Papers by Author: Muammer Din Arif

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Authors: A.K.M. Nurul Amin, A.A. Che Omar, M.A. Mohammed Kamal, Mahmoud M.A. Nassar, N.F. Mohd Zaib, Muammer Din Arif
Abstract: Soda lime glass is widely used in optics, chemical apparatus, camera lens, micro gas turbines, light bulbs etc. on account of its high hardness, corrosion resistance, and excellent optical properties. These require high dimensional accuracy and flawless surface finish. However, soda lime glass is inherently brittle leading to subsurface crack propagation and fracture which compromise its functionality. To avoid these defects, the machining needs to be performed under ductile mode conditions. Therefore, this research investigates the viability and requisite conditions for achieving ductile regime machining (DRM) in high speed micro-end milling of soda lime glass. Machining was performed at high cutting speeds (30,000 to 50,000 rpm), feed rate (5 to 15 mm/min), and depth of cut (3 to 7 μm). A surface profilometer was then used to measure the surface roughness and a scanning electron microscope (SEM) used to scrutinize the resultant machined surfaces. The results demonstrate that ductile streaks and rounded gummy chips (without sharp or jagged edges) are produced in all runs. In addition, there are no subsurface cracks and the minimum surface roughness attained is 0.08μm. These indicate that DRM of soda lime glass is obtainable using high-speed micro end milling in a conventional end mill with tungsten carbide inserts.
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Authors: A.K.M. Nurul Amin, Suhaily Mokhtar, Muammer Din Arif
Abstract: Inconel 718 is used for high-temperature applications in aerospace, nuclear, and automotive industries due to its resistance, at high temperatures, to corrosion, fatigue, creep, oxidation, and deformation. Unfortunately, these same qualities also impair its machinability and researchers have investigated on ways to machine it economically. Some unconventional machining practices such as: Plasma Enhanced and Laser Assisted Machining etc. have been applied. However these practices increase the machining cost. This research investigated the viability of high speed end milling of Inconel 718 using circular Silicon Nitride (ceramic) inserts under room temperature conditions. Tool wear (flank and notch wear), machining vibration amplitude and average surface roughness were evaluated for the feasibility analysis. A vertical CNC mill was used to machine Inconel 718 samples using different combinations of three primary machining parameters: cutting speed, feed, and depth of cut. Vibration data acquisition device and Datalog DasyLab 5.6 software were used to analyze machining vibration. Scanning Electron Microscope (SEM) and surface profilometer were utilized to measure tool (flank and notch) wear and surface roughness, respectively. It was observed that the machining vibrations, in high speed machining, was reasonable (0.045 V on the average). This resulted in acceptable tool wear (averages: flank wear = 0.25 mm, notch wear = 0.45 mm) and semi-finished surface roughness (0.30 µm) measured after every 30 mm length of cut. Thus, room temperature high speed machining of Inconel 718 using circular silicon nitride inserts is a practical option.
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Authors: A.K.M. Nurul Amin, Siti Nurshahida Mohd Nasir, Noor Syairah Khalid, Muammer Din Arif
Abstract: Review of past research indicated that ductile mode machining of silicon can produce surface roughness values as low as 0.22 µm, which is about half of 0.40 µm, the usual standard roughness value to avoid fine grinding and rough polishing operations. The current research investigated and compared the surface roughness and integrity attained in high speed end milling of silicon (using diamond coated tools) under ductile mode machining conditions. Two different types of end milling machines were utilized, CNC and conventional milling machines. Additionally, the effect of compressed air on the resultant surface roughness was investigated. The air blowing fixture, designed for mounting the compressed air hose, consisted of fixed and movable jaws, air blower clamp, fasteners, and the air gun. Air blowing was used to prevent silicon chips from settling on the machined surface, since it was observed to be an acute problem in high speed ductile mode machining of silicon. The three machining parameters: spindle speed, depth of cut, and feed rate were varied within the ranges 60,000 to 80,000 rpm, 10 to 20 µm, and 5 to 15 mm/min respectively. The resultant machined surfaces were analysed using Wyko NT 1100 and SurfTest SV-500 profilometers in order to measure the attaine surface roughnesses and surface profile. The machined surfaces had almost no deposition and was of excellent finish.
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Authors: A.K.M. Nurul Amin, Fawaz Mohsen Abdullah, Ummu Atiqah Khairiyah B. Mohammad, Muammer Din Arif
Abstract: Chatter is a self-excited and violent form of vibration which is almost unavoidable in all machining processes. It affects surface roughness, machining accuracy, cutting tool and machine tool life, metal removal rate; and consequently operation cost. This research work focuses on investigation of the influence of the cutting parameters on chatter and implementation of a method based on application of permanent magnet for controlling chatter during turning of stainless steel AISI 304 using coated carbide tool. For this purpose, a powerful permanent bar magnet (of strength 1250-1350 Gauss) was placed inside a specially developed fixture mounted on the lathe machine carriage, to apply magnetic field to the base of the tool holder in the Z direction. The effectiveness of the application of the magnet on chatter suppression was measured in terms of reduction of amplitude of chatter compared to conventional turning. To achieve this, a small central composite design (CCD) of the Response Surface Methodology (RSM) with five levels and an alpha value of 1.4142, was used in the design of the experiments (DoE). Design-Expert 6.0 software was utilized in the model development process. Vibration monitoring was done using an online vibration monitoring system. FFT analysis of the recorded vibration signals was conducted using DASYLab software to evaluate the peak chatter amplitudes and their corresponding excited frequencies. The acceleration amplitude was found to be reduced by a maximum of 73.43% and an average of 31.58% due to the effect of damping on the resonant amplitude offered by the magnetic field created by the permanent magnet.
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Authors: A.K.M. Nurul Amin, Syidatul Akma Sulaiman, Muammer Din Arif
Abstract: Chatter is defined as the self-excited violent relative dynamic motion between the cutting tool and work piece. Chatter is detrimental to all machining operations. In metal turning operations it leads to inferior surface topography, reduced productivity, and shortened tool life. Avoidance of chatter has mostly been through reliance on heuristics such as: limiting material removal rates (to stay within the dynamic stability boundary) or selecting low spindle speeds and shallow depth of cuts. However, the correct understanding of the mechanism of chatter formation in metal cutting reveals that chip morphology and segmentation play a predominant role in chatter formation during machining. Chatter is found to appear as a resonance phenomenon when the frequency of chip serration is equal to or integer multiple of the prominent natural frequency/frequencies of the system component(s). Hence, it is important to study the chip serration frequency. At lower cutting speeds the chip is often discontinuous, while it becomes serrated as the cutting speed is increased. It has been identified that the chip formation process at higher speeds also has a discrete nature, associated with the periodic shearing process of the chip. In this paper a statistical technique is proposed to predict the frequency of chip serration as a function of cutting parameters for two different tool overhang values in turning of stainless steel AISI 304 using Response Surface Methodology (RSM).
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Authors: A.K.M. Nurul Amin, Muammer Din Arif, Muhd Amir Hafiz B. Ahamad Mohrodi, Israd H. Jaafar
Abstract: Chatter, the self-excited and violent oscillatory motion between the tool and the work-piece, is detrimental to all machining operations, especially turning. It can lead to poor surface topography, reduced productivity, excessive tool wear, and damaged machine-tool components. Several theories have been introduced to explain chatter, but their predictions have not always been reliable. Therefore, chatter avoidance has relied on inefficient techniques like limiting material removal rates or expensive setups such as actuators and ultrasonic vibration damping systems. However, a deeper investigation into chatter formation reveals that chip morphology and segmentation play a significant role during incidence of machining chatter. The novel Resonance theory of chatter combines the concept of mode coupling of the machining setup and serrated chip formation, to explain the incidence of chatter. To validate the postulates of this theory, models for chip serration frequency are essential. At the same time, a reliable and economical chatter control method is required. To this end, the current research work developed an empirical mathematical model of chip serration frequency in turning of stainless steel AISI 304 using Response Surface Methodology (RSM). Also, it investigated the influence of damping provided by magnetic field from a permanent magnet. The developed chip serration model shows good agreement with experimental data.
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Authors: A.K.M. Nurul Amin, A.A. Che Omar, M.A.Mohammed Kamal, Mahmoud M.A. Nassar, N.F. Mohd Zaib, Muammer Din Arif
Abstract: Soda lime glass is used extensively in camera lens, micro gas turbines, light bulbs, tablewares, optics, and chemical apparatus owing to its high hardness, excellent optical properties, and good corrosion and chemical resistance. Such applications of soda lime glass demand high machining and finishing precision. On the other hand, machining of glass poses significant challenges due to its inherent brittleness. The process of removal of material from glass, if not done in ductile mode, can generate subsurface cracks and brittle fractures which have adverse effects on its functionality. This research investigates the high speed micro-end milling of soda lime glass in order to obtain ductile regime machining. It has been found by other researchers that ductile mode machining can avoid sub-surface cracks and brittle fractures. However, in ductile mode machining, the gummy chips settle permanently on the machined surface affecting adversely the surface finish. In order to avoid such chip settlement, compressed air was directed using a special air delivery nozzle to blow away the resultant gummy chips, thereby preventing them from settling on the machined surface. Response surface methodology (RSM) and a commercial NC end mill were used to design and perform the machining runs, respectively. Machining was done using: high spindle speeds from 30,000 to 50,000 rpm, feed rates from 5 to 15 mm/min, and depth of cuts from 3 to 7 μm. Three different diameter carbide tools were used: 0.5, 1, and 2 mm. A surface profilometer was used to analyze the surface roughness of the resultant machined surface. Subsequently, the data was used for finding the best combination of cutting parameters required to obtain the lowest surface roughness. The results demonstrate that high speed machining is a viable option for obtaining ductile regime machining and generating machined surfaces with very low surface roughness in the range of 0.08μm – 0.22 μm, using 0.5 mm carbide end mill cutter.
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Authors: A.K.M. Nurul Amin, Muammer Din Arif, Noor Hawa B. Mohamad Rasdi, Khairus Syakirah B. Mahmud, Abdul Hakam B. Ibrahim, Mohd Firdaus B. Zawani, Amir Faris B. Abdul Malik
Abstract: Thermal or heat assisted machining is used to machine hard and difficult-to-machine materials such as Inconel and Titanium alloys. The main concept is that localized surface heating of the work-piece reduces the yield strength of the material significantly, making it amenable to plastic deformation and machining. Thus, heat assisted machining has been used for over a century. However, the heating technique and temperature are very much dependent on the type of working material. Therefore, a multitude of heating techniques has been applied over the years including Laser Assisted Machining (LAM) and Plasma Enhanced Machining (PEM) in the industry. But such processes are very expensive and have not been found in wide scale applications. The authors of the current research have therefore looked into the application of a simple Tungsten Inert Gas (TIG) welding setup to perform heat assisted turning of AISI 304 Stainless Steel. Such welding equipment is relatively cheap and available. Also, stainless steel is perennially used in the industry for high strength applications. Hence, it is very important to determine with optimal cutting temperature when applying a TIG setup for heat assisted machining of stainless steel. This paper describes three separate techniques for determining the optimum temperature. All three processes applied the same experimental setup but used different variables for evaluating the best temperature. The first process used vibration amplitude reduction with increment in temperature to identify the desired temperature. The second process used chip shrinkage coefficient to locate the same temperature. And finally, the third process investigated tool wear as a criterion for determining the optimum temperature. In all three cases the three primary cutting parameters: cutting speed, feed, and depth of cut, were varied in the same pattern. The results obtained from all three approaches showed that 450oC was undoubtedly the best temperature for heat assisted machining of stainless steel.
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Authors: A.K.M. Nurul Amin, Ummu Atiqah Khairiyah Mohamad, Muammer Din Arif
Abstract: Machine tool chatter is a type of intensive self-excited vibration of the individual components in a machine-tool-fixture-work system. Chatter affects the cutting process and may lead to negative effects concerning surface quality, cutting tool life, and machining precision. However, modern manufacturing industries and their end users demand fine surface finish, high dimensional accuracy as well as low operation costs which include the cost of tooling. Therefore, any effective damping technique, which reduces or eliminates chatter, will significantly improve tool life and will be a profitable technique to implement in the industry. This paper presents a novel chatter control method in turning of (AISI 304) stainless steel by using permanent magnets. The study compared tool wear under two different cutting conditions: normal turning and turning with magnetic damping. A specail fixture made of mild steel was designed and fabricated in order to attach a powerful neodymium permanent magnet (4500 Gauss) to the carraige of a Harrison M390 engine lathe. The arrangement ensured that the magnet was placed exactly below the tool shank. The main idea was that the magnet will provide effective damping by attracting the steel tool shank and restricting its vertical vibratory motion during cutting operations. A Kistler 50g accelerometer, placed at the bottom front end of the tool shank was used to sense vibration. The data was then collected using a Dewetron DAQ module and analyzed using Dewesoft (version 7) software in a powerful Dell workstation. Response surface methodology (RSM) in Design Expert software (version 6) was used to design the sequence of experiments needed based on three primary cutting parameters: cutting speed, feed, and depth of cut. The tool overhang was kept constant at 120 mm in order to facilitate the attachment of the magnet fixture. Analysis of the recorded vibration signals in the frequency domain indicated that significant reduction in the vibration amplitude, as much as 86%, was obtained with magnetic damping. Next tool wear was analysed and measured using a scanning electron microscope (SEM). It is found that tool wear is reduced considerably by a maximum of 87.8% with the magnetic damping method. Therefore, this new magnetic damping method can be very cost effective, in terms of vibration reduction and tool life extension, if applied to industrial turning operations of metals.
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Authors: A.K.M. Nurul Amin, Muammer Din Arif, Siti Aminatuzzuhriyah B. Haji Subir, Fawaz Mohsen Abdullah
Abstract: Chatter is a type of intensive self-excited vibration commonly encountered in machining. It reduces productivity and precision, and is more noticeable in the machining of difficult-to-cut alloys like hardened steel. In such cases chatter causes excessive tool wear, especially flank wear, which in turn affects the stability of the cutting edge leading to premature tool failure, poor surface finish, and unsatisfactory machining performance. Nowadays, however, the demand is for fine finish, high accuracy, and low operation costs. Therefore, any technique which significantly reduces chatter is profitable for the industry. This paper demonstrates the viability and effectiveness of a novel chatter control strategy in the turning of (AISI 304) stainless steel by using permanent bar magnets. Reduction in chatter and corresponding tool flank wear are compared from results for both undamped and magnetically damped turning using coated carbide inserts. Special fixtures and keyway were made from mild steel in order to affix the magnets on the lathe’s carriage. The two ferrite magnets (1500 Gauss each) were placed below and beside the tool shank for damping from Z and X directions, respectively. Response surface methodology (RSM) was used to design the experimental runs in terms of the three primary cutting parameters: cutting speed, feed, and depth of cut. A Kistler 50g accelerometer measured the vibrations. The data was subsequently processed using DasyLab (version 6) software. The tool wear was measured using scanning electron microscope (SEM). Results indicate that this damping setup can reduce vibration amplitude by 47.36% and tool wear by 63.85%, on average. Thus, this technique is a simple and economical way of lowering vibration and tool wear in the turning of stainless steel.
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