M. Rasidi Ibrahim

Numerical analysis of laser preheating for laser assisted micro milling of Inconel 718

Micro milling of super alloy materials such as nickel based alloys such as Inconel 718 is challenging due to the excellent of its mechanical properties. Therefore, new techniques have been suggested to enhance the machinability of nickel based alloys by pre-heating the workpiece’s surface to reduce its strength and ductility. The prediction of fluctuated temperature distribution generated by pulsed wave laser in laser assisted micro milling (LAMM) is crucial. The selection of processing parameter by minimize the effect on the processing characteristic is decisive to ensure the machining quality is high. Determining the effect of heat generated in underneath surface is important to make sure that the cutting tools are able to cut the material with maximum depth of cut and minimum defects in terms of tool wear and tool life. In this study the simulation was carried by using Ansys APDL. In order to confirm the actual and distribution irradiation of temperature from simulation, an experimental was done to validate the results. The experiment was conducted by using Nd:YAG laser with wavelength 1064 nm.

Effect of triggering angles on the crushing mechanisms of hybrid woven kenaf/aluminum hollow cylinders

This paper presents the effect of triggering angles constructed on the top of hybrid woven kenaf/aluminium hollow cylinders on the energy absorption performances. The crushing performances of aluminium tubes can be found widely in open literature. However, lack number of work on the hybridizing the aluminium tubes with woven kenaf fibre is found. Woven kenaf mats are produced and bathed with polymeric resin before they are wrapped around the aluminium tubes twice. Different fibre orientations, +-θ° are used where θ = 0, 15, 30 and 45. Once the hybrid composite hardened, one of their end are chamfered using different angles of 0o, 30o, 45o and 60o. The tubes are quasi-statically compressed in order to obtain their force-displacement responses and crashworthiness parameters are extracted and discussed with the relation of fibre orientations and chamfering angles. It is found that the chamfering angles are only affected the force-displacement curves during the first stage of elastic deformation whereas there is no obvious effect in the second stage. However, varying the fibre orientations are slightly increased the force-displacement curves especially when the fibre is orientated with 30o. Based on the fracture mechanism observations, most of composite experienced large fragmentation indicating that the composites absorbed the crushing energy ineffectively.

Numerical modelling of steel tubes under oblique crushing forces

This paper presents the numerical assessment of crushing responses of elliptical tubes under crushing forces. Based on the literature survey, tremendous amount of works on the axial crushing behaviour can be found. However, the studies on the oblique crushing responses are rarely found. Therefore, this work investigates numerically the elliptical tubes under compressions. The numerical model of the tubes are developed using ANSYS finite element program. Two important parameters are used such as elliptical ratios and oblique angles. The tubes are compressed quasi-statically and the force-displacement curves are extracted. Then, the area under the curves are calculated and it is represented the performances of energy absorptions. It is found numerically that the introductions of oblique angles during the crushing processes decrease the crushing performances. However, the elliptical-shaped tubes capable to enhance the energy absorption capabilities. On the other hand, the elliptical-shaped tubes produced the enhancement on the energy absorption capabilities.

Combined mode I stress intensity factors of slanted cracks

The solutions of stress intensity factors of slanted cracks in plain strain plate are hard to find in open literature. There are some previous solutions of stress intensity factors available, however they are not studied completed except for the case of plain stress. The slanted cracks are modelled numerically using ANSYS finite element program. There are ten slanted angles and seven relative crack depths are used and the plate containing cracks is assumed to fulfil the plain strain condition. The plate is then forced uni-axially the stress intensity factors are determined according to the displacement extrapolation method. Based on the numerical analysis, it is found that slanted angles have inverse effects on the behaviour of stress intensity factors. Increasing such angles capable to reduce the mode I stress intensity factors. On the other hand, it is also enhanced the capability of mode II stress intensity factors at the crack tip. Due to difficulty of determining stress intensity factors numerically, a regression technique is used to formulate mathematical expressions which are capable to predict the stress intensity factors in reasonable accuracies.

Electrical discharge machining of polycrystalline diamond using copper electrode – finishing condition

Research on machining process of Polycrystalline Diamond (PCD) is becoming important as the material was believed suitable to be used for cutting tools of advanced aeronautical structure. Electrical Discharge Machining (EDM) was regarded as the suitable method to machine PCD due its noncontact process nature. The objective of this research is to determine the influence of several EDM parameter such as sparking current, pulse duration, and pulse interval to the material removal rate and surface roughness of the machined PCD. Instead of significantly influenced the material removal rate, the sparking current was also highly influenced tha surface roughness. Highest material removal rate of approximately 0.005mm3/s was recorded by the EDM process with the highest current used of 5A, and lowest pulse interval of 1μs. The influence of pulse duration is not clearly seen at the lowest pulse interval used. On the other hand, 0.4μm was the lowest surface roughness value obtained in this research indicated by the highest sparking current, highest sparking duration and lowest sparking interval of 5A, 1μs and 1μs respectively.

Preliminary Study on Kano Model in the Conceptual Design Activities for Product Lifecycle Improvement

Product manufactured with short life cycle had only one major issue, it can lead to increasing volume of waste. Day by day, this untreated waste had consumed many landfill spaces, waiting for any possible alternatives. Lack of product recovery knowledge and recyclability features imprinted into product design are one of the main reason behind all this. Sustainable awareness aspect should not just be implied into peoples mind, but also onto product design. This paper presents a preliminary study on Kano model method in the conceptual design activities to improve product lifecycle. Kano model is a survey-type method, used to analyze and distinguished product qualities or features, also how the customers may have perceived them. Three important attributes of Kano model are performance, attractive and must-be. The proposed approach enables better understanding of customer requirements while providing a way for Kano model to be integrated into engineering design to improve products end-of-life. Further works will be continued to provide a better lifecycle option (increase percentage of reuse, remanufacture or recycle, whereby decrease percentage of waste) of a product using Kano model approach.

Investigation of 1-Dimensional ultrasonic vibration compliance mechanism based on finite element analysis

The conventional milling has many difficulties in the processing of hard and brittle material. Hence, ultrasonic vibration assisted milling (UVAM) was proposed to overcome this problem. The objective of this research is to study the behavior of compliance mechanism (CM) as the critical part affect the performance of the UVAM. The design of the CM was investigated and focuses on 1-Dimensional. Experimental result was obtained from a portable laser digital vibrometer. While the 1-Dimensional value such as safety factor, deformation of hinges and stress analysis are obtained from finite elements simulation. Finally, the findings help to find the best design judging from the most travelled distance of the piezoelectric actuators. In addition, this paper would provide a clear picture the behavior of the CM embedded in the UVAM, which can provide good data and to improve the machining on reducing tool wear, and lower cutting force on the workpiece surface roughness.

The Influence of Injection Molding Parameter on Properties of Thermally Conductive Plastic

Thermally conductive plastic is the composite between metal-plastic material that is becoming popular because if it special characteristic. Injection moulding was regarded as the best process for mass manufacturing of the plastic composite due to its low production cost. The objective of this research is to find the best combination of the injection parameter setting and to find the most significant factor that effect the strength and thermal conductivity of the composite. Several parameter such as the volume percentage of copper powder, nozzle temperature and injection pressure of injection moulding machine were investigated. The analysis was done using Design Expert Software by implementing design of experiment method. From the analysis, the significant effects were determined and mathematical models of only significant effect were established. In order to ensure the validity of the model, confirmation run was done and percentage errors were calculated. It was found that the best combination parameter setting to maximize the value of tensile strength is volume percentage of copper powder of 3.00%, the nozzle temperature of 195oC and the injection pressure of 65%, and the best combination parameter settings to maximize the value of thermal conductivity is volume percentage of copper powder of 7.00%, the nozzle temperature of 195oC and the injection pressure of 65% as recommended.