Mohd Azlan Suhaimi

Overview of nanofluid application through minimum quantity lubrication (MQL) in metal cutting process

Pollution related activities in addition to handling cost of conventional cutting fluid application in metal cutting industry has generated a lot of concern over time. The desire for a green machining environment which will preserve the environment through reduction or elimination of machining related pollution, reduction in oil consumption and safety of the machine operators without compromising an efficient machining process led to search for alternatives to conventional cutting fluid. Amongst the alternatives of dry machining, cryogenic cooling, high pressure cooling, near dry or minimum quantity lubrication (MQL), MQL have shown remarkable performance in terms of cost, machining output, safety of environment and machine operators. However, the MQL under aggressive machining or very high speed machining pose certain restriction as the lubrication media cannot perform efficiently at elevated temperature. In compensating for the shortcomings of MQL technique, high thermal conductivity nanoparticles are introduced in cutting fluids for use in the MQL lubrication process. They have indicated enhanced performance of machining process and significant reduction of loads on the environment. The present work is aimed at evaluating the application and performance of nanofluid in metal cutting process through MQL lubrication technique highlighting their impacts and prospects as lubrication strategy in metal cutting process for sustainable green manufacturing. Enhanced performance of vegetable oil based nanofluids over mineral oil-based nanofluids have been reported and thus highlighted.Pollution related activities in addition to handling cost of conventional cutting fluid application in metal cutting industry has generated a lot of concern over time. The desire for a green machining environment which will preserve the environment through reduction or elimination of machining related pollution, reduction in oil consumption and safety of the machine operators without compromising an efficient machining process led to search for alternatives to conventional cutting fluid. Amongst the alternatives of dry machining, cryogenic cooling, high pressure cooling, near dry or minimum quantity lubrication (MQL), MQL have shown remarkable performance in terms of cost, machining output, safety of environment and machine operators. However, the MQL under aggressive machining or very high speed machining pose certain restriction as the lubrication media cannot perform efficiently at elevated temperature. In compensating for the shortcomings of MQL technique, high thermal conductivity nanoparticles are i...

Rough Cut Machining for Impellers with 3-Axis and 5-Axis NC Machines

In recent times, impeller machining has posed a new challenge to engineers due to demand from aerospace, automobiles, and ship building industries. Various methods are introduced by researchers in machining impellers by using 5-axis milling machine; this is because the 5-axis method has the flexibility of tool orientation to machine the extremely twisted surfaces between the blades of impellers. When impellers are machined by a 5-axis machine, the time consumed is very long and the process creates a bottleneck in the manufacturing line. The problem causes increase in the manufacturing lead time and manufacturing cost. To overcome the problem, this paper introduces a new method of machining impellers by integrating 3-axis and 5-axis machine. This paper opens up a new field in impeller machining with the aim to reduce rough-cut time. The results show that by applying this strategy, total machining time of an impeller can be reduced significantly up to 17%.