Surface finish and dimensional accuracy is one of the most important requirements in machining pr... more Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.
International Journal of Metrology and Quality Engineering
Aluminum alloys 7075 (Al 7075) are widely used for various industrial components in which machini... more Aluminum alloys 7075 (Al 7075) are widely used for various industrial components in which machining operations are often conducted during their manufacturing process. However, the machining operations could introduce defects on the machined surfaces of the components which will be carried over and may lead to either issues in the subsequent fabrication process or failure during the products' service life. This study investigates the machined surface's defects of Al 7075 underwent drilling operations using imaging and topographical techniques which include optical microscope, scanning electron microscope and 3D surface profiler. Surface roughness was analysed with respect to the surface defects to investigate the correlation between the roughness parameters and topographical features of the machined surfaces. The defects found on the machined surfaces of Al 7075 are microcrack, adhesion, feed mark and burr. Surface roughness was found to be highly influenced by topographical ...
The objective of this paper are to predict the cutting force using predictive model of finite ele... more The objective of this paper are to predict the cutting force using predictive model of finite element method (FEM) and validate thru experiments, and to analyze the influence of cutting parameters during the circular end milling of AISI 1018 medium carbon still employing uncoated carbide tool. Three level of cutting speed, feed rate and depth of cut are designed accordingly. Result of cutting forces is evaluated and validated. Analysis also been made by considering the percentage of error in FEM and experimental work by Dynoware Software. The results obtained by simulation using Abaqus software and experimental work, it shows small percentage of error and it is suggested that the predictive model is reliable whereas the FEM value captures the qualitative trends fairly well in regard to the change of cutting speed, feed rate and depth of cu
Aluminium alloys are widely used in manufacturing industry due to the need of lightweight compone... more Aluminium alloys are widely used in manufacturing industry due to the need of lightweight components and low production cost. However, mechanical assembly of the alloy which requires drilling operations is challenging due to chip accumulation and heat at the cutting tool and workpiece interface. This often causes material adhesion on cutting edges, built-up edge, accelerated tool wear, shorter tool life and poor drilled hole quality. This paper investigates the effect drilling conditions (dry and chilled air at 10°C) on the wear mechanisms of tungsten carbide cutting tools during drilling Aluminium alloy 7075 (Al 7075) at two different feed rates. Chilled or cold air was used as a cooling medium in drilling Al 7075 to promote green manufacturing. Drilling operations of Al 7075 were performed at a constant cutting speed of 123 m/min with feed rates of 0.01 and 0.1 mm/rev. The cutting tools’ flank wear were measured using an optical microscope with Dino-Capture software and further ex...
Lubricant is an important element that acts as a cutting fluid and coolant in metal cutting proce... more Lubricant is an important element that acts as a cutting fluid and coolant in metal cutting processes. The function of the lubricant is to reduce the heat generated at the cutting tool-workpiece and cutting tool- chips interfaces. The heat generated at the cutting zone promotes rapid wear progression of the cutting tool which leads to high cutting force, poor surface finish and inaccurate dimensional tolerance of the component being cut. The lubricant supplied during metal cutting processes in flood machining is unfavorable as it contributes to high manufacturing cost, hazardous to machinists and contributes to environmental issues. Lubrication through Minimum Quantity Lubrication (MQL) was introduced to replace the flood cutting. MQL flow at 50ml/h to 100ml/h through the external or internal channel and sprayed towards the cutting zone. A lot of studies were conducted to observe the effect of MQL on various types of ferrous and non-ferrous metal with regards to the cutting force, surface integrity and tool wear progression during metal cutting processes. In this paper, a review of available literature on MQL applications during machining Aluminum Alloys was conducted. Factors such as MQL base and techniques, cutting parameters and cutting tools were observed to be important in the metal cutting processes. The performance, advantages and disadvantages of each study were highlighted base on the outcome of the conducted studie
Burr formation is a major challenge during drilling which could cause poor assembly and may lead ... more Burr formation is a major challenge during drilling which could cause poor assembly and may lead to part rejection. One of the factors which could result in an increment of burr height and deteriorating the hole quality is poor selection of cutting parameters and drilling environment. aluminium alloy (Al7075) is usually drilled in dry condition due to the concern over the use and disposal of cutting fluid which could lead to environmental pollution. However, dry drilling can cause high heat generation which can highly influence the burr formation. Therefore, this research aims to investigate the effectiveness of chilled air as a cooling medium in drilling Al7075 to improve the machined surface integrity in aspects of burr formation. Drilling operations of Al7075 were performed at cutting speeds and feed rates of 82 - 123 m/min and 0.01 - 0.1 mm/rev. The lowest burr height was obtained when drilling using the higher cutting speed and feed rate of 123 m/min and 0.01 mm/rev. Whereas, t...
Drilling or creating holes in composite parts are a necessary and sensible task, preponderantly f... more Drilling or creating holes in composite parts are a necessary and sensible task, preponderantly for facilitating the assembly of joints. Within the present investigation, the drilling operation of natural fiber reinforced thermosetting (epoxy) composite laminates was assessed in terms of the drilling force. This study conjointly incorporated the employment of a Box Behnken Design with 17 test runs within which machining parameters corresponding to the cutting speed (20 – 70 m/min), feed rate (0.1 – 0.3 mm/rev) and drill sizes (6,9 and 12 mm) were taken as input variables. The consequences of two different types of tool materials (non-coated HSS and non-coated carbide) were conjointly evaluated within the study. The Response Surface Methodology (RSM) was used to analyze the thrust force when drilling woven kenaf fiber reinforced composites with non-coated HSS and non-coated carbide drill bits. Based on the study, the drill size and feed rate were found to be the most significant fact...
Kenaf is known by its scientific name, Hibiscus cannabinus, which is similar to jute and cotton, ... more Kenaf is known by its scientific name, Hibiscus cannabinus, which is similar to jute and cotton, and is also a warm-season annual fibrous crop. In the past, it was used to make sackcloth, and its twine was used to manufacture rope. Kenaf is also used as a cordage crop. A machine’s surface quality normally depends for its reliability in the service application. The machining process changes the mechanical and chemical properties of individual constituents used for the composite. The objectives of this research are to study the effects of milling parameters and to determine the optimum conditions for a range of milling parameters to minimize the delamination factor (Fd) in milling kenaf fiber-reinforced plastic composite using the Taguchi Method. The Taguchi Method L8 (2) design was used to conduct a non-sequential experiment. The experimental results were analyzed using the Minitab 16 software. A study was carried out to investigate the relationship between the milling parameters, an...
ARPN journal of engineering and applied sciences, 2016
The surface roughness factor (Ra) of a milled kenaf reinforced plastic are depending on the milli... more The surface roughness factor (Ra) of a milled kenaf reinforced plastic are depending on the milling parameters (spindle speed, feed rate and depth of cut). Therefore, a study was carried out to investigate the relationship between the milling parameters and their effects on a kenaf reinforced plastic. The composite panels were fabricated using vacuum assisted resin transfer molding (VARTM) method. A full factorial design of experiments was used as an initial step to screen the significance of the parameters on the defects using Analysis of Variance (ANOVA). If the curvature of the collected data shows significant, Response Surface Methodology (RSM) is then applied for obtaining a quadratic modelling equation which has more reliable in expressing the optimization. Thus, the objective of this research is obtaining an optimum setting of milling parameters and modelling equations to minimize the surface roughness factor (Ra) of milled kenaf reinforced plastic. The spindle speed and feed...
Surface finish and dimensional accuracy is one of the most important requirements in machining pr... more Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.
International Journal of Metrology and Quality Engineering
Aluminum alloys 7075 (Al 7075) are widely used for various industrial components in which machini... more Aluminum alloys 7075 (Al 7075) are widely used for various industrial components in which machining operations are often conducted during their manufacturing process. However, the machining operations could introduce defects on the machined surfaces of the components which will be carried over and may lead to either issues in the subsequent fabrication process or failure during the products' service life. This study investigates the machined surface's defects of Al 7075 underwent drilling operations using imaging and topographical techniques which include optical microscope, scanning electron microscope and 3D surface profiler. Surface roughness was analysed with respect to the surface defects to investigate the correlation between the roughness parameters and topographical features of the machined surfaces. The defects found on the machined surfaces of Al 7075 are microcrack, adhesion, feed mark and burr. Surface roughness was found to be highly influenced by topographical ...
The objective of this paper are to predict the cutting force using predictive model of finite ele... more The objective of this paper are to predict the cutting force using predictive model of finite element method (FEM) and validate thru experiments, and to analyze the influence of cutting parameters during the circular end milling of AISI 1018 medium carbon still employing uncoated carbide tool. Three level of cutting speed, feed rate and depth of cut are designed accordingly. Result of cutting forces is evaluated and validated. Analysis also been made by considering the percentage of error in FEM and experimental work by Dynoware Software. The results obtained by simulation using Abaqus software and experimental work, it shows small percentage of error and it is suggested that the predictive model is reliable whereas the FEM value captures the qualitative trends fairly well in regard to the change of cutting speed, feed rate and depth of cu
Aluminium alloys are widely used in manufacturing industry due to the need of lightweight compone... more Aluminium alloys are widely used in manufacturing industry due to the need of lightweight components and low production cost. However, mechanical assembly of the alloy which requires drilling operations is challenging due to chip accumulation and heat at the cutting tool and workpiece interface. This often causes material adhesion on cutting edges, built-up edge, accelerated tool wear, shorter tool life and poor drilled hole quality. This paper investigates the effect drilling conditions (dry and chilled air at 10°C) on the wear mechanisms of tungsten carbide cutting tools during drilling Aluminium alloy 7075 (Al 7075) at two different feed rates. Chilled or cold air was used as a cooling medium in drilling Al 7075 to promote green manufacturing. Drilling operations of Al 7075 were performed at a constant cutting speed of 123 m/min with feed rates of 0.01 and 0.1 mm/rev. The cutting tools’ flank wear were measured using an optical microscope with Dino-Capture software and further ex...
Lubricant is an important element that acts as a cutting fluid and coolant in metal cutting proce... more Lubricant is an important element that acts as a cutting fluid and coolant in metal cutting processes. The function of the lubricant is to reduce the heat generated at the cutting tool-workpiece and cutting tool- chips interfaces. The heat generated at the cutting zone promotes rapid wear progression of the cutting tool which leads to high cutting force, poor surface finish and inaccurate dimensional tolerance of the component being cut. The lubricant supplied during metal cutting processes in flood machining is unfavorable as it contributes to high manufacturing cost, hazardous to machinists and contributes to environmental issues. Lubrication through Minimum Quantity Lubrication (MQL) was introduced to replace the flood cutting. MQL flow at 50ml/h to 100ml/h through the external or internal channel and sprayed towards the cutting zone. A lot of studies were conducted to observe the effect of MQL on various types of ferrous and non-ferrous metal with regards to the cutting force, surface integrity and tool wear progression during metal cutting processes. In this paper, a review of available literature on MQL applications during machining Aluminum Alloys was conducted. Factors such as MQL base and techniques, cutting parameters and cutting tools were observed to be important in the metal cutting processes. The performance, advantages and disadvantages of each study were highlighted base on the outcome of the conducted studie
Burr formation is a major challenge during drilling which could cause poor assembly and may lead ... more Burr formation is a major challenge during drilling which could cause poor assembly and may lead to part rejection. One of the factors which could result in an increment of burr height and deteriorating the hole quality is poor selection of cutting parameters and drilling environment. aluminium alloy (Al7075) is usually drilled in dry condition due to the concern over the use and disposal of cutting fluid which could lead to environmental pollution. However, dry drilling can cause high heat generation which can highly influence the burr formation. Therefore, this research aims to investigate the effectiveness of chilled air as a cooling medium in drilling Al7075 to improve the machined surface integrity in aspects of burr formation. Drilling operations of Al7075 were performed at cutting speeds and feed rates of 82 - 123 m/min and 0.01 - 0.1 mm/rev. The lowest burr height was obtained when drilling using the higher cutting speed and feed rate of 123 m/min and 0.01 mm/rev. Whereas, t...
Drilling or creating holes in composite parts are a necessary and sensible task, preponderantly f... more Drilling or creating holes in composite parts are a necessary and sensible task, preponderantly for facilitating the assembly of joints. Within the present investigation, the drilling operation of natural fiber reinforced thermosetting (epoxy) composite laminates was assessed in terms of the drilling force. This study conjointly incorporated the employment of a Box Behnken Design with 17 test runs within which machining parameters corresponding to the cutting speed (20 – 70 m/min), feed rate (0.1 – 0.3 mm/rev) and drill sizes (6,9 and 12 mm) were taken as input variables. The consequences of two different types of tool materials (non-coated HSS and non-coated carbide) were conjointly evaluated within the study. The Response Surface Methodology (RSM) was used to analyze the thrust force when drilling woven kenaf fiber reinforced composites with non-coated HSS and non-coated carbide drill bits. Based on the study, the drill size and feed rate were found to be the most significant fact...
Kenaf is known by its scientific name, Hibiscus cannabinus, which is similar to jute and cotton, ... more Kenaf is known by its scientific name, Hibiscus cannabinus, which is similar to jute and cotton, and is also a warm-season annual fibrous crop. In the past, it was used to make sackcloth, and its twine was used to manufacture rope. Kenaf is also used as a cordage crop. A machine’s surface quality normally depends for its reliability in the service application. The machining process changes the mechanical and chemical properties of individual constituents used for the composite. The objectives of this research are to study the effects of milling parameters and to determine the optimum conditions for a range of milling parameters to minimize the delamination factor (Fd) in milling kenaf fiber-reinforced plastic composite using the Taguchi Method. The Taguchi Method L8 (2) design was used to conduct a non-sequential experiment. The experimental results were analyzed using the Minitab 16 software. A study was carried out to investigate the relationship between the milling parameters, an...
ARPN journal of engineering and applied sciences, 2016
The surface roughness factor (Ra) of a milled kenaf reinforced plastic are depending on the milli... more The surface roughness factor (Ra) of a milled kenaf reinforced plastic are depending on the milling parameters (spindle speed, feed rate and depth of cut). Therefore, a study was carried out to investigate the relationship between the milling parameters and their effects on a kenaf reinforced plastic. The composite panels were fabricated using vacuum assisted resin transfer molding (VARTM) method. A full factorial design of experiments was used as an initial step to screen the significance of the parameters on the defects using Analysis of Variance (ANOVA). If the curvature of the collected data shows significant, Response Surface Methodology (RSM) is then applied for obtaining a quadratic modelling equation which has more reliable in expressing the optimization. Thus, the objective of this research is obtaining an optimum setting of milling parameters and modelling equations to minimize the surface roughness factor (Ra) of milled kenaf reinforced plastic. The spindle speed and feed...
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Papers by SUHAILY MOKHTAR