R. Izamshah | Universiti Teknikal Malaysia Melaka (original) (raw)

Papers by R. Izamshah

International Journal of Manufacturing Technology and Management, 2019

Demand for complex micro-sized shape components has driven the industries on the development of a... more Demand for complex micro-sized shape components has driven the industries on the development of a new machine and fabrication technique. One of the latest techniques is by combining a sparking electrode wire with a rotating workpiece, known as cylindrical wire electrical discharge turning (CWEDT). However, owing to the uncontrolled discharge energy, the existence of dynamic run-out and valid wire positioning compensation estimations in the CWEDT process affect its capability of producing micro-sized components. This paper proposes a new compensation configuration model for the CWEDT process that aims to improve the dimensional accuracy. The developed configuration model emphasises the way to obtain the desired diameter that can be used as the input value for positioning the electrode wire through a machine system. Sets of experimental runs were performed to confirm its validity. Analytical results show that the developed model has improved the part accuracy up to 95% and is capable of eliminating overcut error, hence, verifying its validity.

The International Journal of Advanced Manufacturing Technology, 2010

In the present study, an attempt has been made to investigate the influence of cutting speed, dep... more In the present study, an attempt has been made to investigate the influence of cutting speed, depth of cut, and feed rate on surface roughness during machining of 7075 Al alloy and 10 wt.% SiC particulate metal-matrix composites. The experiments were conducted on a CNC Turning Machine using tungsten carbide and polycrystalline diamond (PCD) inserts. Surface roughness of 7075Al alloy with

Key Engineering Materials, 2010

In an attempt to decrease weight, new commercial and military aircraft are designs with unitised ... more In an attempt to decrease weight, new commercial and military aircraft are designs with unitised monolithic metal structural components which contains of thinner ribs (i.e., walls) and webs (i.e., floors). Most of the unitised monolithic metal structural components are machined from solid plate or forgings with the start-to-finish weight ratio of 20:1. The resulting thin-walled structure often suffers a deformation which causes a dimensional surface error due to the action of the cutting force generated during the machining process. To alleviate the resulting surface errors, current practices rely on machining through repetitive feeding several times and manual calibration which resulting in long cycle times, low productivity and high operating cost. A finite element analysis (FEA) machining model is developed in this project to specifically predict the distortion or deflection of the part during end milling process. The model aims to provide an input for downstream decision making ...

Lecture Notes in Mechanical Engineering, 2022

Machining and Machinability of Fiber Reinforced Polymer Composites, 2020

Machining of hardened mould and die material is a very challenging process due to the high streng... more Machining of hardened mould and die material is a very challenging process due to the high strength of the materials. Rough machined surface and premature tool wear are some of the issues that are related when machining with this material. On the other hand, ultrasonic assisted machining (UAM) technique has proven to improve the machined surface and tool life especially for brittle materials such as glass and quartz. Based on the capabilities of UAM technique and to overcome the problem owned by a conventional milling method, this paper evaluate the UAM technique for machining hardened AISI D2 material with the aim to improve the machined surface. Experiments of ultrasonic assisted milling were conducted to investigate the surface roughness of machines surface during slot milling cutting operation. From the conducted investigation, surface roughness values was improved from 0.60 m (non ultrasonic) to 0.26 m (ultrasonic) at 37 m/min (cutting speed), 65 mm/min (feed rate) and 0.4 mm...

The requirement of drilling process of Carbon Fibre Reinforced Plastic (CFRP) is vital in order t... more The requirement of drilling process of Carbon Fibre Reinforced Plastic (CFRP) is vital in order to fulfil final assembly specifications. Despite the excellent mechanical properties of composites, they are hard to be machined due to its toughness. The damages such as peel-up and push-out delamination usually occur during its machining. To provide drilling induced delamination is a priority to reduce parts rejection and lead to waste in time and money. In this work, a comparative study of three geometries under different cutting conditions is presented. Application Taguchi’s design of experiments for this experimental works increase the analysis reliability. Various penetration angle drilling also studied to determine the effect of thrust force and delamination. Thrust force was monitored during drilling tests, and delamination extension was quantified using image processing software. Results are processed using analysis of variance (ANOVA) then further presented by response surface g...

Wire electrical discharge machining (WEDM) is one of nontraditional processes known as a solution... more Wire electrical discharge machining (WEDM) is one of nontraditional processes known as a solution for machining difficult-to-machine material. In this study, the existing parameters provided by WEDM machine (Mitsubishi RA90) were tested and compared for machining Ti6Al4V purposely for parameter screening further optimization. A statistical approach namely one way analysis of variance (ANOVA) with Tukey’s multiple comparison was used for effective comparison focusing on surface roughness, kerf width and material removal rate. The descriptive statistic yielded that Power Supply 1 (HP) of Mitsubishi RA90 produced higher surface roughness, kerf width and MRR compared to other conditions. In addition, the statistical comparison indicated significant difference on surface roughness for every type of categories except power supply 3 (LA) as indicated by Tukey’s multiple comparisons. For kerf width, only power supply 2 (HP/MP) rejected alternative hypothesis which indicated that all the mea...

During the orthopedic bone drilling surgery procedures, the friction between the drill and bones ... more During the orthopedic bone drilling surgery procedures, the friction between the drill and bones surface leads to a localized temperature increase results in thermal necrosis on the soft tissue surrounding the hole. The magnitudes of the friction energy are greatly dependent with the drill geometry design. Recognizing the importance on studying this phenomenon, this paper aim to investigate the effects of drill geometry on temperatures during the bone drilling procedure. Totals of 17 drills were design and tested with different geometry namely point angle, helix angle and web thickness on different penetration angle (0⁰, 15⁰, and 30⁰) to mimic the manually control penetration by the surgeon. From the conducted investigation, the most significant parameter that affects the temperature rise was the penetration angle followed by the point angle. In addition, the interaction between helix angle and web thickness also controlled the drilling temperature. From the result, the optimum dril...

Lecture Notes in Mechanical Engineering, 2019

Machining hardened D2 tool steel material for mold and die application facing many problems such ... more Machining hardened D2 tool steel material for mold and die application facing many problems such as low material removal rate, poor machined surface, high cutting force, extreme machining temperature and rapid tool wear. A new machining strategies using rotary ultrasonic assisted end milling (RUAEM) is proposed aim to improve material removal rate (MRR) and machining time. To evaluate on the effectiveness, machining test were perform between conventional machining and RUAEM with different slurry concentration ranging from 0 to 20% alumina oxide contents. Taguchi statistical technique was used as the experiment design consists of independent variables i.e. cutting speed, feed rate, depth of cut, frequency vibration, amplitude vibration and abbrasive slurry concentration with MRR as the machining response. The highest MRR with an average value of 161.58 mg/min was obtained from the combination of runs no. 12-e (Speed of 30 rpm, 45 mm/min feed rate, 30 µm depth of cut, frequency of 27 kHz, 1 µm amplitude and 20% concentration). From ANOVA analysis, it proved that the strongest machining parameter factor that affecting the material removal rate (MRR) are cutting speed (A), feed rate (B), depth of cut (C), % slurry concentration (E), cutting speed & depth of cut (AC), cutting speed & frequency (AD) and cutting speed & amplitude (AE). The result indicates that by adding ultrasonic frequency can improve the MRR values in machining hardened materials.

Journal of Physics: Conference Series, 2018

Engine mounting suffers from fluctuating forces which may results in sudden failure due to fatigu... more Engine mounting suffers from fluctuating forces which may results in sudden failure due to fatigue. Graphene nanoplatelets have attracted great interest due to their exceptional physical, mechanical and thermal properties. Natural rubber/ethylene propylene diene monomer (NR/EPDM) reinforced with graphene nanoplatelets (GNPs) were investigated to improve the properties of NR/EPDM blend prior to fatigue and mechanical properties for engine mounting service. Firstly, the NR/EPDM blends and nanocomposite were tested for tensile properties and followed by the fatigue properties (tensile mode) using displacementcontrolled. Tensile plot shows that the NR/EPDM nanocomposite has higher tensile value of 95% compared to NR/EPDM blend. The S-N curve illustrates that NR/EPDM blend and NR/EPDM nanocomposite break by the same cycle which is 100 000 cycles. The fracture behaviour of loading conditions was supported via morphological analysis using scanning electron microscopy (SEM) and X-ray diffraction (XRD) analysis.

IOP Conference Series: Materials Science and Engineering, 2019

The use of carbon fibres reinforced plastic (CFRP) composites material for product structures has... more The use of carbon fibres reinforced plastic (CFRP) composites material for product structures has been steadily increasing due to the superior material properties such as high strength, low weight and corrosion resistance especially in aerospace industry. This work presents a research on the influence of various router or burrs tool geometrical feature towards surface roughness in edge trimming process on a specific CFRP material. CFRP panel which measured in 3.41mm thickness with 28 plies in total has been chosen to be the main study material. Three various geometrical features of router tool made of uncoated tungsten carbide material with diameter of 6.35mm which vary in number of flute and helix angle were utilized to investigate the effect of surface roughness in edge trimming of CFRP material. Surface roughness measurement was taken using Mitutoyo Surftest SJ-410. Furthermore, optical microscope Nikon MM-800 is utilized to further observe the trimmed surfaces. The result reveals that tool type 3 (T3) resulted the lowest surface roughness with respect to the overall averaged Ra value which ranged between 2.22µm to 5.29µm whilst tool type 1 (T1) obtained the highest Ra values ranged between 2.86µm to 19.36µm. On the other hand, the tool type 2 (T2) falls in the middle between the rests of two others type of tool which stated the range of Ra average value was between 3.91µm to 5.28µm. This result is also supported by photomicrographs observation taken by optical microscope which elaborated and discussed further in this paper.

Transactions of the IMF, 2016

Interest is currently being focused on promoting environmentally friendly manufacturing without s... more Interest is currently being focused on promoting environmentally friendly manufacturing without sacrificing productivity by utilising a minimum quantity lubrication (MQL) as a biodegradable coolant in the end-milling of Inconel 718. This study was carried out to compare the costs of applying machining and lubrication to the end-milling process at various cutting conditions. The high-speed cutting of Inconel 718 was performed using response surface methodology, and the optimisation conditions of the physical vapour deposition TiAlN/AlCrN-coated carbide tool consumption and the MQL were evaluated according to the performance of the tool, i.e. machining time and material removed. In addition, the number of cutting tool edges was taken into consideration when calculating the machining cost. The machining performance at maximum tool life, the minimum surface roughness and force were compared with the optimum conditions, and the results showed that the application of MQL and the use of a ball nose end mill under optimum conditions are competitive. The multi-objective optimisation of cutting parameters, with regard to the criteria for the maximum material removed (9.029 cm3) and the lowest total cost (US $ 0.11 cm−3), provided a combination of parameters that met the requirements for green manufacturing, i.e. by reducing the usage of cutting tools and the consumption of lubrication.

Structural titanium alloys are coming in for increased use because they are light, ductile and ha... more Structural titanium alloys are coming in for increased use because they are light, ductile and have good fatigue and corrosion-resistance properties As a result; more manufacturing engineers are learning that machining these alloys can be a tricky job due to their unique physical and chemical properties. The problems are worsened when machining with the lowrigidity part which makes the precision difficult to master. This paper consist of two parts, a new CAD/CAE/CAM integrated methodology for predicting the surface errors when machining a thin-wall low rigidity component and secondly, the statistical analysis to determine the correlation between a criterion variable (form errors) and a combination of a predictor (cutting parameters and component attributes). The proposed model would be an efficient means for analysing the root cause of errors induced during machining of thin-wall parts and provide an input for downstream decision making on error compensation. A set of machining tests have been done in order to validate the accuracy of the model and the results between simulation and experiment were found in a good agreement

A friction stir welding (FSW) is normally used to join two similar or dissimilar laps or butt joi... more A friction stir welding (FSW) is normally used to join two similar or dissimilar laps or butt joints for alloys and/or materials. FSW produces good joint efficiency, especially for dissimilar ones as compared to other welding methods. In the present study, a single-pass FSW is used for butt joining of the 5083 and 6061 aluminum alloy plates lap to steel (electro-galvanized steel) by employing the plunging and diffusion assisted bonding techniques. The backscattered electron detector image obtained from a scanning electron microscope showed the existence of an intermetallic reaction layer at the welded interface zone. The compositions of the intermetallic layers were investigated by utilizing energy-dispersive X-ray spectroscopy. The tensile tests were used to examine the joint efficiency of specimens welded by using different welding parameters. It was found that at 900 rpm rotational speed and 20 mm/min welding speed, the maximum joint efficiency was 73%.

The paper presents a studyof the effect of operating variable parameter; cutting speed, feed rate... more The paper presents a studyof the effect of operating variable parameter; cutting speed, feed rate, depth of cut and width of cut on heat being generated when end milling under MQL condition. The response surface methodology (RSM) was employed in the experiment, and a Box-Behnken design was used to determine the cause and effect of the relationship between the input variables and response. The investigated milling parameters were cutting speed (100-140 m/min), feed rate (0.1-0.2 mm/tooth), depth of cut (0.5-1.0 mm) and width of cut (0.2-1.8 mm). Result of this study show ball nose end milling generates low temperature ranging from 69°C to 359°C. Experimental data and statistical analysis showed that heat generation was dominated by radial depth of cut, followed by axial depth of cut. Feed rate and cutting speed were found statistically not significant. The linear models were developed with a 92% confidence level. The optimum condition required for minimum heat generated include cutting speed of 117 m/min, feed rate of 0.11 mm/rev, axial depth of cut of 0.57 mm, and radial depth of cut of 0.21 mm. With this optimum condition, a minimum heat generated of 68°C was obtained.

Wear, 2019

Inconel 718 known as hard-to-cut material due to its superior mechanical properties; high creep r... more Inconel 718 known as hard-to-cut material due to its superior mechanical properties; high creep resistance, high fatigue strength, and able to withstand at elevated temperature which remains as challenge to possesses a lower surface roughness (Ra) during machining. The surface topology indicates the integrity of the machined parts. The quality of the Inconel 718 surface during end milling process was investigated. The experiments involved the use of PVD coated with TiAlN/ AlCrN ball nose tungsten carbide with varying of cutting speeds (Vc) ranging between 100 and 140 m/min, a feed rate (fz) of 0.1-0.2 mm/tooth, and an axial depth of cut (DoC) of 0.5-1.0 mm. The effects of the width of cut (WoC) between 0.2 and 1.8 mm were carried out. Due to the profile of the milled surface is complex; some variations in gap distance on the spiral profile were detected. The cutting path area to be found that, the new cut is overlapped which generate a new surface roughness by eliminating the previous cut thus the non-uniform feed marks being created on the machined surface. The surface roughness measured in feed direction was found to be lowered than pick a direction. Furthermore it was found that the WoC are causes the variation in Ra. During machining at low feed rates, the phenomenon of carbide particles was observed which results third body abrasion of machined surface. The particles are then trapped between the fragments and tear surface of the workpiece, thus increases the surface roughness. Based on the interaction effect of WoC and fz, it can be concluded that the feed rate effects on the quality of machined surface whilst WoC controls Ra variation.

The International Journal of Advanced Manufacturing Technology

IOP Conference Series: Materials Science and Engineering

Inconel 718 has been widely used in aerospace because of its excellent mechanical properties such... more Inconel 718 has been widely used in aerospace because of its excellent mechanical properties such as good corrosion resistance, strong creep resistance and high fatigue strength. However, these excellent properties also lead to heavy tool damage and high cutting force in the milling process. There is no reported investigation on ultrasonic assisted machining (UAM) of Inconel 718 parts. In this paper, UAM is proposed as the potential technique to reduce tool damage and the cutting force of Inconel 718 parts. This review paper provides an overview of UAM to investigate the relationship between the tool wear and the cutting force with ultrasonic vibration compared to without ultrasonic vibration assisted. Throughout the study, the UAM scopes are related to the tool life of coated carbide insert, the force generated during the cutting process and also the final surface finish of the workpiece by using various parameters during the machining activity.

IOP Conference Series: Materials Science and Engineering

This work reports studies on the aerodynamics of air flow in the plenum chamber of a swirling flu... more This work reports studies on the aerodynamics of air flow in the plenum chamber of a swirling fluidized bed. The study focused on the effect of annular spiral blade distributor configuration whereby the effect of various pitch length (60 mm, 80 mm and 100 mm) via various horizontal inclination angle (0°, 12° and 15°). The CFD method is used to compute and obtain the performance results as well as pressure drop data. Moreover, high pressure drop is undesirable since high pumping power is needed to sustain the pressure needed to run the swirling fluidized bed processes. It should be as low as possible to reduce the power being wasted during the processes. The numerical result at the parameter of horizontal blade inclination of 15° via pitch length of spiral blade distributor of 100 mm shows that effect on large overlapping length of blade (trapezoidal) area consume less pressure drop.

International Journal of Manufacturing Technology and Management, 2019

Demand for complex micro-sized shape components has driven the industries on the development of a... more Demand for complex micro-sized shape components has driven the industries on the development of a new machine and fabrication technique. One of the latest techniques is by combining a sparking electrode wire with a rotating workpiece, known as cylindrical wire electrical discharge turning (CWEDT). However, owing to the uncontrolled discharge energy, the existence of dynamic run-out and valid wire positioning compensation estimations in the CWEDT process affect its capability of producing micro-sized components. This paper proposes a new compensation configuration model for the CWEDT process that aims to improve the dimensional accuracy. The developed configuration model emphasises the way to obtain the desired diameter that can be used as the input value for positioning the electrode wire through a machine system. Sets of experimental runs were performed to confirm its validity. Analytical results show that the developed model has improved the part accuracy up to 95% and is capable of eliminating overcut error, hence, verifying its validity.

The International Journal of Advanced Manufacturing Technology, 2010

In the present study, an attempt has been made to investigate the influence of cutting speed, dep... more In the present study, an attempt has been made to investigate the influence of cutting speed, depth of cut, and feed rate on surface roughness during machining of 7075 Al alloy and 10 wt.% SiC particulate metal-matrix composites. The experiments were conducted on a CNC Turning Machine using tungsten carbide and polycrystalline diamond (PCD) inserts. Surface roughness of 7075Al alloy with

Key Engineering Materials, 2010

In an attempt to decrease weight, new commercial and military aircraft are designs with unitised ... more In an attempt to decrease weight, new commercial and military aircraft are designs with unitised monolithic metal structural components which contains of thinner ribs (i.e., walls) and webs (i.e., floors). Most of the unitised monolithic metal structural components are machined from solid plate or forgings with the start-to-finish weight ratio of 20:1. The resulting thin-walled structure often suffers a deformation which causes a dimensional surface error due to the action of the cutting force generated during the machining process. To alleviate the resulting surface errors, current practices rely on machining through repetitive feeding several times and manual calibration which resulting in long cycle times, low productivity and high operating cost. A finite element analysis (FEA) machining model is developed in this project to specifically predict the distortion or deflection of the part during end milling process. The model aims to provide an input for downstream decision making ...

Lecture Notes in Mechanical Engineering, 2022

Machining and Machinability of Fiber Reinforced Polymer Composites, 2020

Machining of hardened mould and die material is a very challenging process due to the high streng... more Machining of hardened mould and die material is a very challenging process due to the high strength of the materials. Rough machined surface and premature tool wear are some of the issues that are related when machining with this material. On the other hand, ultrasonic assisted machining (UAM) technique has proven to improve the machined surface and tool life especially for brittle materials such as glass and quartz. Based on the capabilities of UAM technique and to overcome the problem owned by a conventional milling method, this paper evaluate the UAM technique for machining hardened AISI D2 material with the aim to improve the machined surface. Experiments of ultrasonic assisted milling were conducted to investigate the surface roughness of machines surface during slot milling cutting operation. From the conducted investigation, surface roughness values was improved from 0.60 m (non ultrasonic) to 0.26 m (ultrasonic) at 37 m/min (cutting speed), 65 mm/min (feed rate) and 0.4 mm...

The requirement of drilling process of Carbon Fibre Reinforced Plastic (CFRP) is vital in order t... more The requirement of drilling process of Carbon Fibre Reinforced Plastic (CFRP) is vital in order to fulfil final assembly specifications. Despite the excellent mechanical properties of composites, they are hard to be machined due to its toughness. The damages such as peel-up and push-out delamination usually occur during its machining. To provide drilling induced delamination is a priority to reduce parts rejection and lead to waste in time and money. In this work, a comparative study of three geometries under different cutting conditions is presented. Application Taguchi’s design of experiments for this experimental works increase the analysis reliability. Various penetration angle drilling also studied to determine the effect of thrust force and delamination. Thrust force was monitored during drilling tests, and delamination extension was quantified using image processing software. Results are processed using analysis of variance (ANOVA) then further presented by response surface g...

Wire electrical discharge machining (WEDM) is one of nontraditional processes known as a solution... more Wire electrical discharge machining (WEDM) is one of nontraditional processes known as a solution for machining difficult-to-machine material. In this study, the existing parameters provided by WEDM machine (Mitsubishi RA90) were tested and compared for machining Ti6Al4V purposely for parameter screening further optimization. A statistical approach namely one way analysis of variance (ANOVA) with Tukey’s multiple comparison was used for effective comparison focusing on surface roughness, kerf width and material removal rate. The descriptive statistic yielded that Power Supply 1 (HP) of Mitsubishi RA90 produced higher surface roughness, kerf width and MRR compared to other conditions. In addition, the statistical comparison indicated significant difference on surface roughness for every type of categories except power supply 3 (LA) as indicated by Tukey’s multiple comparisons. For kerf width, only power supply 2 (HP/MP) rejected alternative hypothesis which indicated that all the mea...

During the orthopedic bone drilling surgery procedures, the friction between the drill and bones ... more During the orthopedic bone drilling surgery procedures, the friction between the drill and bones surface leads to a localized temperature increase results in thermal necrosis on the soft tissue surrounding the hole. The magnitudes of the friction energy are greatly dependent with the drill geometry design. Recognizing the importance on studying this phenomenon, this paper aim to investigate the effects of drill geometry on temperatures during the bone drilling procedure. Totals of 17 drills were design and tested with different geometry namely point angle, helix angle and web thickness on different penetration angle (0⁰, 15⁰, and 30⁰) to mimic the manually control penetration by the surgeon. From the conducted investigation, the most significant parameter that affects the temperature rise was the penetration angle followed by the point angle. In addition, the interaction between helix angle and web thickness also controlled the drilling temperature. From the result, the optimum dril...

Lecture Notes in Mechanical Engineering, 2019

Machining hardened D2 tool steel material for mold and die application facing many problems such ... more Machining hardened D2 tool steel material for mold and die application facing many problems such as low material removal rate, poor machined surface, high cutting force, extreme machining temperature and rapid tool wear. A new machining strategies using rotary ultrasonic assisted end milling (RUAEM) is proposed aim to improve material removal rate (MRR) and machining time. To evaluate on the effectiveness, machining test were perform between conventional machining and RUAEM with different slurry concentration ranging from 0 to 20% alumina oxide contents. Taguchi statistical technique was used as the experiment design consists of independent variables i.e. cutting speed, feed rate, depth of cut, frequency vibration, amplitude vibration and abbrasive slurry concentration with MRR as the machining response. The highest MRR with an average value of 161.58 mg/min was obtained from the combination of runs no. 12-e (Speed of 30 rpm, 45 mm/min feed rate, 30 µm depth of cut, frequency of 27 kHz, 1 µm amplitude and 20% concentration). From ANOVA analysis, it proved that the strongest machining parameter factor that affecting the material removal rate (MRR) are cutting speed (A), feed rate (B), depth of cut (C), % slurry concentration (E), cutting speed & depth of cut (AC), cutting speed & frequency (AD) and cutting speed & amplitude (AE). The result indicates that by adding ultrasonic frequency can improve the MRR values in machining hardened materials.

Journal of Physics: Conference Series, 2018

Engine mounting suffers from fluctuating forces which may results in sudden failure due to fatigu... more Engine mounting suffers from fluctuating forces which may results in sudden failure due to fatigue. Graphene nanoplatelets have attracted great interest due to their exceptional physical, mechanical and thermal properties. Natural rubber/ethylene propylene diene monomer (NR/EPDM) reinforced with graphene nanoplatelets (GNPs) were investigated to improve the properties of NR/EPDM blend prior to fatigue and mechanical properties for engine mounting service. Firstly, the NR/EPDM blends and nanocomposite were tested for tensile properties and followed by the fatigue properties (tensile mode) using displacementcontrolled. Tensile plot shows that the NR/EPDM nanocomposite has higher tensile value of 95% compared to NR/EPDM blend. The S-N curve illustrates that NR/EPDM blend and NR/EPDM nanocomposite break by the same cycle which is 100 000 cycles. The fracture behaviour of loading conditions was supported via morphological analysis using scanning electron microscopy (SEM) and X-ray diffraction (XRD) analysis.

IOP Conference Series: Materials Science and Engineering, 2019

The use of carbon fibres reinforced plastic (CFRP) composites material for product structures has... more The use of carbon fibres reinforced plastic (CFRP) composites material for product structures has been steadily increasing due to the superior material properties such as high strength, low weight and corrosion resistance especially in aerospace industry. This work presents a research on the influence of various router or burrs tool geometrical feature towards surface roughness in edge trimming process on a specific CFRP material. CFRP panel which measured in 3.41mm thickness with 28 plies in total has been chosen to be the main study material. Three various geometrical features of router tool made of uncoated tungsten carbide material with diameter of 6.35mm which vary in number of flute and helix angle were utilized to investigate the effect of surface roughness in edge trimming of CFRP material. Surface roughness measurement was taken using Mitutoyo Surftest SJ-410. Furthermore, optical microscope Nikon MM-800 is utilized to further observe the trimmed surfaces. The result reveals that tool type 3 (T3) resulted the lowest surface roughness with respect to the overall averaged Ra value which ranged between 2.22µm to 5.29µm whilst tool type 1 (T1) obtained the highest Ra values ranged between 2.86µm to 19.36µm. On the other hand, the tool type 2 (T2) falls in the middle between the rests of two others type of tool which stated the range of Ra average value was between 3.91µm to 5.28µm. This result is also supported by photomicrographs observation taken by optical microscope which elaborated and discussed further in this paper.

Transactions of the IMF, 2016

Interest is currently being focused on promoting environmentally friendly manufacturing without s... more Interest is currently being focused on promoting environmentally friendly manufacturing without sacrificing productivity by utilising a minimum quantity lubrication (MQL) as a biodegradable coolant in the end-milling of Inconel 718. This study was carried out to compare the costs of applying machining and lubrication to the end-milling process at various cutting conditions. The high-speed cutting of Inconel 718 was performed using response surface methodology, and the optimisation conditions of the physical vapour deposition TiAlN/AlCrN-coated carbide tool consumption and the MQL were evaluated according to the performance of the tool, i.e. machining time and material removed. In addition, the number of cutting tool edges was taken into consideration when calculating the machining cost. The machining performance at maximum tool life, the minimum surface roughness and force were compared with the optimum conditions, and the results showed that the application of MQL and the use of a ball nose end mill under optimum conditions are competitive. The multi-objective optimisation of cutting parameters, with regard to the criteria for the maximum material removed (9.029 cm3) and the lowest total cost (US $ 0.11 cm−3), provided a combination of parameters that met the requirements for green manufacturing, i.e. by reducing the usage of cutting tools and the consumption of lubrication.

Structural titanium alloys are coming in for increased use because they are light, ductile and ha... more Structural titanium alloys are coming in for increased use because they are light, ductile and have good fatigue and corrosion-resistance properties As a result; more manufacturing engineers are learning that machining these alloys can be a tricky job due to their unique physical and chemical properties. The problems are worsened when machining with the lowrigidity part which makes the precision difficult to master. This paper consist of two parts, a new CAD/CAE/CAM integrated methodology for predicting the surface errors when machining a thin-wall low rigidity component and secondly, the statistical analysis to determine the correlation between a criterion variable (form errors) and a combination of a predictor (cutting parameters and component attributes). The proposed model would be an efficient means for analysing the root cause of errors induced during machining of thin-wall parts and provide an input for downstream decision making on error compensation. A set of machining tests have been done in order to validate the accuracy of the model and the results between simulation and experiment were found in a good agreement

A friction stir welding (FSW) is normally used to join two similar or dissimilar laps or butt joi... more A friction stir welding (FSW) is normally used to join two similar or dissimilar laps or butt joints for alloys and/or materials. FSW produces good joint efficiency, especially for dissimilar ones as compared to other welding methods. In the present study, a single-pass FSW is used for butt joining of the 5083 and 6061 aluminum alloy plates lap to steel (electro-galvanized steel) by employing the plunging and diffusion assisted bonding techniques. The backscattered electron detector image obtained from a scanning electron microscope showed the existence of an intermetallic reaction layer at the welded interface zone. The compositions of the intermetallic layers were investigated by utilizing energy-dispersive X-ray spectroscopy. The tensile tests were used to examine the joint efficiency of specimens welded by using different welding parameters. It was found that at 900 rpm rotational speed and 20 mm/min welding speed, the maximum joint efficiency was 73%.

The paper presents a studyof the effect of operating variable parameter; cutting speed, feed rate... more The paper presents a studyof the effect of operating variable parameter; cutting speed, feed rate, depth of cut and width of cut on heat being generated when end milling under MQL condition. The response surface methodology (RSM) was employed in the experiment, and a Box-Behnken design was used to determine the cause and effect of the relationship between the input variables and response. The investigated milling parameters were cutting speed (100-140 m/min), feed rate (0.1-0.2 mm/tooth), depth of cut (0.5-1.0 mm) and width of cut (0.2-1.8 mm). Result of this study show ball nose end milling generates low temperature ranging from 69°C to 359°C. Experimental data and statistical analysis showed that heat generation was dominated by radial depth of cut, followed by axial depth of cut. Feed rate and cutting speed were found statistically not significant. The linear models were developed with a 92% confidence level. The optimum condition required for minimum heat generated include cutting speed of 117 m/min, feed rate of 0.11 mm/rev, axial depth of cut of 0.57 mm, and radial depth of cut of 0.21 mm. With this optimum condition, a minimum heat generated of 68°C was obtained.

Wear, 2019

Inconel 718 known as hard-to-cut material due to its superior mechanical properties; high creep r... more Inconel 718 known as hard-to-cut material due to its superior mechanical properties; high creep resistance, high fatigue strength, and able to withstand at elevated temperature which remains as challenge to possesses a lower surface roughness (Ra) during machining. The surface topology indicates the integrity of the machined parts. The quality of the Inconel 718 surface during end milling process was investigated. The experiments involved the use of PVD coated with TiAlN/ AlCrN ball nose tungsten carbide with varying of cutting speeds (Vc) ranging between 100 and 140 m/min, a feed rate (fz) of 0.1-0.2 mm/tooth, and an axial depth of cut (DoC) of 0.5-1.0 mm. The effects of the width of cut (WoC) between 0.2 and 1.8 mm were carried out. Due to the profile of the milled surface is complex; some variations in gap distance on the spiral profile were detected. The cutting path area to be found that, the new cut is overlapped which generate a new surface roughness by eliminating the previous cut thus the non-uniform feed marks being created on the machined surface. The surface roughness measured in feed direction was found to be lowered than pick a direction. Furthermore it was found that the WoC are causes the variation in Ra. During machining at low feed rates, the phenomenon of carbide particles was observed which results third body abrasion of machined surface. The particles are then trapped between the fragments and tear surface of the workpiece, thus increases the surface roughness. Based on the interaction effect of WoC and fz, it can be concluded that the feed rate effects on the quality of machined surface whilst WoC controls Ra variation.

The International Journal of Advanced Manufacturing Technology

IOP Conference Series: Materials Science and Engineering

Inconel 718 has been widely used in aerospace because of its excellent mechanical properties such... more Inconel 718 has been widely used in aerospace because of its excellent mechanical properties such as good corrosion resistance, strong creep resistance and high fatigue strength. However, these excellent properties also lead to heavy tool damage and high cutting force in the milling process. There is no reported investigation on ultrasonic assisted machining (UAM) of Inconel 718 parts. In this paper, UAM is proposed as the potential technique to reduce tool damage and the cutting force of Inconel 718 parts. This review paper provides an overview of UAM to investigate the relationship between the tool wear and the cutting force with ultrasonic vibration compared to without ultrasonic vibration assisted. Throughout the study, the UAM scopes are related to the tool life of coated carbide insert, the force generated during the cutting process and also the final surface finish of the workpiece by using various parameters during the machining activity.

IOP Conference Series: Materials Science and Engineering

This work reports studies on the aerodynamics of air flow in the plenum chamber of a swirling flu... more This work reports studies on the aerodynamics of air flow in the plenum chamber of a swirling fluidized bed. The study focused on the effect of annular spiral blade distributor configuration whereby the effect of various pitch length (60 mm, 80 mm and 100 mm) via various horizontal inclination angle (0°, 12° and 15°). The CFD method is used to compute and obtain the performance results as well as pressure drop data. Moreover, high pressure drop is undesirable since high pumping power is needed to sustain the pressure needed to run the swirling fluidized bed processes. It should be as low as possible to reduce the power being wasted during the processes. The numerical result at the parameter of horizontal blade inclination of 15° via pitch length of spiral blade distributor of 100 mm shows that effect on large overlapping length of blade (trapezoidal) area consume less pressure drop.