Abdullah Wagiman | Universiti Tun Hussein Onn Malaysia (original) (raw)

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Papers by Abdullah Wagiman

Research paper thumbnail of A Study on Surface Roughness and Burr Formation of Al6061 with Different Spindle Speed and Federate for Small End Milling Cutter

This paper reports the results of experiments to investigate surface roughness and burr formation... more This paper reports the results of experiments to investigate surface roughness and burr formation during the slot milling of Aluminum 6061. The experiment was carried out with small cutting tool diameter and several of spindles speed and federate. Generally, cutting parameters will influence on surface roughness and the formation of burrs in small slot milling operations. Although it is not possible to avoid burr formation by modifying the cutting parameters, the burr size can be reduced by selecting the appropriate values. The results showed that slot milling with cutting tool with diameter 2.0mm and 3.0mm have a similar behavior for surface roughness with respect to federate and spindle speed. The larger cutting tool diameter results in a larger burr formed. Burr height increased due to larger chip load as the spindle speed increased. It also shown that Burr-breakage type of burr more significant in cutting AL6061

Research paper thumbnail of Improving Surface Smoothness of Aluminium Alloys Multi-Bead Weld for Welding Rapid Forming Application

Applied Mechanics and Materials, 2015

ABSTRACT Understanding the interference of multi-bead parameters on surface smoothness is essenti... more ABSTRACT Understanding the interference of multi-bead parameters on surface smoothness is essential for accuracy of the formed parts made by welding rapid forming. This paper presents an investigation on surface smoothness of multi-bead aluminium alloys. Deposition path planning and overlap ratio is manipulated in order to improve surface smoothness. Observation on bead cross section indicates that deposition path planning has remarkable effect on the surface smoothness. Multi-bead that developed using continuous path planning produced surface smoothness of 0.46 mm – 1.34 mm and most bead present wavy type surfaces. The surface smoothness is improved by increasing the overlap ratio. Meanwhile, skip path planning produced good surface smoothness of 0.11 mm – 0.28 mm. An improved surface smoothness featuring flat surface type is obtained with this path planning.

Research paper thumbnail of Effect of Heat Treatment Parameters in Plasma Arc Surface Hardening of AISI 4340 Steel

Applied Mechanics and Materials, 2014

Research paper thumbnail of Effect of GMAW-CMT Heat Input on Weld Bead Profile Geometry for Freeform Fabrication of Aluminium Parts

Applied Mechanics and Materials, 2013

ABSTRACT In developing a new method for weld based freeform fabrication, parameter affecting the ... more ABSTRACT In developing a new method for weld based freeform fabrication, parameter affecting the geometry of single-pass need to be determined as it has great influence on dimensional accuracy and mechanical property of metallic part. In this paper, profile geometry and microstructure of single pass weld bead developed using Gas Metal Arc Welding – Cold Metal Transfer (GMAW-CMT) was investigated. Observation on cross sectional weld bead indicates GMAW-CMT has capability to produce free spatter and crack defect weld bead. Profile geometry measurement shows weld bead develop at higher heat input has width size larger than the weld bead develop at lower heat input. Microstructure examination in the substrate reveals formation of columnar dendritic, cellular and planar structure while at buildup layer exhibit equiaxed dendritic structure Introduction

Research paper thumbnail of Titanium Alloy Welding Using Middle Range Power Pulsed Wave Laser

Applied Mechanics and Materials, 2013

Laser welding are well reported to be excellent in precision parts joining with high reputations ... more Laser welding are well reported to be excellent in precision parts joining with high reputations in external finishing. However, the process in obtaining the best processing parameters is not an easy task. In the case of pulse wave laser, the parameter setting constrained by the laser generator specification. Each laser parameters such as pulse width t p , pulse repetition rate f p and average laser power P avg has relation which others. Increasing one parameter will directly decreases the maximum value of other parameters. The limited applicable combination and rage of processing parameters make it difficult to obtain the optimized processing parameters. This study is conducted to investigate the influence of each lasing parameters on the welding penetration capability. The range of applicable parameters for titanium alloy sheet metal has been successfully clarified

Research paper thumbnail of Effect of Machining Parameters on Hole Quality of Micro Drilling for Brass

Modern Applied Science, 2009

This paper present the effect of drilling parameter such as spindle speed, feed rate and drilling... more This paper present the effect of drilling parameter such as spindle speed, feed rate and drilling tool size on material removal rate (MRR), surface roughness, dimensional accuracy and burr. In this work, a study on optimum drilling parameter for HSS drilling tool in micro-drilling processes in order to find the best drilling parameter for brass as a workpiece material. Micro drilling experiment with 0.5 mm to 1.0 mm drill sizes were performed by changing the spindle speed and feed at three different levels. The results were analyzed using microscope and surface roughness device. Comparatives analysis has been done between surface roughness, MRR and accuracy of drilled holes by experimentation. From the result, the surface roughness are mostly influenced by spindle speed and feed rate. As the spindle and feed rate increases, the surface roughness will decrease. The tool diameter gives less influence on the value of surface roughness. The value of MRR is decreased when the tool diameter, spindle speed and feedrate are decreases. As drilling tool diameter, feedrate and spindle speed increase the dimensional accuracy of drilled hole will decrease. The increment of spindle speed and feed rate value mostly will affect the tool wear and size of burr on the edge of drilled holes.

Research paper thumbnail of Investigation of surface roughness and material removal rate (MRR) on tool steel using brass and copper electrode for electrical discharge grinding (EDG) process

International Journal of Integrated Engineering, 2009

This paper presents the investigation on surface roughness and material removal rate (MRR) of too... more This paper presents the investigation on surface roughness and material removal rate (MRR) of tool steel machined with brass and copper electrode for Electrical Discharge Grinding (EDG) process. The machining parameter include pulse ON time, pulse OFF time, peak current and capacitance. Analysis of variance (ANOVA) with Taguchi method is used to investigate the significant effect on the performance characteristic and the optimal cutting parameters of EDG. The result shows that, the surface roughness value when using of both tool materials are mostly influenced by pulse ON time and peak current. The capacitance parameter in both experiments was not giving any significant effect. The significant factors for the material removal rate due to the machining parameter are peak current parameter and ON time parameter but it also can increase the machining time

Research paper thumbnail of Plasma arc surface modification of ASSAB 705 steel

Modification of steel surface by hardening process is traditionally done either by oxy-fuel, indu... more Modification of steel surface by hardening process is traditionally done either by oxy-fuel, induction, laser or electron beam hardening. The technique using plasma arc which needed low initial cost is a new alternative for surface hardening. In this work, single and multiple pass of plasma arc was used to improve the hardness of ASSAB 705 steel surface. The variable parameters investigated were scanning velocity, operating current, gas pressure and stand off distance. After single pass scanning treatment, four types of surfaces were observed. They were fully-melted, partially-melted, non-melted and inconstant-affected where each type of surface indicated different type of roughness. This work has showed that scanning speed and operating current was significantly influence the type of surface and roughness values. Analysis on nonmelted surface after treatment gives maximum depth of hardened layer of about 186.7 um as well as hardness values of about 1100 HV50. It was also observed that the depth of harden layer and hardness value was significantly decreases with increase in scanning speed or with decreasing operating current. Microstructure analysis on hardened layer also revealed the formation of martensite structure. Single pass scanning treatment produced approximately 2 mm width of hardened surface. Larger area of hardened surface could be produced by multiple pass scanning treatment. However the treatment produced uneven hardness due to reheating effect on prior hardened layer. The results from this work indicate that plasma arc is viable tool for surface hardening.

Research paper thumbnail of Development of Wood-Based Composites Material for 3D Printing Process

Applied Mechanics and …, 2013

This paper presents the development of wood-based composites material for 3D Printing process. Th... more This paper presents the development of wood-based composites material for 3D Printing process. The aim is to characterize the waste material from wood powder (WD) as an alternative material and low cost production for rapid prototyping product. The powder blends containing wood powder (90-120µm) with commercial ZP102 material from Z Corporation was used as the composite material. The materials were mechanically blended to produce composition of WD/ZP102(vol.%) 25:70, 50:50 and 75:25 respectively. The material was successfully processed on 3D printers machine, to produce three-dimensional components and followed by post-treatment with ZMax solution to enhance the mechanical properties. The mechanical properties, dimensional accuracy and surface quality of the components were evaluated and the results were compared with the standard ZP102 material. The result shows that the mechanical properties improved with the increased of wood powder content up to 50 (vol.%). However, dimensional accuracy and surface quality were decreased as the wood content increased. Further work on powder preparation is continued for surface quality improvement.

Research paper thumbnail of Rapid prototyping of wood-based material

Research paper thumbnail of Effect of machining parameters on hole quality of micro drilling for brass

Modern Applied Science, 2009

This paper present the effect of drilling parameter such as spindle speed, feed rate and drilling... more This paper present the effect of drilling parameter such as spindle speed, feed rate and drilling tool size on material removal rate (MRR), surface roughness, dimensional accuracy and burr. In this work, a study on optimum drilling parameter for HSS drilling tool in micro-drilling processes in order to find the best drilling parameter for brass as a workpiece material. Micro drilling experiment with 0.5 mm to 1.0 mm drill sizes were performed by changing the spindle speed and feed at three different levels. The results were analyzed using microscope and surface roughness device. Comparatives analysis has been done between surface roughness, MRR and accuracy of drilled holes by experimentation. From the result, the surface roughness are mostly influenced by spindle speed and feed rate. As the spindle and feed rate increases, the surface roughness will decrease. The tool diameter gives less influence on the value of surface roughness. The value of MRR is decreased when the tool diameter, spindle speed and feedrate are decreases. As drilling tool diameter, feedrate and spindle speed increase the dimensional accuracy of drilled hole will decrease. The increment of spindle speed and feed rate value mostly will affect the tool wear and size of burr on the edge of drilled holes.

Research paper thumbnail of A Study on Surface Roughness and Burr Formation of Al6061 with Different Spindle Speed and Federate for Small End Milling Cutter

This paper reports the results of experiments to investigate surface roughness and burr formation... more This paper reports the results of experiments to investigate surface roughness and burr formation during the slot milling of Aluminum 6061. The experiment was carried out with small cutting tool diameter and several of spindles speed and federate. Generally, cutting parameters will influence on surface roughness and the formation of burrs in small slot milling operations. Although it is not possible to avoid burr formation by modifying the cutting parameters, the burr size can be reduced by selecting the appropriate values. The results showed that slot milling with cutting tool with diameter 2.0mm and 3.0mm have a similar behavior for surface roughness with respect to federate and spindle speed. The larger cutting tool diameter results in a larger burr formed. Burr height increased due to larger chip load as the spindle speed increased. It also shown that Burr-breakage type of burr more significant in cutting AL6061

Research paper thumbnail of Improving Surface Smoothness of Aluminium Alloys Multi-Bead Weld for Welding Rapid Forming Application

Applied Mechanics and Materials, 2015

ABSTRACT Understanding the interference of multi-bead parameters on surface smoothness is essenti... more ABSTRACT Understanding the interference of multi-bead parameters on surface smoothness is essential for accuracy of the formed parts made by welding rapid forming. This paper presents an investigation on surface smoothness of multi-bead aluminium alloys. Deposition path planning and overlap ratio is manipulated in order to improve surface smoothness. Observation on bead cross section indicates that deposition path planning has remarkable effect on the surface smoothness. Multi-bead that developed using continuous path planning produced surface smoothness of 0.46 mm – 1.34 mm and most bead present wavy type surfaces. The surface smoothness is improved by increasing the overlap ratio. Meanwhile, skip path planning produced good surface smoothness of 0.11 mm – 0.28 mm. An improved surface smoothness featuring flat surface type is obtained with this path planning.

Research paper thumbnail of Effect of Heat Treatment Parameters in Plasma Arc Surface Hardening of AISI 4340 Steel

Applied Mechanics and Materials, 2014

Research paper thumbnail of Effect of GMAW-CMT Heat Input on Weld Bead Profile Geometry for Freeform Fabrication of Aluminium Parts

Applied Mechanics and Materials, 2013

ABSTRACT In developing a new method for weld based freeform fabrication, parameter affecting the ... more ABSTRACT In developing a new method for weld based freeform fabrication, parameter affecting the geometry of single-pass need to be determined as it has great influence on dimensional accuracy and mechanical property of metallic part. In this paper, profile geometry and microstructure of single pass weld bead developed using Gas Metal Arc Welding – Cold Metal Transfer (GMAW-CMT) was investigated. Observation on cross sectional weld bead indicates GMAW-CMT has capability to produce free spatter and crack defect weld bead. Profile geometry measurement shows weld bead develop at higher heat input has width size larger than the weld bead develop at lower heat input. Microstructure examination in the substrate reveals formation of columnar dendritic, cellular and planar structure while at buildup layer exhibit equiaxed dendritic structure Introduction

Research paper thumbnail of Titanium Alloy Welding Using Middle Range Power Pulsed Wave Laser

Applied Mechanics and Materials, 2013

Laser welding are well reported to be excellent in precision parts joining with high reputations ... more Laser welding are well reported to be excellent in precision parts joining with high reputations in external finishing. However, the process in obtaining the best processing parameters is not an easy task. In the case of pulse wave laser, the parameter setting constrained by the laser generator specification. Each laser parameters such as pulse width t p , pulse repetition rate f p and average laser power P avg has relation which others. Increasing one parameter will directly decreases the maximum value of other parameters. The limited applicable combination and rage of processing parameters make it difficult to obtain the optimized processing parameters. This study is conducted to investigate the influence of each lasing parameters on the welding penetration capability. The range of applicable parameters for titanium alloy sheet metal has been successfully clarified

Research paper thumbnail of Effect of Machining Parameters on Hole Quality of Micro Drilling for Brass

Modern Applied Science, 2009

This paper present the effect of drilling parameter such as spindle speed, feed rate and drilling... more This paper present the effect of drilling parameter such as spindle speed, feed rate and drilling tool size on material removal rate (MRR), surface roughness, dimensional accuracy and burr. In this work, a study on optimum drilling parameter for HSS drilling tool in micro-drilling processes in order to find the best drilling parameter for brass as a workpiece material. Micro drilling experiment with 0.5 mm to 1.0 mm drill sizes were performed by changing the spindle speed and feed at three different levels. The results were analyzed using microscope and surface roughness device. Comparatives analysis has been done between surface roughness, MRR and accuracy of drilled holes by experimentation. From the result, the surface roughness are mostly influenced by spindle speed and feed rate. As the spindle and feed rate increases, the surface roughness will decrease. The tool diameter gives less influence on the value of surface roughness. The value of MRR is decreased when the tool diameter, spindle speed and feedrate are decreases. As drilling tool diameter, feedrate and spindle speed increase the dimensional accuracy of drilled hole will decrease. The increment of spindle speed and feed rate value mostly will affect the tool wear and size of burr on the edge of drilled holes.

Research paper thumbnail of Investigation of surface roughness and material removal rate (MRR) on tool steel using brass and copper electrode for electrical discharge grinding (EDG) process

International Journal of Integrated Engineering, 2009

This paper presents the investigation on surface roughness and material removal rate (MRR) of too... more This paper presents the investigation on surface roughness and material removal rate (MRR) of tool steel machined with brass and copper electrode for Electrical Discharge Grinding (EDG) process. The machining parameter include pulse ON time, pulse OFF time, peak current and capacitance. Analysis of variance (ANOVA) with Taguchi method is used to investigate the significant effect on the performance characteristic and the optimal cutting parameters of EDG. The result shows that, the surface roughness value when using of both tool materials are mostly influenced by pulse ON time and peak current. The capacitance parameter in both experiments was not giving any significant effect. The significant factors for the material removal rate due to the machining parameter are peak current parameter and ON time parameter but it also can increase the machining time

Research paper thumbnail of Plasma arc surface modification of ASSAB 705 steel

Modification of steel surface by hardening process is traditionally done either by oxy-fuel, indu... more Modification of steel surface by hardening process is traditionally done either by oxy-fuel, induction, laser or electron beam hardening. The technique using plasma arc which needed low initial cost is a new alternative for surface hardening. In this work, single and multiple pass of plasma arc was used to improve the hardness of ASSAB 705 steel surface. The variable parameters investigated were scanning velocity, operating current, gas pressure and stand off distance. After single pass scanning treatment, four types of surfaces were observed. They were fully-melted, partially-melted, non-melted and inconstant-affected where each type of surface indicated different type of roughness. This work has showed that scanning speed and operating current was significantly influence the type of surface and roughness values. Analysis on nonmelted surface after treatment gives maximum depth of hardened layer of about 186.7 um as well as hardness values of about 1100 HV50. It was also observed that the depth of harden layer and hardness value was significantly decreases with increase in scanning speed or with decreasing operating current. Microstructure analysis on hardened layer also revealed the formation of martensite structure. Single pass scanning treatment produced approximately 2 mm width of hardened surface. Larger area of hardened surface could be produced by multiple pass scanning treatment. However the treatment produced uneven hardness due to reheating effect on prior hardened layer. The results from this work indicate that plasma arc is viable tool for surface hardening.

Research paper thumbnail of Development of Wood-Based Composites Material for 3D Printing Process

Applied Mechanics and …, 2013

This paper presents the development of wood-based composites material for 3D Printing process. Th... more This paper presents the development of wood-based composites material for 3D Printing process. The aim is to characterize the waste material from wood powder (WD) as an alternative material and low cost production for rapid prototyping product. The powder blends containing wood powder (90-120µm) with commercial ZP102 material from Z Corporation was used as the composite material. The materials were mechanically blended to produce composition of WD/ZP102(vol.%) 25:70, 50:50 and 75:25 respectively. The material was successfully processed on 3D printers machine, to produce three-dimensional components and followed by post-treatment with ZMax solution to enhance the mechanical properties. The mechanical properties, dimensional accuracy and surface quality of the components were evaluated and the results were compared with the standard ZP102 material. The result shows that the mechanical properties improved with the increased of wood powder content up to 50 (vol.%). However, dimensional accuracy and surface quality were decreased as the wood content increased. Further work on powder preparation is continued for surface quality improvement.

Research paper thumbnail of Rapid prototyping of wood-based material

Research paper thumbnail of Effect of machining parameters on hole quality of micro drilling for brass

Modern Applied Science, 2009

This paper present the effect of drilling parameter such as spindle speed, feed rate and drilling... more This paper present the effect of drilling parameter such as spindle speed, feed rate and drilling tool size on material removal rate (MRR), surface roughness, dimensional accuracy and burr. In this work, a study on optimum drilling parameter for HSS drilling tool in micro-drilling processes in order to find the best drilling parameter for brass as a workpiece material. Micro drilling experiment with 0.5 mm to 1.0 mm drill sizes were performed by changing the spindle speed and feed at three different levels. The results were analyzed using microscope and surface roughness device. Comparatives analysis has been done between surface roughness, MRR and accuracy of drilled holes by experimentation. From the result, the surface roughness are mostly influenced by spindle speed and feed rate. As the spindle and feed rate increases, the surface roughness will decrease. The tool diameter gives less influence on the value of surface roughness. The value of MRR is decreased when the tool diameter, spindle speed and feedrate are decreases. As drilling tool diameter, feedrate and spindle speed increase the dimensional accuracy of drilled hole will decrease. The increment of spindle speed and feed rate value mostly will affect the tool wear and size of burr on the edge of drilled holes.