The thin-walled component is mostly used in the aerospace industry. During machining the thin-wal... more The thin-walled component is mostly used in the aerospace industry. During machining the thin-walled components, deflection of wall occurs and causes the surface dimensional error. This paper focuses on the effect of end mill helix angle on the surface dimensional error and surface roughness when machining thin wall structure. End mills uncoated carbide were fabricated with a difference helix angle which are 25°, 30°, 35°, 40° and 45°. The results show, helix angle 35° produce smaller surface dimensional error and smoothest followed by 40°, 45°, 30° and 25°. The smaller helix angle provided high cutting force that causes more surface dimensional error due to chatter and reduction of contact time when then end mill engage with the workpiece material. Results from this research help to guide the machinist to machine thin-wall component with the right cutting tool.
Carbon Fiber Reinforced Plastics (CFRP) exhibit superior characteristics such as high specific st... more Carbon Fiber Reinforced Plastics (CFRP) exhibit superior characteristics such as high specific strength, high specific modulus, fatigue strength and endurance. During the manufacture of components from CFRP, it is usually necessary to carry out a post-machining step. Generally, after curing process, the parts will be trimmed in order to meet the required tolerances. Due to the heterogeneous composition and anisotropy of composite materials, machining procedures can damage the material in ways that directly affect its mechanical properties. Currently a costly try and error approach is employed to determine the optimal process conditions. Thus, this study focused on numerical modelling of machining CFRP composites using cross-nick router. A set of machining tests were performed in order to validate the accuracy of the model. Good agreement between simulation and experimental results show the validity of the model in handling real-field problems. The proposed numerical modeling techniq...
EMITTER International Journal of Engineering Technology
Sustainability plays an important role in manufacturing industries through economically-sound pro... more Sustainability plays an important role in manufacturing industries through economically-sound processes that able to minimize negative environmental impacts while having the social benefits. In this present study, the modeling of wire electrical discharge machining (WEDM) cutting process using an artificial neural network (ANN) for prediction has been carried out with a focus on sustainable production. The objective was to develop an ANN model for prediction of two sustainable measures which were material removal rate (as an economic aspect) and surface roughness (as a social aspect) of titanium alloy with ten input parameters. By concerning environmental pollution due to its intrinsic characteristics such as liquid wastes, the water-based dielectric fluid has been used in this study which represents an environmental aspect in sustainability. For this purpose, a feed-forward backpropagation ANN was developed and trained using the minimal experimental data. The other empirical modell...
This study presents an optimization of injection moulding parameters on mechanical properties of ... more This study presents an optimization of injection moulding parameters on mechanical properties of plastic part using Taguchi method and Grey Relational Analysis (GRA) approach. The orthogonal array with L9 was used as the experimental design. Grey relational analysis for ultimate tensile strength, modulus and percentage of elongation from the Taguchi method can convert optimization of the multiple performance characteristics into optimization of a single performance characteristic called the grey relational grade (GRG). It is found that mould temperature of 62oC, melt temperature of 280oC, injection time of 0.70s and cooling time 15.4s are found as the optimum process setting. Furthermore, ANOVA result shows that the cooling time is the most influenced factor that affects the mechanical properties of plastic part followed by mould temperature and melt temperature.
Quaternary nickel alloy of Ni-Co-Cu-P has been successfully deposit on Fe substrate for corrosion... more Quaternary nickel alloy of Ni-Co-Cu-P has been successfully deposit on Fe substrate for corrosion resistant material. However, the reaction mechanism of quaternary nickel alloy deposition is less known and requires investigation. In this study, using similar bath component is used to produce electroless Ni-Cu-Co-P alloy. Cyclic voltammetry (CV) study is done in various plating bath component at bath pH 4.50, 4.75 and 5.00. A coating of Ni-Cu-Co-P alloy was deposited on a Fe substrate to evaluate surface morphology and composition. From CV results, higher bath pH, increases the [H2PO2-] oxidation peak and shifted the oxidation potential towards less noble potential. The reduction potential of the Ni alloy moved to noble potential, hence, elevate deposition rate from 3.95 to 5.95 mm/hr. The Ni-Cu-Co-P alloy composition on Fe substrate in descending manner is Ni (68.55 – 82.09 wt%), Cu (14.11 – 27.80 wt%) and Co (1.32 - 1.52wt%). The P content remained lower than 3.00 wt%. Hence, Co ac...
Trimming process using Solid Carbide, 4 flute endmill of 8mm diameter tool on stacks of multidire... more Trimming process using Solid Carbide, 4 flute endmill of 8mm diameter tool on stacks of multidirectional CFRP/Al-2024 in a CNC Milling machine was experimentally investigated. The machining parameters considered were spindle speed (N), feed rate (fr) and depth of cut (dc). The aims were to analyze the influence factors and the interaction of these parameters with respect to surface quality produced. A Two Level Factorial Design method was used to plan systematic experiments. The influence factors and the interaction between these parameters are analyzed and the optimum machining parameters for minimizing the surface roughness is determined. The analysis of variance (ANOVA) shows that dc and fr are the most significant parameters to the overall performance of surface quality. Surface roughness of CFRP is found to be 1.778 µm and Al2024 is found to be 0.983 µm at the setting of N = 1860 rpm, fr = 620 mm/min and dc = 0.12 mm respectively. The validation test shows deviation of predicte...
This article presents the tool life study of two different grades of Inconel 718. Tool life of ba... more This article presents the tool life study of two different grades of Inconel 718. Tool life of ball nose cutting tools were investigated by considering the numerical parameters of cutting speed, feed rate, depth of cut and width of cut. The categorical factor is material grade. Two sets of different cutting parameters that were previously using design of experiment (DOE) approaches were combined and analysed using historical data of response surface methodology (RSM). This method can be used to determine the dominant factors to identify the interaction between cutting parameter and tool life. ANOVA result shows that the type of material with different grade is not significant in contributing to tool life compared to width of cut, cutting speed, feed rate, and depth of cut. The best combination for untreated Inconel 718 is Vc = 102 m/min, fz = 0.11 mm/tooth, ap = 0.52 mm and ae = 0.28 mm in order to obtain predicted tool life of 127 min, whereas the best combination of double aging i...
This paper reports on the effect of wire electrical discharge machine (WEDM) cutting parameter on... more This paper reports on the effect of wire electrical discharge machine (WEDM) cutting parameter on the subsurface hardness of Inconel 718. The response surface methodology (RSM) using Box-Behnken design was used to conduct the experiment and analyze the relationship between control variables and responses. A total of 8 runs was carried out during the experiment. The Historical Data of Response Surface Methodology (RSM) was used as a tool of design of experiment (DOE). The selected WEDM parameters were Voltage (40-42V), feed rate (6-8V) and current (0.5-1.5 mm/min). The subsurface hardness was measured at the distance of 50 µm, 100 µm, 300 µm, 500 µm beneath the cutting surface. Observation of the results shows that the subsurface hardness is higher at the distance of 50µm than 500 um. The hardness was gradually decreased toward bulk hardness of HV0.1 270. Analysis of variance (ANOVA) was used to identify the significant effect of the factors on the response. Based on the analysis, fe...
This article presents the tool wear mechanism when machining Aluminium alloy 6061-T6 with PVD coa... more This article presents the tool wear mechanism when machining Aluminium alloy 6061-T6 with PVD coated carbide under dry cutting condition. Cutting parameters selected were cutting speed, Vc = 115-145 m/min; feed rate fz = 0.15-0.2 mm/tooth and depth of cut, ap = 0.5-0.75 mm. The result showed the tool life of PVD TiAlN ranged from 11 to 97 min. Full factorial approach was employed to exhibit relationship between parameter input and output. From the analysis, cutting speed was found to be the most significant factor for tool performance followed by feed rate and depth of cut. It was also found that most of failure modes occurred were notch wear and flaking near those found near depth of cut line.
The thin-walled component is mostly used in the aerospace industry. During machining the thin-wal... more The thin-walled component is mostly used in the aerospace industry. During machining the thin-walled components, deflection of wall occurs and causes the surface dimensional error. This paper focuses on the effect of end mill helix angle on the surface dimensional error and surface roughness when machining thin wall structure. End mills uncoated carbide were fabricated with a difference helix angle which are 25°, 30°, 35°, 40° and 45°. The results show, helix angle 35° produce smaller surface dimensional error and smoothest followed by 40°, 45°, 30° and 25°. The smaller helix angle provided high cutting force that causes more surface dimensional error due to chatter and reduction of contact time when then end mill engage with the workpiece material. Results from this research help to guide the machinist to machine thin-wall component with the right cutting tool.
Carbon Fiber Reinforced Plastics (CFRP) exhibit superior characteristics such as high specific st... more Carbon Fiber Reinforced Plastics (CFRP) exhibit superior characteristics such as high specific strength, high specific modulus, fatigue strength and endurance. During the manufacture of components from CFRP, it is usually necessary to carry out a post-machining step. Generally, after curing process, the parts will be trimmed in order to meet the required tolerances. Due to the heterogeneous composition and anisotropy of composite materials, machining procedures can damage the material in ways that directly affect its mechanical properties. Currently a costly try and error approach is employed to determine the optimal process conditions. Thus, this study focused on numerical modelling of machining CFRP composites using cross-nick router. A set of machining tests were performed in order to validate the accuracy of the model. Good agreement between simulation and experimental results show the validity of the model in handling real-field problems. The proposed numerical modeling techniq...
EMITTER International Journal of Engineering Technology
Sustainability plays an important role in manufacturing industries through economically-sound pro... more Sustainability plays an important role in manufacturing industries through economically-sound processes that able to minimize negative environmental impacts while having the social benefits. In this present study, the modeling of wire electrical discharge machining (WEDM) cutting process using an artificial neural network (ANN) for prediction has been carried out with a focus on sustainable production. The objective was to develop an ANN model for prediction of two sustainable measures which were material removal rate (as an economic aspect) and surface roughness (as a social aspect) of titanium alloy with ten input parameters. By concerning environmental pollution due to its intrinsic characteristics such as liquid wastes, the water-based dielectric fluid has been used in this study which represents an environmental aspect in sustainability. For this purpose, a feed-forward backpropagation ANN was developed and trained using the minimal experimental data. The other empirical modell...
This study presents an optimization of injection moulding parameters on mechanical properties of ... more This study presents an optimization of injection moulding parameters on mechanical properties of plastic part using Taguchi method and Grey Relational Analysis (GRA) approach. The orthogonal array with L9 was used as the experimental design. Grey relational analysis for ultimate tensile strength, modulus and percentage of elongation from the Taguchi method can convert optimization of the multiple performance characteristics into optimization of a single performance characteristic called the grey relational grade (GRG). It is found that mould temperature of 62oC, melt temperature of 280oC, injection time of 0.70s and cooling time 15.4s are found as the optimum process setting. Furthermore, ANOVA result shows that the cooling time is the most influenced factor that affects the mechanical properties of plastic part followed by mould temperature and melt temperature.
Quaternary nickel alloy of Ni-Co-Cu-P has been successfully deposit on Fe substrate for corrosion... more Quaternary nickel alloy of Ni-Co-Cu-P has been successfully deposit on Fe substrate for corrosion resistant material. However, the reaction mechanism of quaternary nickel alloy deposition is less known and requires investigation. In this study, using similar bath component is used to produce electroless Ni-Cu-Co-P alloy. Cyclic voltammetry (CV) study is done in various plating bath component at bath pH 4.50, 4.75 and 5.00. A coating of Ni-Cu-Co-P alloy was deposited on a Fe substrate to evaluate surface morphology and composition. From CV results, higher bath pH, increases the [H2PO2-] oxidation peak and shifted the oxidation potential towards less noble potential. The reduction potential of the Ni alloy moved to noble potential, hence, elevate deposition rate from 3.95 to 5.95 mm/hr. The Ni-Cu-Co-P alloy composition on Fe substrate in descending manner is Ni (68.55 – 82.09 wt%), Cu (14.11 – 27.80 wt%) and Co (1.32 - 1.52wt%). The P content remained lower than 3.00 wt%. Hence, Co ac...
Trimming process using Solid Carbide, 4 flute endmill of 8mm diameter tool on stacks of multidire... more Trimming process using Solid Carbide, 4 flute endmill of 8mm diameter tool on stacks of multidirectional CFRP/Al-2024 in a CNC Milling machine was experimentally investigated. The machining parameters considered were spindle speed (N), feed rate (fr) and depth of cut (dc). The aims were to analyze the influence factors and the interaction of these parameters with respect to surface quality produced. A Two Level Factorial Design method was used to plan systematic experiments. The influence factors and the interaction between these parameters are analyzed and the optimum machining parameters for minimizing the surface roughness is determined. The analysis of variance (ANOVA) shows that dc and fr are the most significant parameters to the overall performance of surface quality. Surface roughness of CFRP is found to be 1.778 µm and Al2024 is found to be 0.983 µm at the setting of N = 1860 rpm, fr = 620 mm/min and dc = 0.12 mm respectively. The validation test shows deviation of predicte...
This article presents the tool life study of two different grades of Inconel 718. Tool life of ba... more This article presents the tool life study of two different grades of Inconel 718. Tool life of ball nose cutting tools were investigated by considering the numerical parameters of cutting speed, feed rate, depth of cut and width of cut. The categorical factor is material grade. Two sets of different cutting parameters that were previously using design of experiment (DOE) approaches were combined and analysed using historical data of response surface methodology (RSM). This method can be used to determine the dominant factors to identify the interaction between cutting parameter and tool life. ANOVA result shows that the type of material with different grade is not significant in contributing to tool life compared to width of cut, cutting speed, feed rate, and depth of cut. The best combination for untreated Inconel 718 is Vc = 102 m/min, fz = 0.11 mm/tooth, ap = 0.52 mm and ae = 0.28 mm in order to obtain predicted tool life of 127 min, whereas the best combination of double aging i...
This paper reports on the effect of wire electrical discharge machine (WEDM) cutting parameter on... more This paper reports on the effect of wire electrical discharge machine (WEDM) cutting parameter on the subsurface hardness of Inconel 718. The response surface methodology (RSM) using Box-Behnken design was used to conduct the experiment and analyze the relationship between control variables and responses. A total of 8 runs was carried out during the experiment. The Historical Data of Response Surface Methodology (RSM) was used as a tool of design of experiment (DOE). The selected WEDM parameters were Voltage (40-42V), feed rate (6-8V) and current (0.5-1.5 mm/min). The subsurface hardness was measured at the distance of 50 µm, 100 µm, 300 µm, 500 µm beneath the cutting surface. Observation of the results shows that the subsurface hardness is higher at the distance of 50µm than 500 um. The hardness was gradually decreased toward bulk hardness of HV0.1 270. Analysis of variance (ANOVA) was used to identify the significant effect of the factors on the response. Based on the analysis, fe...
This article presents the tool wear mechanism when machining Aluminium alloy 6061-T6 with PVD coa... more This article presents the tool wear mechanism when machining Aluminium alloy 6061-T6 with PVD coated carbide under dry cutting condition. Cutting parameters selected were cutting speed, Vc = 115-145 m/min; feed rate fz = 0.15-0.2 mm/tooth and depth of cut, ap = 0.5-0.75 mm. The result showed the tool life of PVD TiAlN ranged from 11 to 97 min. Full factorial approach was employed to exhibit relationship between parameter input and output. From the analysis, cutting speed was found to be the most significant factor for tool performance followed by feed rate and depth of cut. It was also found that most of failure modes occurred were notch wear and flaking near those found near depth of cut line.
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Papers by Mohd Shahir Kasim