Convection Heat Transfer in Enclosures with Rotating and Fixed Obstacles Sep 2024 - Oct 2024
Convection Heat Transfer in Enclosures with Rotating and Fixed Obstacles Sep 2024 - Oct 2024
Khalil Khanafer, S.M. Aithal, Mixed convection heat transfer in a lid-driven cavity with a rotating circular cylinder, International Communications in Heat and Mass Transfer, Volume 86, 2017, Pages 131-142, ISSN 0735-1933, https://doi.org/10.1016/j.icheatmasstransfer.2017.05.025.
K. Khanafer, S.M. Aithal, K. Vafai, Mixed convection heat transfer in a differentially heated cavity with two rotating cylinders, International Journal of Thermal Sciences, Volume 135, 2019, Pages 117-132, ISSN 1290-0729, https://doi.org/10.1016/j.ijthermalsci.2018.07.020.
Zheng, G.F., Ha, M.Y., Yoon, H.S. et al. A numerical study on mixed convection in a lid-driven cavity with a circular cylinder. J Mech Sci Technol 27, 273–286 (2013). https://doi.org/10.1007/s12206-012-1201-1
J.M. Lee, M.Y. Ha, H.S. Yoon, Natural convection in a square enclosure with a circular cylinder at different horizontal and diagonal locations, International Journal of Heat and Mass Transfer, Volume 53, Issues 25–26, 2010, Pages 5905-5919, ISSN 0017-9310, https://doi.org/10.1016/j.ijheatmasstransfer.2010.07.043.
B. Calcagni, F. Marsili, M. Paroncini, Natural convective heat transfer in square enclosures heated from below, Applied Thermal Engineering, Volume 25, Issue 16, 2005, Pages 2522-2531, ISSN 1359-4311, https://doi.org/10.1016/j.applthermaleng.2004.11.032.
Akand W. Islam, Muhammad A.R. Sharif, Eric S. Carlson, Mixed convection in a lid driven square cavity with an isothermally heated square blockage inside, International Journal of Heat and Mass Transfer, Volume 55, Issues 19–20, 2012, Pages 5244-5255, ISSN 0017-9310, https://doi.org/10.1016/j.ijheatmasstransfer.2012.05.032.
Khalil Khanafer, S.M. Aithal, Laminar mixed convection flow and heat transfer characteristics in a lid driven cavity with a circular cylinder, International Journal of Heat and Mass Transfer, Volume 66, 2013, Pages 200-209, ISSN 0017-9310, https://doi.org/10.1016/j.ijheatmasstransfer.2013.07.023.
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