Browsing by Author "Jamil, Muhammad"

Now showing 1 - 7 of 7
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    An experimental investigation on Cryo-LN2 turning of hardened steel: a sustainability assessment
    (IOS Press, 2019-09-12) Khan, Aqib Mashood; Jamil, Muhammad; Hao, Xiuqing; Ning, He; Sarfraz, Shoaib; Goher, Kamran; Shehab, Essam
    To achieve an excellent workpiece surface quality and long tool life in machining of hardened steel is an inordinate challenge. Recently, conventional flood cooling assisted machining processes are used to address this problem. However, such proposed processes have adverse effects on the environment as well as on the machine shop worker’s health. Hence, in this study, the effects of traditionally used flood cooling and sustainable Cryo-LN2 techniques on the six machining indices, such as surface roughness, cutting power, energy consumption, tool life, tool wear, and productivity in the external turning of AISI-52100 have been investigated. Comparative results showed that Cryo-LN2 technique outperformed flood cooling for all measured indices. The Cryo-LN2 assisted turning process yielded 18% less energy consumption and 66% more productivity. The findings of the current study encourage metal processing industries to use such type of sustainable techniques in the machine shop.
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    An integrated analysis of productivity, hole quality and cost estimation of single-pulse laser drilling process
    (Sage, 2020-11-03) Sarfraz, Shoaib; Shehab, Essam; Salonitis, Konstantinos; Suder, Wojciech; Niamat, Misbah; Jamil, Muhammad
    Laser drilling is a well-established manufacturing process utilised to produce holes in various aeroengine components. This research presents an experimental investigation on the effects of laser drilling process parameters on productivity (material removal rate), hole quality (hole taper) and drilling cost. Single-pulse drilling was employed to drill a thin-walled Inconel 718 superalloy plate of 1mm thickness using pulsed Nd:YAG laser. The experiments were designed using Box-Behnken statistical approach to investigate the impacts of pulse energy, pulse duration, gas pressure and gas flow rate on the selected responses. Multi-objective optimisation was performed using response surface methodology (RSM) based grey rational analysis (GRA) to identify optimal drilling conditions aiming to maximise the MRR and minimise hole taper and drilling cost. The optimal combination of drilling parameters was found as pulse energy of 20 J, pulse duration of 6 ms, gas pressure of 100 psi and gas flow rate of 40 mm3/s. A detailed cost analysis identified labour cost, gas consumption and machine costs as the major cost elements of the laser drilling process
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    Internal cracks and non-metallic inclusions as root causes of casting failure in sugar mill roller shafts
    (MDPI, 2019-08-03) Jamil, Muhammad; Khan, Aqib Mashood; Hegab, Hussien; Sarfraz, Shoaib; Sharma, Neeraj; Mia, Mozammel; Gupta, Munish Kumar; Zhao, GuLong; Moustabchir, H.; Pruncu, Catalin I.
    The sugar mill roller shaft is one of the critical parts of the sugar industry. It requires careful manufacturing and testing in order to meet the stringent specification when it is used for applications under continuous fatigue and wear environments. For heavy industry, the manufacturing of such heavy parts (>600 mm diameter) is a challenge, owing to ease of occurrence of surface/subsurface cracks and inclusions that lead to the rejection of the final product. Therefore, the identification and continuous reduction of defects are inevitable tasks. If the defect activity is controlled, this offers the possibility to extend the component (sugar mill roller) life cycle and resistance to failure. The current study aims to explore the benefits of using ultrasonic testing (UT) to avoid the rejection of the shaft in heavy industry. This study performed a rigorous evaluation of defects through destructive and nondestructive quality checks in order to detect the causes and effects of rejection. The results gathered in this study depict macro-surface cracks and sub-surface microcracks. The results also found alumina and oxide type non-metallic inclusions, which led to surface/subsurface cracks and ultimately the rejection of the mill roller shaft. A root cause analysis (RCA) approach highlighted the refractory lining, the hot-top of the furnace and the ladle as significant causes of inclusions. The low-quality flux and refractory lining material of the furnace and the hot-top, which were possible causes of rejection, were replaced by standard materials with better quality, applied by their standardized procedure, to prevent this problem in future production. The feedback statistics, evaluated over more than one year, indicated that the rejection rate was reduced for defective production by up to 7.6%.
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    Investigation of temperature in orthopaedic drilling using response surface methodology
    (Pakistan Association for the Advancement of Science, 2016-09-30) Jamil, Muhammad; Sarfraz, Shoaib; Jahanzaib, Mirza
    Rise in temperature is inevitable in orthopaedic drilling. Massive research had been done in the field of orthopaedic drilling to investigate the effect of cutting conditions, bone related parameters, and drill bit geometric parameters on heat generation and minimum surrounding tissues injury. In present research, contradictory conclusions regarding the cutting conditions and drill bit geometric parameters were observed. Minimum temperature of 31°C was achieved at speed of 186 rpm, feed of 0.196 mm/rev, drill diameter of 3.85mm, and drill tip angle of 110°. Response Surface Methodology (RSM) was used to develop a mathematical model to predict the type of relationship between inputs and response. It was concluded that the most influencing parameter was drill diameter.
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    Multi-objective optimization of energy consumption and surface quality in nanofluid SQCL assisted face milling
    (MDPI, 2019-02-21) Khan, Aqib Mashood; Jamil, Muhammad; Salonitis, Konstantinos; Sarfraz, Shoaib; Zhao, Wei; He, Ning; Mia, Mozammel; Zhao, GuoLong
    Considering the significance of improving the energy efficiency, surface quality and material removal quantity of machining processes, the present study is conducted in the form of an experimental investigation and a multi-objective optimization. The experiments were conducted by face milling AISI 1045 steel on a Computer Numerical Controlled (CNC) milling machine using a carbide cutting tool. The Cu-nano-fluid, dispersed in distilled water, was impinged in small quantity cooling lubrication (SQCL) spray applied to the cutting zone. The data of surface roughness and active cutting energy were measured while the material removal rate was calculated. A multi-objective optimization was performed by the integration of the Taguchi method, Grey Relational Analysis (GRA), and the Non-Dominated Sorting Genetic Algorithm (NSGA-II). The optimum results calculated were a cutting speed of 1200 rev/min, a feed rate of 320 mm/min, a depth of cut of 0.5 mm, and a width of cut of 15 mm. It was also endowed with a 20.7% reduction in energy consumption. Furthermore, the use of SQCL promoted sustainable manufacturing. The novelty of the work is in reducing energy consumption under nano fluid assisted machining while paying adequate attention to material removal quantity and the product’s surface quality.
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    Multi-response optimisation of machining aluminium-6061 under eco-friendly electrostatic minimum quantity lubrication environment
    (Inderscience, 2019-10-09) Jamil, Muhammad; Khan, Aqib Mashood; He, Ning; Li, Liang; Zhao, Wei; Sarfraz, Shoaib
    The emerging grave consequences of conventional coolants on health, ecology and product quality, have pushed the scientific research to explore eco-friendly lubrication technique. Electrostatic minimum quantity lubrication (EMQL) has been underscored as a burgeoning technology to cut-down bete noire impacts in machining. This research confers the adoption of a negatively charged cold mist of air-castor oil employed in turning of aluminium-6061T6 material by varying the cutting conditions, as per experimental designed through response surface methodology (RSM). For comprehensive sagacity, a range of cutting speed, feed, depth of cut and EMQL-flow rate were considered. Material removal rate, tool life, surface roughness and power consumption of machine tool were adopted as performance measures. To satisfy multi-criterion simultaneously, RSM-based grey relational analysis (GRA) was employed for multi-objective optimisation. Highest proportion of grey relational grade (GRG) as a single desideratum response function, provided a trade-off between performance measures with 15.56% improvement in GRG.
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    Taguchi-based GRA for parametric optimization in turning of AISI L6 tool steel under cryogenic cooling
    (IOS Press, 2019-09-12) ul Haq, Emran; Li, Liang; Jamil, Muhammad; Khan, Aqib Mashood; Sarfraz, Shoaib; Shehab, Essam
    Cutting fluids have frequent use in industrial sector to improve the machinability. Due to the negative impact on our ecology, recent focus has shifted to explore some environment-friendly cooling techniques such as cryogenic cooling. Cryogenic cooling involving liquid nitrogen is one of the alternative techniques which improves the efficiency of the machining process and is environmentally friendly as well. In current work, cutting parameters in turning such as cutting speed and feed rate were optimized under cryogenic cooling for machining of AISI L6 tool steel which is difficult to cut material. The output parameters under consideration are surface roughness, cutting energy, tool wear and Material Removal Rate (MRR). The optimization for multi-responses was carried out through Taguchi based Grey Relational Analysis (GRA). For experimental design, tests were based on L9 orthogonal array. According to the GRA optimization results, optimum cutting speed level was 160 m/min and the feed rate was 0.16 mm/rev. The percentage improvement in Grey Relational Grade (GRG) was calculated as 19.07%, thus showing the advantage of using the GRA.