Mohd Amran

Warpage Analysis of Different Number Cooling Channels for Dumbbell Plastic Part in Injection Moulding

Warpage deflection is one of the common pitfalls in plastic injection moulding which is always affected the quality and accuracy of the plastic products. It occurs due to the influences of mould temperature during injection moulding process and it is related to the number of cooling system existed in the mould. Therefore, this paper studies the effect of cooling channels on warpage of dumbbell plastic part having different number of cooling channel using Moldflow software. Warpage analysis was run using four and eight cooling channels. Parameters involved in this study are injection time, packing time, melt temperature and mould temperature. The result of warpage from simulation analysis was projected on the graphic having different colour which is presented the actual value of warpage. It is found from warpage simulation result that the maximum warpage for four cooling channels is 1.283mm and the maximum warpage for eight cooling channels is 1.280mm. It shows that the increasing of the number of cooling channel from four to eight channels in the injection mould reduces the warpage deflection about 0.2%. Thus, the result shows that the number of cooling system in the mould plays an important role on the quality of plastic part during injection moulding process.

Development of Jig for Sintering Hollow Tube Mat

This paper presents the development of a jig for sintering a hollow tube mat. The jig consisted of metal frames, clampers, rails and wheels that were assembled together to hold a stack of hollow tubes in a form of a honeycomb structure. The sintering process involved a large oven where the hollow tube was sintered up to 120°C within two hours. During the sintering process, a partial of plastic parts was melted to allow diffusion around the particle cores. A clamping force from the jig held the tubes to make sure that the molten region around the sintered tubes retained in contact. This gives the compact a sufficient strength to hold together as the heat was removed. The jig developed in this study was capable to produce a hollow cellular mat within the size of approximately 1m (width) x 1m (length) x 1m (height).

Design Simulation on Fatigue Life of Fiber Reinforced Polymer Composites

Fibre reinforced polymer composites have been widely used in automotive industries due to its high tensile strength, lightweight and potential resistance towards environmental conditions. This paper presents a study on the fatigue life prediction of fibre-reinforced polymer (FRP) and the application of FRP composite in manufacturing engineering industries. Four designs of I-beam with different thickness and fillet were studied. The analyses of fatigue life of the designs were done using ANSYS software. Results from the analysis showed that the combination of glass/polyester and the design of I-beam with a fillet of 10mm and thickness of 20mm was the best combination in terms of its good fatigue life, factor of safety and stronger top surface.

The Effect of Binder on Mechanical Properties of Kenaf Fibre/Polypropylene Composites Using Full Factorial Method

The effect of maleated polypropylene (MAPP) as binder on the mechanical properties of kenaf fibre/polypropylene (KF/PP) composites is studied. Ratios between kenaf fibre and PP having 10:90, 30:70 and 50:50 in weight ratio were selected. Further, MAPP having 1, 3 and 5 percent in percentage of weight ratio was mixed in KF/PP composites. Hot press machine was used to produce tensile test samples of KF/PP composites. The mechanical properties that are tensile strength, tensile modulus and elongation at break of KF-PP composites were obtained from tensile test result. It is found that the tensile strength and tensile modulus increase with increasing the kenaf fibre loading and higher percentage of MAPP. Further, the elongation at break for KF/PP composites shows lower result when increasing of kenaf fibre loading. However, when percentage of MAPP added in KF/PP composites increases, the elongation at break increased slightly. Thus, result shows that kenaf fibre/PP composites with binder were better in tensile strength, tensile modulus however the elongation at break shows weak result unless the binder was added.

Development of Database for Checking Fixtures for Automotive Parts

The purpose of this study is to develop a database for checking fixtures for automotive parts. The parts used in the fixture checking process were automotive parts such as clamper, stand and toggle. The goal of this project is to implement a database of checking fixtures parts. The project started with identifying the current problems that were faced by the designer at a design department, in a support service for automotive industries. Idle time has been the major problem that designer have to faced. All the data and information related to this project has been sought and explored in the literature review. Catia software is used as the CAD software to construct three-dimensional models for the design of all the parts in the parts library. All the parts are organized in three different sizes which are determined by the size of car body panel. Referring to the result, new libraries were developed and created using the Catia software to aid designers in the checking fixture design process. The validation of the new libraries had been conducted with the company’s design engineer to test the effectiveness, usability and relevancy. In summary, this database and method can potentially accelerate the checking fixtures design process to be faster and more efficient.

Design and Development of Weaving Aid Tool for Rattan Handicraft

The main purpose of this project is to design and develop an assisting tool in manufacturing of rattan handicraft. Rattan is a non-timber forest resource which has a variety of functions in the making of handicrafts and furniture. The production of rattan handicraft typically carried out using manual and traditional methods. However, there are some problems to be faced by the craftsman in making the handicrafts such as the time constraints for the creation of products, due to the difficulty in term of the size, and the pain in the hands while making the handicraft products. Therefore, assisting tools or devices in manufacturing of rattan handicraft are needed to solve the problem. The methods used are questionnaire survey, CATIA software for RULA analysis and SolidWork software for FEA analysis.

Optimization of Cutter Geometry Features to Minimise Cutting Force on Machining Polyetheretherketone (PEEK) Engineering Plastic

Machining of thermoplastic material poses several challenges due to its low melting temperature and high thermal expansion which directly related to cutting force. Thus, controlling the cutting force and temperature is desirable for machining polyetheretherketone (PEEK). The cutting force is dependent on friction and shearing action produced by the tool. It is indicated the cutting force is significantly affected by tool cutter geometry. This paper aims to control the cutting force by optimizing the cutter geometries especially rake, clearance and helix angle on machining PEEK. The two –flutes of solid carbide ball nose end mills were used to conduct the experiments and the cutting force acquired was measured using piezoelectric dynamometer. Response Surface Methodology (RSM) approach was applied to design and analyse the optimal combination of tool geometry feature for machining PEEK. Based on obtained results, the best optimal values of tool geometry which contribute to minimum of cutting force were 17° rake angle, 26° of helix angle and 10° of clearance angle. The best control of tool geometry ultimately improves the cutting performance and reduces defect caused by high cutting forces.

Cutting Technology Innovation in Production of Porous Cellular Mat

Innovative developments of hollow cellular mat for lightweight structure must satisfy sustainability, fit for purpose and optimize design concepts. However, such materials necessitate appropriate cutting technology to allow trimming and shaping operations to be easily carried out on an excessive porous and perhaps non uniformity nature. This paper presents a work that aims at studying the machinability of porous cellular mat using a newly innovative cutting technology. A large structure of vertical bandsaw has been fabricated to cut the product with the size of 1m (width) x 1m (height) x 1m (long). The systems also equipped with a feeding table and strong structure frame to avoid product shifting during the cutting operation. The surface integrity showed minimum deformation with uniformed direction of surface removal marks. The cutting technology developed in this study is suitable for the hollow cellular mat for its simple trimming and shaping process and fine surface profile.

Multi Objective Optimization of Cutting Parameters in Machining Cellulose Based Hybrid Composites

Cellulose based hybrid composites are gaining popularity in the growing green communities. With extensive studies and increasing applications for future advancement, the need for an accurate and reliable guidance in machining this type of composites has increased enormously. Smooth and defect free machined surface are always the ultimate objectives. The present work deals with the study of machining parameters (i.e. spindle speed, feed rate and depth of cut) and their effects on machining performance (i.e. surface roughness and delamination) to establish an optimized setup of machining parameters in achieving multi objective machining performance. Cellulose based hybrid composites consist of jute (a bast fiber) and glass fiber embedded in polyester resins. Response Surface Methodology (RSM) using Box-Behnken Design (BBD) was chosen as the design of experiment approach for this study. Based on that experimental approach, 17 experimental runs were conducted. Mathematical model for each response was developed based on the experimental data. Adequacy of the models were analyzed statistically using Analysis of Variance (ANOVA) in determining the significant input variables and possible interactions. The multi objective optimization was performed through numerical optimization, and the predicted results were validated. The agreement between the experimental and selected solution was found to be strong, between 95% to 96%, thus validating the solution as the optimal machining condition. The findings suggest that feed rate was the main factor affecting surface roughness and delamination .