Shazarel Shamsudin

The Effects of Parameter Settings on Shrinkage and Warpage in Injection Molding through Cadmould 3D-F Simulation and Taguchi Method

This study is focused on the effects of process parameters in plastic injection molding towards shrinkage and warpage problem of High Density Polyethylene (HDPE) specimen. The aim was to identify the main effects of different process parameters on warpage and shrinkage defects via numerical simulation software and experimental validation. Series of simulations were carried out using Cadmould 3D-F in order to utilize the combination of process parameters based on three level of L9 Taguchi orthogonal design. The Signal to Noise (S/N) ratio and the Analysis of Variance (ANOVA) were used to optimize the levels and to point out the impact of the process parameters on warpage and shrinkage. From the results, it showed that the most affected parameter on the warpage and shrinkage is packing time, with the P value of 48.93%, followed by melting temperature with 40.58%. The filling time and packing pressure were not a significant factor because they only contribute 7.30% and 3.19% of P value, respectively.

The Effects of Injection Moulding Processing Parameters and Mould Gate Size towards Weld Line Strength

Plastic moulded parts should have good mechanical properties and free from defects. Tensile behaviour of plastics plays an important role in defining the quality of injection-moulded products. In this study, numerical simulation (Cadmould) was employed to investigate the influence of gate sizes as well as the injection moulding parameters towards the occurrences of weld lines at Acrylonitrile Butadiene Styrene (ABS) specimens. This research begins from the simulation, fabrication of mould, practical injection process and tensile test. The double gates mould was used to present the weld line defects. The result shows that the smaller gate size produces less weld line in plastic parts, which was verified through simulation process. The optimal parameter setting that produced good tensile strength specimens was also validated experimentally in this research

Solid-state recycling of light metals: A review

This article provides an intensive review of the past and current research work on the solid-state recycling of light metals. The review includes an experimental aspect of the relevant works that clearly clarify the effects of several critical factors noted as chip preparation, reinforcing phases, die geometry, process parameter selection and performance of miscellaneous methods over the quality of the extruded profiles. Likewise, reviews of numerical and analytical works on the solid-state recycling were presented to understand the strengthening phenomena of chip-based billet through the plastic deformation. Finally, concluding remarks underline challenges of direct recycling method and subsequently highlight the potential future work on making the method as a promising alternative for sustainable manufacturing agenda.

Mechanical and physical properties of AlSi10Mg processed through selective laser melting

In the past few decade, Additive Manufacturing (AM) has become popular and substantial to manufacture direct functional parts in varieties industrial applications even in very challenging like aerospace, medical and manufacturing sectors. Selective Laser Melting (SLM) is one of the most efficient technique in the additive Manufacturing (AM) which able to manufacture metal component directly from Computer Aided Design (CAD) file data. Accuracy, mechanical and physical properties are essentials requirement in order to meet the demand of those engineering components. In this paper, the mechanical properties of SLM manufactured AlSi10Mg samples such as hardness, tensile strength, and impact toughness are investigated and compared to conventionally high pressure die cast A360 alloy. The results exposed that the hardness and the yield strength of AlSi10Mg samples by SLM were increased by 42% and 31% respectively to those of conventionally high pressure die cast A360 alloy even though without comprehensive post ...

Investigation on Mechanical Properties of Pulsed Nd:YAG Laser Welding on AISI 304 Stainless Steel to AISI 1008 Steel

Product with low cost, lightweight and enhanced mechanical properties were the main reasons welding dissimilar materials thrived by most of the industries. The laser welding technique which has high-energy density beam was found suitable of carrying this task. This paper attempts to investigate welding of AISI 304 stainless steel to AISI 1008 steel through Nd:YAG pulse laser method. The main objective of this study was to find out the weldability of these materials and investigate the mechanical properties of the welded butt joints. Peak power, pulse duration and weld speed combinations were carefully selected with the aims of producing weld with a good tensile strength, minimum heat affected zone (HAZ) and acceptable welding profile. Response surface methodology (RSM) approach was adopted as statistical design technique for tensile strength optimization. Statistical based mathematical model was developed to describe effects of each process parameters on the weld tensile strength and for response prediction within the parameter ranges. The microstructure of the weld and heat affected zones were observed via optical microscope. The results indicate the developed model can predict the response within ±9% of error from the actual values.

Conjectured the Behaviour of a Recycled Metal Matrix Composite (MMC–AlR) Developed through Hot Press Forging by Means of 3D FEM Simulation

Melting aluminium waste to produce a secondary bulk material is such an energy-intensive recycling technique that it also indirectly threatens the environment. Hot press forging is introduced as an alternative. Mixing the waste with another substance is a proven practice that enhances the material integrity. To cope with the technology revolution, a finite element is utilised to predict the behaviour without a practical trial. Utilising commercial software, DEFORM 3D, the conjectures were demonstrated scientifically. The flow stress of the material was modified to suit the material used in the actual experiment. It is acknowledged that the stress–strain had gradually increased in each step. Due to the confined forming space, the temperature decreased by ~0.5% because the heat could not simply vacate the area. A reduction of ~10% of the flesh observed in the simulation is roughly the same as in the actual experiment. Above all, the simulation abides by the standards and follows what has been done previously. Through the finite element utilisation, this study forecasted the performance of the recycled composite. The results presented may facilitate improvement of the recycling issue and conserve the environment for a better future.

Integrating Simulation with Experiment for Recycled Metal Matrix Composite (MMC-AlR) Developed through Hot Press Forging

This study proposes of harmonizing the original approach of aluminium alloy recycling through hot press forging. By eradicating the melting phase, most of the waste generation can be significantly reduced. To cope with the technology revolution, the finite element is utilised to predict the material behaviour without practically executing the trial. By employing three-dimensional finite element analysis through DEFORM 3D, the evaluations were demonstrated by simulating the isothermal forging process. The flow stress of the material was modified to adequate with the aluminium-based metal matrix composite used in the actual experiment. To that extent, this study found out that the strain of the workpiece had gradually increased on each step. A reduction of ~10% of the flesh observed in the simulation is roughly the same as existed on the experiment workpiece. Above all, the simulation conducted abides by the standard and follows the actual practice that has been done previously. Through the finite element utilization, this study discussed the performance of the recycled based composite. The result presented here may facilitate improvement in the recycling issue and also conserved the environment for the better future.

Microstructures and Tensile Characteristics on Direct Recycled Aluminium Chips AA6061/Al Powder by Hot Pressing Method

This research aims to investigate the effect on tensile strength of the recycled chip AA6061 aluminium alloy metal by using powder metallurgy method. Material used is recycled aluminium Chip AA6061 and Al powder. The recycled AA6061 chips mixed together with various compositions of Al powder content were fabricated to form a specimen by hot compaction technique. The compaction using hot pressed at 30 tons with holding time of 60 minutes. The final product was analyzed by tensile test shown the specimen A5 have higher ultimate tensile strength (UTS) 156.404 MPa and yield strength (YS) at 107.399 MPa. Scanning Electron Microscopy (SEM) was conducted to observe the microstructure of fracture surface existing on the tensile specimens.

Benchmarking of dimensional accuracy and surface roughness for AlSi10Mg part by selective laser melting (SLM)

Selective Laser Melting (SLM) is an advance Additive Manufacturing (AM) procedure that a component is manufactured in a layer by layer manner by melting the top surface of a powder bed with a high intensity laser according to sliced 3D CAD data. AlSi10Mg alloy is a traditional cast alloy that is often used for die-casting. Because of its good mechanical and other properties, this alloy has been widely used in the automotive industry. In this study the SLM process is characterized according to these requirements for mould manufacturing application and find the feasibility for manufacturing it by examining the surface roughness and dimensional accuracy of the benchmark produced through SLM process at constant parameters. The benchmark produced by SLM shows the potential of SLM in a manufacturing application particularly in moulds.Selective Laser Melting (SLM) is an advance Additive Manufacturing (AM) procedure that a component is manufactured in a layer by layer manner by melting the top surface of a powder bed with a high intensity laser according to sliced 3D CAD data. AlSi10Mg alloy is a traditional cast alloy that is often used for die-casting. Because of its good mechanical and other properties, this alloy has been widely used in the automotive industry. In this study the SLM process is characterized according to these requirements for mould manufacturing application and find the feasibility for manufacturing it by examining the surface roughness and dimensional accuracy of the benchmark produced through SLM process at constant parameters. The benchmark produced by SLM shows the potential of SLM in a manufacturing application particularly in moulds.

Parametric optimisation of heat treated recycling aluminium (AA6061) by response surface methodology

Alternating typical primary aluminium production with recycling route should benefit various parties, including the environment since the need of high cost and massive energy consumption will be ruled out. At present, hot extrusion is preferred as the effective solid-state recycling process compared to the typical method of melting the swarf at high temperature. However, the ideal properties of extruded product can only be achieved through a controlled process used to alter the microstructure to impart properties which benefit the working life of a component, which also known as heat treatment process. To that extent, this work ought to investigate the effect of extrusion temperature and ageing time on the hardness of the recycled aluminium chips. By employing Analysis of Variance (ANOVA) for full factorial design with centre point, a total of 11 runs were carried out randomly. Three dissimilar extrusion temperatures were used to obtain gear-shape billet. Extruded billets were cut and ground before entering the treatment phase at three different ageing times. Ageing time was found as the influential factor to affect the material hardness, rather than the extrusion temperature. Sufficient ageing time allows the impurity atoms to interfere the dislocation phenomena and yield great hardness. Yet, the extrusion temperatures still act to assist the bonding activities via interparticle diffusion transport matter.