Journal of Advanced Research in Fluid Mechanics and Thermal Sciences, 2022
In the aerospace field, titanium alloys are extensively used for the airframe and engine parts to... more In the aerospace field, titanium alloys are extensively used for the airframe and engine parts to improve aircraft fuel consumption. Drilling through these parts in a single-shot process to produce high quality holes is challenging. During drilling, high temperatures are generated owing to the friction between the cutting tool and workpiece, causing the process becomes inefficient in terms of tool life and surface quality. To reduce the temperature produced in the cutting zone, different types of cooling techniques during drilling have been used by researchers. In this study, the feasibility of quarry dust suspension as coolant in drilling of titanium alloy was performed. The effects of different concentrations of quarry dust on surface roughness, thrust force, and burr formation were evaluated, and their machining performances were compared with those obtained using aluminium oxide suspension. Before the experiments, both suspensions were prepared by dispersing quarry dust and alum...
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 ...
This paper presents some research into the wear and damage of the flat end-mill cutting tools und... more This paper presents some research into the wear and damage of the flat end-mill cutting tools under machining with copper based metal. A series of cutting tests have been carried at cutting time 35, 70, 105, and 140 minutes. The cutting speed, depth of cut and feed rate were kept constant at 2750 rpm, 0.05 mm and 280 mm/min, respectively.
Flow analysis of three plate family injection mould using pin point gate that consist of four cav... more Flow analysis of three plate family injection mould using pin point gate that consist of four cavities was studied. The responses investigated were volumetric shrinkage, in-cavity residual stress and deflection. The experiment was conducted using Taguchi method with L9 orthogonal array. The parameters involved in this study were mould temperature, melt temperature, injection time and cooling time. The plastic specimens were designed using CATIA V5 and the drawing was imported to Autodesk Moldflow Insight (AMI) simulation software environment. The feed system such as sprue, runner, pin-point gate and cooling system of three plate mould were designed inside the simulation software. Flow analysis was conducted under cool + fill + pack + warp analysis. From the flow analysis using Taguchi method, the lowest volumetric shrinkage obtained is 7.907%. For other responses, the lowest in-cavity residual stress and deflection found are 27.69 MPa and 0.9203 mm respectively. After optimization using optimized parameters, the value of volumetric shrinkage is reduced about 2.88% to 7.678%. In-cavity residual stress is reduced about 0.14% to 27.41 MPa, while deflection of plastic parts is reduced about 0.30% to 0.9176 mm. From ANOVA results, it is found that melt temperature is the most important factors affecting volumetric shrinkage, in-cavity residual stress and deflection of plastic parts.
As for the diesel engine, it is well known as one of the largest contributors to environmental po... more As for the diesel engine, it is well known as one of the largest contributors to environmental pollution, which cause by exhaust emission. Therefore, due to the energy constraint, the rising cost of raw petroleum and environmental change with the expanding request for vitality preservation and environmental protection further enhancement in fuel adaptability and emission reduction in a diesel engine are direly required. The outflows framed are indigent upon the engine configuration, power yield and working burden. The complete ignition of fuel prompts real diminishments in the development of fumes discharges. Complete on combustion will leads a significant mechanical power for the vehicle, which is perfect on the air-fuel mixture. With a specific end goal to diminish NOx and PM arrangement it is important to comprehend the components of its development.
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%.
Metal matrix composite is composite material that combines the metallic properties of matrix allo... more Metal matrix composite is composite material that combines the metallic properties of matrix alloys and additional element to reinforce the product. This paper evaluates the machining performance of uncoated carbide and coated carbide in terms of surface integrity during end milling of LM6 aluminium MMC. The parameter of cutting speed, feed rate and axial depth of cut were kept constant at 3000 rpm spindle speed, 60 mm/min feed rate and 0.5 axial dept of cut. The radial depth of cut were varied from 0.01mm to 0.1 mm. The results indicated that uncoated carbide show the better performance in terms of surface roughness and surface profile, as compared to coated carbide. On the other hand, coated carbide cutting tools suffered with built-up-edge formation at the tool edge, hence caused shearing effect and deterioration at the tool-chip interface. This study is expected to provide understanding of machining metal matrix composites based materials.
This paper details the application of Taguchi method to determine the effect of cutter geometrica... more This paper details the application of Taguchi method to determine the effect of cutter geometrical features for machining Polyetheretherketones (PEEK) thermoplastic. The planned experiment was conducted by using Taguchi’s orthogonal array taking into account the ball nose geometrical parameters such as helix angle, rake angle, clearance angle and number of flute. The measured response is the machined surface roughness, which is important for the component functionality. In addition, ANOVA was used to validate the percentage contribution of each factor. The obtained results reveals that, less number of flutes is the main factor contributed towards fine surface roughness for this thermoplastic. Fewer flutes provide a smooth flow of chip ejection and minimize the friction on the cutting zone which is vital for polymeric material such as PEEK. High helix and rake angles also influence the machined surface roughness as both angles provide optimum shearing force to produced better surface...
Abstract: The High Pressure Waterjet Assisted Machining (HPWAM) is a machining process that invol... more Abstract: The High Pressure Waterjet Assisted Machining (HPWAM) is a machining process that involves high pressure coolant being delivered at the cutting zone. This paper investigates the performance of conventional and HPWAM when machining Ti-6Al-4V titanium alloy. The evaluations were based on the tool life, wear mechanisms, surface profile and chip formation. The coolant pressures, cutting speed, feed rate and depth of cut were set at 11-20.3 MPa, 110m/min, 0.15 mm/rev and 0.5 mm respectively. The results showed that improved tool life as much as 195 % can be achieved when machining Ti-6Al-4V with HPWAM due to better coolant access at the cutting zone. Surfaces generated when machining with HPWAM were generally acceptable with negligible physical damage. Long and continuous chip formations were observed when machining in conventional coolant supply corresponded to the low coolant pressure. Increasing coolant pressure significantly reduces the chip size, resulting in a reduction i...
Journal of Advanced Research in Fluid Mechanics and Thermal Sciences, 2022
In the aerospace field, titanium alloys are extensively used for the airframe and engine parts to... more In the aerospace field, titanium alloys are extensively used for the airframe and engine parts to improve aircraft fuel consumption. Drilling through these parts in a single-shot process to produce high quality holes is challenging. During drilling, high temperatures are generated owing to the friction between the cutting tool and workpiece, causing the process becomes inefficient in terms of tool life and surface quality. To reduce the temperature produced in the cutting zone, different types of cooling techniques during drilling have been used by researchers. In this study, the feasibility of quarry dust suspension as coolant in drilling of titanium alloy was performed. The effects of different concentrations of quarry dust on surface roughness, thrust force, and burr formation were evaluated, and their machining performances were compared with those obtained using aluminium oxide suspension. Before the experiments, both suspensions were prepared by dispersing quarry dust and alum...
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 ...
This paper presents some research into the wear and damage of the flat end-mill cutting tools und... more This paper presents some research into the wear and damage of the flat end-mill cutting tools under machining with copper based metal. A series of cutting tests have been carried at cutting time 35, 70, 105, and 140 minutes. The cutting speed, depth of cut and feed rate were kept constant at 2750 rpm, 0.05 mm and 280 mm/min, respectively.
Flow analysis of three plate family injection mould using pin point gate that consist of four cav... more Flow analysis of three plate family injection mould using pin point gate that consist of four cavities was studied. The responses investigated were volumetric shrinkage, in-cavity residual stress and deflection. The experiment was conducted using Taguchi method with L9 orthogonal array. The parameters involved in this study were mould temperature, melt temperature, injection time and cooling time. The plastic specimens were designed using CATIA V5 and the drawing was imported to Autodesk Moldflow Insight (AMI) simulation software environment. The feed system such as sprue, runner, pin-point gate and cooling system of three plate mould were designed inside the simulation software. Flow analysis was conducted under cool + fill + pack + warp analysis. From the flow analysis using Taguchi method, the lowest volumetric shrinkage obtained is 7.907%. For other responses, the lowest in-cavity residual stress and deflection found are 27.69 MPa and 0.9203 mm respectively. After optimization using optimized parameters, the value of volumetric shrinkage is reduced about 2.88% to 7.678%. In-cavity residual stress is reduced about 0.14% to 27.41 MPa, while deflection of plastic parts is reduced about 0.30% to 0.9176 mm. From ANOVA results, it is found that melt temperature is the most important factors affecting volumetric shrinkage, in-cavity residual stress and deflection of plastic parts.
As for the diesel engine, it is well known as one of the largest contributors to environmental po... more As for the diesel engine, it is well known as one of the largest contributors to environmental pollution, which cause by exhaust emission. Therefore, due to the energy constraint, the rising cost of raw petroleum and environmental change with the expanding request for vitality preservation and environmental protection further enhancement in fuel adaptability and emission reduction in a diesel engine are direly required. The outflows framed are indigent upon the engine configuration, power yield and working burden. The complete ignition of fuel prompts real diminishments in the development of fumes discharges. Complete on combustion will leads a significant mechanical power for the vehicle, which is perfect on the air-fuel mixture. With a specific end goal to diminish NOx and PM arrangement it is important to comprehend the components of its development.
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%.
Metal matrix composite is composite material that combines the metallic properties of matrix allo... more Metal matrix composite is composite material that combines the metallic properties of matrix alloys and additional element to reinforce the product. This paper evaluates the machining performance of uncoated carbide and coated carbide in terms of surface integrity during end milling of LM6 aluminium MMC. The parameter of cutting speed, feed rate and axial depth of cut were kept constant at 3000 rpm spindle speed, 60 mm/min feed rate and 0.5 axial dept of cut. The radial depth of cut were varied from 0.01mm to 0.1 mm. The results indicated that uncoated carbide show the better performance in terms of surface roughness and surface profile, as compared to coated carbide. On the other hand, coated carbide cutting tools suffered with built-up-edge formation at the tool edge, hence caused shearing effect and deterioration at the tool-chip interface. This study is expected to provide understanding of machining metal matrix composites based materials.
This paper details the application of Taguchi method to determine the effect of cutter geometrica... more This paper details the application of Taguchi method to determine the effect of cutter geometrical features for machining Polyetheretherketones (PEEK) thermoplastic. The planned experiment was conducted by using Taguchi’s orthogonal array taking into account the ball nose geometrical parameters such as helix angle, rake angle, clearance angle and number of flute. The measured response is the machined surface roughness, which is important for the component functionality. In addition, ANOVA was used to validate the percentage contribution of each factor. The obtained results reveals that, less number of flutes is the main factor contributed towards fine surface roughness for this thermoplastic. Fewer flutes provide a smooth flow of chip ejection and minimize the friction on the cutting zone which is vital for polymeric material such as PEEK. High helix and rake angles also influence the machined surface roughness as both angles provide optimum shearing force to produced better surface...
Abstract: The High Pressure Waterjet Assisted Machining (HPWAM) is a machining process that invol... more Abstract: The High Pressure Waterjet Assisted Machining (HPWAM) is a machining process that involves high pressure coolant being delivered at the cutting zone. This paper investigates the performance of conventional and HPWAM when machining Ti-6Al-4V titanium alloy. The evaluations were based on the tool life, wear mechanisms, surface profile and chip formation. The coolant pressures, cutting speed, feed rate and depth of cut were set at 11-20.3 MPa, 110m/min, 0.15 mm/rev and 0.5 mm respectively. The results showed that improved tool life as much as 195 % can be achieved when machining Ti-6Al-4V with HPWAM due to better coolant access at the cutting zone. Surfaces generated when machining with HPWAM were generally acceptable with negligible physical damage. Long and continuous chip formations were observed when machining in conventional coolant supply corresponded to the low coolant pressure. Increasing coolant pressure significantly reduces the chip size, resulting in a reduction i...
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