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Conference Presentations by Azreen Zainol

Journal of Advanced Manufacturing Technology, 2018

Nowadays, the challenge in machining industries is focused on achieving high-quality product on c... more Nowadays, the challenge in machining industries is focused on achieving high-quality product on component accuracy, and high production rate. It is necessary to enhance existing technology and develop the product with reasonable cost. Thus, researchers have developed advanced technology such as high-speed machining. High-speed machining plays a very important role in achieving cost and time savings together with better surface finish and dimensional accuracy. High-speed machining is being widely employed in the aerospace industry. Aluminum 7075-T6 is one of the popular materials with attractive properties such as high tensile strength, toughness and high corrosion resistance. Minimum quantity lubrication is known as a technique to provide the best cutting performances. This paper provides the recent studies in minimum quantity lubrication and high-speed machining of aluminum 7075-T6. The influence of high-speed machining process parameters in term the surface roughness and relevant cutting fluid technique have been discussed based on the findings of the recent studies.

Papers by Azreen Zainol

International Journal of Recent Technology and Engineering, 2019

 Abstract: This research deals the experimental works on the effect of minimum quantity lubricat... more  Abstract: This research deals the experimental works on the effect of minimum quantity lubrication (MQL) and dry cutting towards the cutting tool life and chip morphology in high-speed milling of aluminum alloy 7075-T6 with uncoated carbide tools. MQL and dry cutting were eco-friendly approaches that highlight essential issues in the field of manufacturing technology. Thus, further investigation required to observe the intensity of those approaches. The experiment was done on computer numerical control (CNC) five axes milling machine at distinct machining parameters, which are cutting speed (500 and 600 m/min), feed rate (0.12 and 0.15 mm/tooth) and axial depth of cut (1.4 and 1.7 mm), while the radial depth of cut restricted to 7 mm. The effect of fluid approaches and machining parameters on eight samples have analyzed the result of the setting of three factors and two levels in accordance with the full factorial design and analyzed further using ANOVA. The MQL flow rate was set at 100 mL/h. The tool life criterion was determined when the tool wear failure reached 0.30 mm. The chips collected from all machining conditions were taken to be examined using an optical microscope. The empirical model of tool life for the MQL and dry cutting has been developed within the experimental ranges evaluated. The prolonged tool lifespan beyond 20.14 minutes and favorable chip formation were obtained at 500 and 600 m/min, 0.12 mm/tooth, and 1.40 mm, respectively under MQL 100 mL/h. MQL 100 mL/h appeared to be one fit for metal cutting industry that prioritizes clean and green machining as well as the use of appropriate machining parameters as it leads to economic benefits in terms of fluid cost-saving and the better machinability.

The International Journal of Integrated Engineering, 2019

Nowadays, aluminum alloy 7075-T6 has received a high demand in the automotive industry due to its... more Nowadays, aluminum alloy 7075-T6 has received a high demand in the automotive industry due to its advantages in the aerospace industry, which possessing exceptional mechanical combinations and chemical elements such as high tensile strength, high strength, high corrosion resistance, zinc, magnesium, and copper to increase their strength. Nevertheless, environmentally friendly approaches are necessary to improvise surface quality and machining performances as well as minimize the adverse environment. This has directly influenced the trend of approach or strategy of cutting fluids towards the machining of high-performance material in the automotive industry. There have been some probations to decrease the volume of cutting fluid application in machining. The approach of cutting fluids become prominent indicator in contribution to minimize the application of cutting fluid so that the machining of aluminum alloy 7075-T6 become more effective and environmental friendly. Thus, results can be found in the low tool wear, minimum heat energy generated and reduced machining cost in encouraging the application of MQL as viable formulations to enhance the machining performance and machined surface quality. The primary objective of review work is summarized all the emerging environmentally friendly approaches towards the high-performance material. Impact of machining process parameters on dependent variables such as surface integrity, tool wear, chip formation, and mechanical properties have been discussed in the light of the findings of the recent study.

Journal of Mechanical Engineering and Science, 2018

Turning operations are a versatile secondary metal cutting process. In metal cutting industry, ma... more Turning operations are a versatile secondary metal cutting process. In metal cutting industry, manufacturing processes are designed to attain minimum manufacturing cost, best quality and improved cutting tool's performance. Nonetheless, the deterioration of cutting tools, occupational diseases amongst the workers and environmental aspects are increasingly becoming a major issue. Therefore, one alternative to reduce the impact of metal cutting activity in term of cutting tool, the health and environment is Portable MQL Applicator. The portable MQL applicator is an equipment that equipped with pneumatic system to deliver a small amount of fluid in the form of aerosol into the cutting zone. The effect of the portable MQL applicator was investigated and compared with the results from dry machining in terms of tool life and material removal rate in turning of Inconel 718 using carbide tool. The results showed that the applications of the portable MQL applicator have successfully resulted in better tool life and improved material removal rate.

Journal of Engineering Science and Technology, 2020

The paper reports the findings of the experimental work to study the impact of machining paramete... more The paper reports the findings of the experimental work to study the impact of machining parameters, particularly cutting speed, feed rate, and axial depth of cut towards cutting tool life and machined surface roughness in high-speed milling aluminium alloy 7075-T6 with bullnose cutter under dry environment. Previous studies found that tool life and surface roughness in machining aluminium alloy 7075-T6 using cemented carbide are unfavourable compared to other materials. However, this observation needs further study. Thus, a raw block of aluminium alloy 7075-T6 was proposed in this experiment. An eight-run experiment was designed according to full factorial design based on two levels of cutting speed (500 m/min, 600 m/min), feed rate (0.12 mm/tooth, 0.15 mm/tooth), and axial depth of cut (1.40 mm, 1.70 mm) and then analysed employed ANOVA. Cutting tool life was restricted by tool wear in the milling process. The microscope and portable surface roughness tester were employed to analyse tool wear and average surface roughness value. Cutting speed and feed rate were found to be a significant factor to the tool life and surface roughness. The longest tool lifespan of 16.79 minutes and lowest surface roughness value of 0.595 µm were determined at a speed of 500 and 600 m/min, respectively, with a low combination of the rest of parameter, which are 0.12 mm/tooth and 1.40 mm.

Journal of Advanced Manufacturing Technology, 2018

Nowadays, the challenge in machining industries is focused on achieving high-quality product on c... more Nowadays, the challenge in machining industries is focused on achieving high-quality product on component accuracy, and high production rate. It is necessary to enhance existing technology and develop the product with reasonable cost. Thus, researchers have developed advanced technology such as high-speed machining. High-speed machining plays a very important role in achieving cost and time savings together with better surface finish and dimensional accuracy. High-speed machining is being widely employed in the aerospace industry. Aluminum 7075-T6 is one of the popular materials with attractive properties such as high tensile strength, toughness and high corrosion resistance. Minimum quantity lubrication is known as a technique to provide the best cutting performances. This paper provides the recent studies in minimum quantity lubrication and high-speed machining of aluminum 7075-T6. The influence of high-speed machining process parameters in term the surface roughness and relevant cutting fluid technique have been discussed based on the findings of the recent studies.

International Journal of Recent Technology and Engineering, 2019

 Abstract: This research deals the experimental works on the effect of minimum quantity lubricat... more  Abstract: This research deals the experimental works on the effect of minimum quantity lubrication (MQL) and dry cutting towards the cutting tool life and chip morphology in high-speed milling of aluminum alloy 7075-T6 with uncoated carbide tools. MQL and dry cutting were eco-friendly approaches that highlight essential issues in the field of manufacturing technology. Thus, further investigation required to observe the intensity of those approaches. The experiment was done on computer numerical control (CNC) five axes milling machine at distinct machining parameters, which are cutting speed (500 and 600 m/min), feed rate (0.12 and 0.15 mm/tooth) and axial depth of cut (1.4 and 1.7 mm), while the radial depth of cut restricted to 7 mm. The effect of fluid approaches and machining parameters on eight samples have analyzed the result of the setting of three factors and two levels in accordance with the full factorial design and analyzed further using ANOVA. The MQL flow rate was set at 100 mL/h. The tool life criterion was determined when the tool wear failure reached 0.30 mm. The chips collected from all machining conditions were taken to be examined using an optical microscope. The empirical model of tool life for the MQL and dry cutting has been developed within the experimental ranges evaluated. The prolonged tool lifespan beyond 20.14 minutes and favorable chip formation were obtained at 500 and 600 m/min, 0.12 mm/tooth, and 1.40 mm, respectively under MQL 100 mL/h. MQL 100 mL/h appeared to be one fit for metal cutting industry that prioritizes clean and green machining as well as the use of appropriate machining parameters as it leads to economic benefits in terms of fluid cost-saving and the better machinability.

The International Journal of Integrated Engineering, 2019

Nowadays, aluminum alloy 7075-T6 has received a high demand in the automotive industry due to its... more Nowadays, aluminum alloy 7075-T6 has received a high demand in the automotive industry due to its advantages in the aerospace industry, which possessing exceptional mechanical combinations and chemical elements such as high tensile strength, high strength, high corrosion resistance, zinc, magnesium, and copper to increase their strength. Nevertheless, environmentally friendly approaches are necessary to improvise surface quality and machining performances as well as minimize the adverse environment. This has directly influenced the trend of approach or strategy of cutting fluids towards the machining of high-performance material in the automotive industry. There have been some probations to decrease the volume of cutting fluid application in machining. The approach of cutting fluids become prominent indicator in contribution to minimize the application of cutting fluid so that the machining of aluminum alloy 7075-T6 become more effective and environmental friendly. Thus, results can be found in the low tool wear, minimum heat energy generated and reduced machining cost in encouraging the application of MQL as viable formulations to enhance the machining performance and machined surface quality. The primary objective of review work is summarized all the emerging environmentally friendly approaches towards the high-performance material. Impact of machining process parameters on dependent variables such as surface integrity, tool wear, chip formation, and mechanical properties have been discussed in the light of the findings of the recent study.

Journal of Mechanical Engineering and Science, 2018

Turning operations are a versatile secondary metal cutting process. In metal cutting industry, ma... more Turning operations are a versatile secondary metal cutting process. In metal cutting industry, manufacturing processes are designed to attain minimum manufacturing cost, best quality and improved cutting tool's performance. Nonetheless, the deterioration of cutting tools, occupational diseases amongst the workers and environmental aspects are increasingly becoming a major issue. Therefore, one alternative to reduce the impact of metal cutting activity in term of cutting tool, the health and environment is Portable MQL Applicator. The portable MQL applicator is an equipment that equipped with pneumatic system to deliver a small amount of fluid in the form of aerosol into the cutting zone. The effect of the portable MQL applicator was investigated and compared with the results from dry machining in terms of tool life and material removal rate in turning of Inconel 718 using carbide tool. The results showed that the applications of the portable MQL applicator have successfully resulted in better tool life and improved material removal rate.

Journal of Engineering Science and Technology, 2020

The paper reports the findings of the experimental work to study the impact of machining paramete... more The paper reports the findings of the experimental work to study the impact of machining parameters, particularly cutting speed, feed rate, and axial depth of cut towards cutting tool life and machined surface roughness in high-speed milling aluminium alloy 7075-T6 with bullnose cutter under dry environment. Previous studies found that tool life and surface roughness in machining aluminium alloy 7075-T6 using cemented carbide are unfavourable compared to other materials. However, this observation needs further study. Thus, a raw block of aluminium alloy 7075-T6 was proposed in this experiment. An eight-run experiment was designed according to full factorial design based on two levels of cutting speed (500 m/min, 600 m/min), feed rate (0.12 mm/tooth, 0.15 mm/tooth), and axial depth of cut (1.40 mm, 1.70 mm) and then analysed employed ANOVA. Cutting tool life was restricted by tool wear in the milling process. The microscope and portable surface roughness tester were employed to analyse tool wear and average surface roughness value. Cutting speed and feed rate were found to be a significant factor to the tool life and surface roughness. The longest tool lifespan of 16.79 minutes and lowest surface roughness value of 0.595 µm were determined at a speed of 500 and 600 m/min, respectively, with a low combination of the rest of parameter, which are 0.12 mm/tooth and 1.40 mm.