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Mr. Mozammel Mia
Imperial College London

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0 Machine Tools
0 Machining
0 Manufacturing
0 Modeling and Simulation

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Journal article
Published: 16 August 2021 in Lubricants
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In most grinding processes, the use of cutting fluid is required, and research has been carried out to reduce the amount of fluid used due to costs and environmental impacts. However, such a reduction of fluid can result in thermal damage to the machined component because the amount of cutting fluid may not be sufficient to lubricate and cool the system. One way of improving the cutting fluid properties is to add micro or nanoparticles of solid lubricants. This paper aims to evaluate the performance of multilayer graphene platelets dispersed in cutting fluid and applied through the technique of minimum quantity of lubrication (MQL) during the peripheral surface grinding of SAE 52100 hardened steel. In this sense, the influence of these solid particles with respect to the surface and sub-surface integrity of the machined components was analyzed, performing the roughness and microhardness measurement and analyzing the ground surfaces. The results showed that the cooling–lubrication conditions employing graphene could obtain smaller roughness values and decreases of microhardness in relation to the reference value and components with better surface texture compared to the conventional MQL technique without solid particles.

ACS Style

Bruno Souza Abrão; Mayara Fernanda Pereira; Leonardo Rosa Ribeiro da Silva; Álisson Rocha Machado; Rogério Valentim Gelamo; Fábio Martinho Cézar de Freitas; Mozammel Mia; Rosemar Batista da Silva. Improvements of the MQL Cooling-Lubrication Condition by the Addition of Multilayer Graphene Platelets in Peripheral Grinding of SAE 52100 Steel. Lubricants 2021, 9, 79 .

AMA Style

Bruno Souza Abrão, Mayara Fernanda Pereira, Leonardo Rosa Ribeiro da Silva, Álisson Rocha Machado, Rogério Valentim Gelamo, Fábio Martinho Cézar de Freitas, Mozammel Mia, Rosemar Batista da Silva. Improvements of the MQL Cooling-Lubrication Condition by the Addition of Multilayer Graphene Platelets in Peripheral Grinding of SAE 52100 Steel. Lubricants. 2021; 9 (8):79.

Chicago/Turabian Style

Bruno Souza Abrão; Mayara Fernanda Pereira; Leonardo Rosa Ribeiro da Silva; Álisson Rocha Machado; Rogério Valentim Gelamo; Fábio Martinho Cézar de Freitas; Mozammel Mia; Rosemar Batista da Silva. 2021. "Improvements of the MQL Cooling-Lubrication Condition by the Addition of Multilayer Graphene Platelets in Peripheral Grinding of SAE 52100 Steel." Lubricants 9, no. 8: 79.

Original article
Published: 16 July 2021 in The International Journal of Advanced Manufacturing Technology
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The recent step towards “Sustainable Manufacturing (SM)” and efforts to reduce the consumption of cutting fluids have become the hot topic of research these days. Various efforts and strategies have been employed in the modern manufacturing sector to control the environmental pollutions generated from the application of cutting fluids. Therefore, in this holistic work, one such effort of reducing the consumption of cutting fluid is employed with the application of minimum quantity lubrication (MQL) and tool texturing. The turning trials were made on titanium alloy:Ti3Al2.5V alloy under dry and MQL conditions using textured and non-textured tools. The tool life, average surface roughness, specific cutting energy, air quality, and chip morphology were studied with the aid of the above-subjected conditions. In the end, the socio-economic aspects of all cooling conditions were studied and analyzed in the context of sustainable manufacturing. The outcomes of this study reveal that the combination of textured tools and minimum quantity lubrication considerably enhance the machining and sustainability performance as contended with other conditions. However, the air quality factor, i.e., PM2.5 particle generation, was less in the case of a textured tool with MQL conditions. Overall, it is worthy to mention that the combination of tool texturing and MQL cooling conditions has been considered as one of the potential combinations in the area of green machining.

ACS Style

Rupinder Singh; Munish Kumar Gupta; Murat Sarikaya; Mozammel Mia; A. Garcia-Collado. Evaluation of machinability-based sustainability indicators in the eco-benign turning of Ti3Al2.5V alloy with textured tools. The International Journal of Advanced Manufacturing Technology 2021, 1 -11.

AMA Style

Rupinder Singh, Munish Kumar Gupta, Murat Sarikaya, Mozammel Mia, A. Garcia-Collado. Evaluation of machinability-based sustainability indicators in the eco-benign turning of Ti3Al2.5V alloy with textured tools. The International Journal of Advanced Manufacturing Technology. 2021; ():1-11.

Chicago/Turabian Style

Rupinder Singh; Munish Kumar Gupta; Murat Sarikaya; Mozammel Mia; A. Garcia-Collado. 2021. "Evaluation of machinability-based sustainability indicators in the eco-benign turning of Ti3Al2.5V alloy with textured tools." The International Journal of Advanced Manufacturing Technology , no. : 1-11.

Journal article
Published: 24 May 2021 in Journal of Materials Research and Technology
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Dies and molds steels are essential materials in the manufacturing industry of engineering products. These materials are usually machined in the hardened condition and therefore, can be problematic to transform them in chips. Calcium treatment can be a viable alternative to increase machinability without compromising the main properties of the steel. The present work investigates the machinability of the calcium treated mold steel, AISI P20 UF, and compares it to the non-treated version of the same material, AISI P20, in slot milling tests with triple coated (TiN, TiCN and Al2O3) cemented carbide tools. A consolidated method that minimizes the number of tests needed for the determination of the extended Taylor's equation coefficients was used and the power consumption was measured during the machining experiments. SEM was used for the exploration of the wear of the used tool and its mechanism. The results showed that the calcium treated steel presented a considerably higher tool life, and although the treatment did not affect the power consumption directly, indirectly it reduced it because of the positive reduction of the tool wear rate allowing the power to be kept at lower levels for more extended periods. Attrition (adhesion) and abrasion were the primary tool wear mechanisms observed when machining the non-treated steel and attrition for the calcium treated material. In this latter case, because of the longer tool lives, chippings of the cutting edge were also present.

ACS Style

Júlio C.G. Milan; Alisson R. Machado; Ítalo V. Tomaz; Leonardo R.R. da Silva; Celso A. Barbosa; Mozammel Mia; Danil Yu Pimenov. Effects of calcium-treatment of a plastic injection mold steel on the tool wear and power consumption in slot milling. Journal of Materials Research and Technology 2021, 13, 1103 -1114.

AMA Style

Júlio C.G. Milan, Alisson R. Machado, Ítalo V. Tomaz, Leonardo R.R. da Silva, Celso A. Barbosa, Mozammel Mia, Danil Yu Pimenov. Effects of calcium-treatment of a plastic injection mold steel on the tool wear and power consumption in slot milling. Journal of Materials Research and Technology. 2021; 13 ():1103-1114.

Chicago/Turabian Style

Júlio C.G. Milan; Alisson R. Machado; Ítalo V. Tomaz; Leonardo R.R. da Silva; Celso A. Barbosa; Mozammel Mia; Danil Yu Pimenov. 2021. "Effects of calcium-treatment of a plastic injection mold steel on the tool wear and power consumption in slot milling." Journal of Materials Research and Technology 13, no. : 1103-1114.

Original article
Published: 15 April 2021 in The International Journal of Advanced Manufacturing Technology
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This study presents the impact of molybdenum (Mo) inclusion on microstructure, mechanical, and machinability behavior of steels manufactured with powder metallurgy (PM) approach. PM steel samples with different molybdenum ratios were pressed at 750-MPa pressing pressure and sintered in the atmosphere-controlled tube furnace at 1400°C for 1 h. While particle size and distribution of phases of PM steels with different molybdenum ratios were determined by optical microscope, mechanical properties were determined by applying tensile test. The results were observed that 3% Mo weight-added steel displayed the maximum yield and tensile strength. In addition, the machinability properties of 3% Mo-added steel, which has the highest yield and tensile strength, were investigated. In this work, we researched the thrust force and surface roughness as machinability output, and drilling parameters on the output were determined by utilizing analysis of variance. Finally, SEM images were taken from the inner surfaces of the machined holes and the fractured surfaces from tensile test, and information about the machinability of this alloy produced with PM was presented. As a result, an increase in yield and tensile strength and a reduction in strain were identified with the increase in Mo content. Moreover, the coated cutting tools are better on the machining output than the uncoated cutting tools in terms of green environment. The most important factors on the Fz and Ra are the coating condition and the feed rate with 56.53% and 43.62% PCR, respectively.

ACS Style

Mehmet Akif Erden; Nafiz Yaşar; Mehmet Erdi Korkmaz; Burak Ayvacı; K Nimel Sworna Ross; Mozammel Mia. Investigation of microstructure, mechanical and machinability properties of Mo-added steel produced by powder metallurgy method. The International Journal of Advanced Manufacturing Technology 2021, 114, 2811 -2827.

AMA Style

Mehmet Akif Erden, Nafiz Yaşar, Mehmet Erdi Korkmaz, Burak Ayvacı, K Nimel Sworna Ross, Mozammel Mia. Investigation of microstructure, mechanical and machinability properties of Mo-added steel produced by powder metallurgy method. The International Journal of Advanced Manufacturing Technology. 2021; 114 (9-10):2811-2827.

Chicago/Turabian Style

Mehmet Akif Erden; Nafiz Yaşar; Mehmet Erdi Korkmaz; Burak Ayvacı; K Nimel Sworna Ross; Mozammel Mia. 2021. "Investigation of microstructure, mechanical and machinability properties of Mo-added steel produced by powder metallurgy method." The International Journal of Advanced Manufacturing Technology 114, no. 9-10: 2811-2827.

Journal article
Published: 12 April 2021 in Materials
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The features of composite materials such as production flexibility, lightness, and excellent strength put them in the class of materials that attract attention in various critical areas, i.e., aerospace, defense, automotive, and shipbuilding. However, the machining of composite materials displays challenges due to the difficulty in obtaining structural integrity. In this study, Cu/Mo-SiCP composite materials were produced by powder metallurgy with varied reinforcement ratios and then their machinability was investigated. In machinability experiments, the process parameters were selected as cutting speed (vC), feed rate (f), depth of cut (aP), and reinforcement ratio (RR). Two levels of these parameters were taken as per the Taguchi’s L8 orthogonal array, and response surface methodology (RSM) is employed for parametric optimization. As a result, the outcomes demonstrated that RR = 5%, f = 0.25 mm/rev, aP = 0.25 mm, vC = 200 m/min for surface roughness, RR = 0%, f = 0.25 mm/rev and aP = 0.25 mm and vC = 200 m/min for flank wear and RR = 0%, f = 0.25 mm/rev, aP = 0.25 mm, vC = 150 m/min for cutting temperature for cutting temperature and flank wear should be selected for the desired results. In addition, ANOVA results indicate that reinforcement ratio is the dominant factor on all response parameters. Microscope images showed that the prominent failure modes on the cutting tool are flank wear, built up edge, and crater wear depending on reinforcement ratio.

ACS Style

Emine Şap; Üsame Usca; Munish Gupta; Mustafa Kuntoğlu; Murat Sarıkaya; Danil Pimenov; Mozammel Mia. Parametric Optimization for Improving the Machining Process of Cu/Mo-SiCP Composites Produced by Powder Metallurgy. Materials 2021, 14, 1921 .

AMA Style

Emine Şap, Üsame Usca, Munish Gupta, Mustafa Kuntoğlu, Murat Sarıkaya, Danil Pimenov, Mozammel Mia. Parametric Optimization for Improving the Machining Process of Cu/Mo-SiCP Composites Produced by Powder Metallurgy. Materials. 2021; 14 (8):1921.

Chicago/Turabian Style

Emine Şap; Üsame Usca; Munish Gupta; Mustafa Kuntoğlu; Murat Sarıkaya; Danil Pimenov; Mozammel Mia. 2021. "Parametric Optimization for Improving the Machining Process of Cu/Mo-SiCP Composites Produced by Powder Metallurgy." Materials 14, no. 8: 1921.

Journal article
Published: 01 April 2021 in Tribology International
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Machining of titanium is considered as a challenging process due to its ability to interact with various tool materials when critical cutting temperature is exceeded, resulting in excessive tool wear and poor surface finish, etc. To exhibit an efficient machining process, this research study has experimentally investigated the key quality indicators of machinability, namely surface roughness, cutting temperature, tool wear, in-depth analysis of worn tool and cutting force in the machining process of α-β titanium alloy, which used in critical applications, under three sustainable cooling environments i.e., dry, liquid nitrogen (LN2) and carbon dioxide (CO2). The effect of cutting speed and feed rate on such performance measures were examined under a function of cooling strategy as the best substitute in machining. As a result, the feasibility of LN2 cooling has been confirmed to be more significant for the machining of α-β titanium alloy when compared to dry and CO2 machining strategies. To sum up, cryogenic cooling (LN2 cooling) assisted machining of α-β titanium has acquiesced as a sustainable strategy in the context of environmental consciousness.

ACS Style

Munish Kumar Gupta; Qinghua Song; Zhanqiang Liu; Murat Sarikaya; Mozammel Mia; Muhammad Jamil; Anil Kumar Singla; Anuj Bansal; Danil Yu Pimenov; Mustafa Kuntoğlu. Tribological performance based machinability investigations in cryogenic cooling assisted turning of α-β titanium Alloy. Tribology International 2021, 160, 107032 .

AMA Style

Munish Kumar Gupta, Qinghua Song, Zhanqiang Liu, Murat Sarikaya, Mozammel Mia, Muhammad Jamil, Anil Kumar Singla, Anuj Bansal, Danil Yu Pimenov, Mustafa Kuntoğlu. Tribological performance based machinability investigations in cryogenic cooling assisted turning of α-β titanium Alloy. Tribology International. 2021; 160 ():107032.

Chicago/Turabian Style

Munish Kumar Gupta; Qinghua Song; Zhanqiang Liu; Murat Sarikaya; Mozammel Mia; Muhammad Jamil; Anil Kumar Singla; Anuj Bansal; Danil Yu Pimenov; Mustafa Kuntoğlu. 2021. "Tribological performance based machinability investigations in cryogenic cooling assisted turning of α-β titanium Alloy." Tribology International 160, no. : 107032.

Journal article
Published: 27 March 2021 in Journal of Materials Research and Technology
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The wide range of aluminium variants (alloys and composites) has made it an important material for aviation, automotive components, auto-transmission locomotive section units, S.C.U.B.A. tanks, ship, vessels, submarines fabrication and design etc. regardless of the fact that the aluminium alloys were being utilized in myriads of sectors owing to its exceptional superior and versatile functional characteristics, the property such as wear-resistant ought to be enhanced in order to further prolong diverse spectrum of applications. An aluminum alloy having lower hardness and tensile strength has been incorporated with silicon carbide that drastically strengthens the properties. This study involves fabrication of aluminium silicon carbide with muscovite/Hydrated aluminium potassium silicate/aluminosilicate in stir casting method to obtain a hybrid metal matrix composite. Maintaining a constant amount of aluminium and silicon carbide, muscovite or hydrated aluminium potassium silicate is varied to obtain three distinctive compositions of (Al/SiC/Muscovite) composites. The mechanical characteristics like tensile-strength, flexural-strength, toughness, hardness, scratch adhesion, percent-porosity and density were studied. The dispersion of muscovite and silicon carbide particles were observed by viewing the microstructure photographs obtained using optical microscopy and Scanning Electron Microscope (SEM). EDAX analysis affirms the presence of reinforcing constituents in Al-Mg-Si-T6 alloy matrix. A drum type wear apparatus was utilized to evaluate the percentage of wear-loss in different compositions using different loads and it was found that the wear-loss decreases linearly as the muscovite percentage was increased.

ACS Style

Shubham Sharma; Jujhar Singh; Munish Kumar Gupta; Mozammel Mia; Shashi Prakash Dwivedi; Ambuj Saxena; Somnath Chattopadhyaya; Rupinder Singh; Danil Yu Pimenov; Mehmet Erdi Korkmaz. Investigation on mechanical, tribological and microstructural properties of Al–Mg–Si–T6/SiC/muscovite-hybrid metal-matrix composites for high strength applications. Journal of Materials Research and Technology 2021, 12, 1564 -1581.

AMA Style

Shubham Sharma, Jujhar Singh, Munish Kumar Gupta, Mozammel Mia, Shashi Prakash Dwivedi, Ambuj Saxena, Somnath Chattopadhyaya, Rupinder Singh, Danil Yu Pimenov, Mehmet Erdi Korkmaz. Investigation on mechanical, tribological and microstructural properties of Al–Mg–Si–T6/SiC/muscovite-hybrid metal-matrix composites for high strength applications. Journal of Materials Research and Technology. 2021; 12 ():1564-1581.

Chicago/Turabian Style

Shubham Sharma; Jujhar Singh; Munish Kumar Gupta; Mozammel Mia; Shashi Prakash Dwivedi; Ambuj Saxena; Somnath Chattopadhyaya; Rupinder Singh; Danil Yu Pimenov; Mehmet Erdi Korkmaz. 2021. "Investigation on mechanical, tribological and microstructural properties of Al–Mg–Si–T6/SiC/muscovite-hybrid metal-matrix composites for high strength applications." Journal of Materials Research and Technology 12, no. : 1564-1581.

Journal article
Published: 24 March 2021 in International Journal of Mechanical Sciences
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Nickel-chromium superalloys (Inconel 625) are used for various conventional/macro-sized products as well as for micro/nano applications. However, machining of these ‘difficult-to-cut’ materials is challenging due to their extreme toughness, high temperature resistance and continuous work hardening. Thus, the tool-based cutting processes require improvements for micro/nano applications as the chip formation mechanisms in micro-to-nanoscale are not yet understood clearly. Hence, in this study, material removal mechanisms have been comprehensively analysed in ultra-precision machining of Inconel 625 at three distinct regimes of micrometer, sub-micrometer and nanometer level. The physical responses of material were analogized to the fundamental mechanisms of cutting, ploughing, sliding and burnishing by the change of removal scale. In microscale cutting, continuous chips with lamella-like structure were noticed akin to conventional cutting. Sub-microscale machining delivers significant variations of the material removal episodes as chip perforation, bifurcation, fragmentation and structural heterogeneity as the tool advances from grain to grain, thus, influencing the change of chip thickness, striations and machining forces. The fluctuation of force profiles noticed due to the material pile-up effect influencing the overall coefficient of friction (COF). Nanoscale removal persisted from the grain cutting phenomena with the transformation of material cutting to material deformation in sliding-like behaviour. Prevalence of damage on the machined surface, induced by tensile stress, diminishes from micro to sub-micrometer removal lengths. Nanoscale machined surface, affected by the high value of negative effective angle of rake and compressive stress, correlated with the slide burnishing (SB) phenomena for improved surface finishing. This study, thus, provides a fundamental basis on various aspects of tool-based processes of Ni-Cr superalloy in terms of material behaviour, tool-work interaction, chip formation and surface generation in micro-to-nanoscale operations.

ACS Style

M. Azizur Rahman; K.S. Woon; Mozammel Mia. Episodes of chip formation in micro-to-nanoscale cutting of Inconel 625. International Journal of Mechanical Sciences 2021, 199, 106407 .

AMA Style

M. Azizur Rahman, K.S. Woon, Mozammel Mia. Episodes of chip formation in micro-to-nanoscale cutting of Inconel 625. International Journal of Mechanical Sciences. 2021; 199 ():106407.

Chicago/Turabian Style

M. Azizur Rahman; K.S. Woon; Mozammel Mia. 2021. "Episodes of chip formation in micro-to-nanoscale cutting of Inconel 625." International Journal of Mechanical Sciences 199, no. : 106407.

Journal article
Published: 11 March 2021 in Journal of Materials Research and Technology
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Aluminum matrix composites (AMCs), reinforced with SiC and Mo, are formulated using stir casting. The influence of SiC and Mo inclusions on microstructural behavior, and machinability of composites was investigated. Microstructural behavior is analyzed using scanning electron microscopy (SEM), X-ray diffraction (XRD) and energy dispersive spectroscopy (EDS) in the form of microhardness, tensile strength, wear behavior, density, and porosity as per ASTM standards. SEM and EDS confirm the existence and dispersion of SiC and Mo particulates in the matrix grain structure. XRD patterns indicate Al5Mo and Al12Mo compounds formation in hybrid composites, but with the least intensity. Optical microscopy imagery confirms dendritic structure formation with the inclusion of SiC and Mo particulates in the base matrix. Machined surface roughness was influenced by speed-feed while tool wear by all inputs.

ACS Style

Jatinder Kumar; Dilbag Singh; Nirmal S. Kalsi; Shubham Sharma; Mozammel Mia; J. Singh; M. Azizur Rahman; Aqib Mashood Khan; Kalagadda Venkateswara Rao. Investigation on the mechanical, tribological, morphological and machinability behavior of stir-casted Al/SiC/Mo reinforced MMCs. Journal of Materials Research and Technology 2021, 12, 930 -946.

AMA Style

Jatinder Kumar, Dilbag Singh, Nirmal S. Kalsi, Shubham Sharma, Mozammel Mia, J. Singh, M. Azizur Rahman, Aqib Mashood Khan, Kalagadda Venkateswara Rao. Investigation on the mechanical, tribological, morphological and machinability behavior of stir-casted Al/SiC/Mo reinforced MMCs. Journal of Materials Research and Technology. 2021; 12 ():930-946.

Chicago/Turabian Style

Jatinder Kumar; Dilbag Singh; Nirmal S. Kalsi; Shubham Sharma; Mozammel Mia; J. Singh; M. Azizur Rahman; Aqib Mashood Khan; Kalagadda Venkateswara Rao. 2021. "Investigation on the mechanical, tribological, morphological and machinability behavior of stir-casted Al/SiC/Mo reinforced MMCs." Journal of Materials Research and Technology 12, no. : 930-946.

Review
Published: 22 January 2021 in Construction and Building Materials
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Glass fibre reinforced epoxy composites have been used in building area (cold store construction), aeroplanes, land and water vehicles, etc., due to their high-specific rigidity and strength, high damping, great resistance to corrosion, and inferior thermal expansion. Unfortunately, epoxy is flammable whilst releasing a substantial amount of smoke and gases, and therefore presenting a possible risk to lives as well as property. The reduction of their fire risks is normally fulfilled by enhancing the fire performance of composite components including the incorporation of fire retardant (FR) into the polymer matrix and by providing protective FR coatings around the composite. To date, two types of FR have been incorporated into the composite system including additive and reactive FR to improve the fire performance of the composite. This review focuses on the research works over the last ten years in improving fire retardancy of glass fibre reinforced epoxy composite through the incorporation of both types of FR. This work also summarises research works regarding geopolymer which is applied on enhancing fire retardancy of epoxy-based material. Finally, this work presents some future research opportunities as regards to the potential of geopolymer to be utilised as one of FRs to improve fire retardancy of glass fibre reinforced epoxy composite.

ACS Style

Shazzuan Shahari; M. Fathullah; Mohd Mustafa Al Bakri Abdullah; Z. Shayfull; Mozammel Mia; Vertic Eridani Budi Darmawan. Recent developments in fire retardant glass fibre reinforced epoxy composite and geopolymer as a potential fire-retardant material: A review. Construction and Building Materials 2021, 277, 122246 .

AMA Style

Shazzuan Shahari, M. Fathullah, Mohd Mustafa Al Bakri Abdullah, Z. Shayfull, Mozammel Mia, Vertic Eridani Budi Darmawan. Recent developments in fire retardant glass fibre reinforced epoxy composite and geopolymer as a potential fire-retardant material: A review. Construction and Building Materials. 2021; 277 ():122246.

Chicago/Turabian Style

Shazzuan Shahari; M. Fathullah; Mohd Mustafa Al Bakri Abdullah; Z. Shayfull; Mozammel Mia; Vertic Eridani Budi Darmawan. 2021. "Recent developments in fire retardant glass fibre reinforced epoxy composite and geopolymer as a potential fire-retardant material: A review." Construction and Building Materials 277, no. : 122246.

Journal article
Published: 21 January 2021 in Renewable and Sustainable Energy Reviews
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The manufacturing industries consume one-third of global energy. Intensive use of electrical energy in industries provides the researchers and experts strong reasons to develop and propose strategies to minimize energy consumption. Evidently, the advanced technologies such as nanofluid minimum quantity lubrication in machining and process optimization accompanied by holistic models can eliminate the use of conventional fluids to reduce production cost and to cope up with environmental issues of global warming and climate change. This study investigates the holistic analysis of four metrics, i.e., surface quality, energy, cost, and carbon emission that influence the impact of the machining process on the environment of China. Al2O3 based nanofluid was prepared and used in the external turning of Haynes 25 alloys to improve the machining and to promote sustainability. Multi-objective optimization was performed to find out a trade-off relation for product quality, energy consumption and production cost. Results showed that the minimum levels of energy consumption and carbon emission were obtained at the high levels of feed rate and cutting speed. The Carbon Emission Factors (CEF) of used resources have the most significant effects on CO2 emissions. Furthermore, the feed rate was found to be the most significant parameter on the machining performance indices. The application of nanoparticles helped to reduce the cutting energy and CO2 emission, which are proportional to electricity consumption. A holistic component activity-based cost model was developed, and it was noted that the overhead and workpiece cost shared more than 95% of the total cost. Multi-objective optimization reduced specific energy by 18.10%, carbon emission by 22.17% and product cost by 16.25%. Moreover, the present study deals with 3E, i.e., Energy, Environment, and Economy. The optimum cutting parameters obtained from the concept of 3E at the machine shop level can significantly improve efficiency of nanofluid MQL assisted machining (NFMQL) process, reduce cost per unit of product, and achieve the low carbon manufacturing goal.

ACS Style

A.M. Khan; L. Liang; M. Mia; M.K. Gupta; Z. Wei; M. Jamil; H. Ning. Development of process performance simulator (PPS) and parametric optimization for sustainable machining considering carbon emission, cost and energy aspects. Renewable and Sustainable Energy Reviews 2021, 139, 110738 .

AMA Style

A.M. Khan, L. Liang, M. Mia, M.K. Gupta, Z. Wei, M. Jamil, H. Ning. Development of process performance simulator (PPS) and parametric optimization for sustainable machining considering carbon emission, cost and energy aspects. Renewable and Sustainable Energy Reviews. 2021; 139 ():110738.

Chicago/Turabian Style

A.M. Khan; L. Liang; M. Mia; M.K. Gupta; Z. Wei; M. Jamil; H. Ning. 2021. "Development of process performance simulator (PPS) and parametric optimization for sustainable machining considering carbon emission, cost and energy aspects." Renewable and Sustainable Energy Reviews 139, no. : 110738.

Review
Published: 20 January 2021 in Journal of Materials Research and Technology
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Products made of titanium and its alloys are widely used in modern areas like the mechanical engineering, instrument making, aerospace and medical sector. High strength and low thermal conductivity are the causes of difficulties with the machinability of these alloys. It is important to find ways to increase machinability by cutting titanium alloys. One way to implement this is to apply various methods of cooling on workpieces of titanium alloys and on cutting tools during machining. In this review article, an extensive analysis of the literature on such cooling techniques as dry, conventional cooling system, minimum quantity of lubricant (MQL), minimum quantity cooling lubrication (MQCL), cryogenic lubrication, and high-pressure cooling (HPC) is performed. The following groups of Ti alloys are considered: high-strength structural and high-temperature Ti alloys, intermetallic compounds, pure titanium, as well as composites CFRPs/Ti alloys. For the processes of turning, milling, drilling, and grinding, etc. it is shown how the type of cooling affects the surface integrity include surface roughness, tool wear, tool life, temperature, cutting forces, environmental aspects, etc. The main advantages, disadvantages and prospects of different cooling methods are also shown. The problems and future trends of these methods for the machining of Ti and its alloys are indicated.

ACS Style

Danil Yu. Pimenov; Mozammel Mia; Munish K. Gupta; Alisson R. Machado; Ítalo V. Tomaz; Murat Sarikaya; Szymon Wojciechowski; Tadeusz Mikolajczyk; Wojciech Kapłonek. Improvement of machinability of Ti and its alloys using cooling-lubrication techniques: a review and future prospect. Journal of Materials Research and Technology 2021, 11, 719 -753.

AMA Style

Danil Yu. Pimenov, Mozammel Mia, Munish K. Gupta, Alisson R. Machado, Ítalo V. Tomaz, Murat Sarikaya, Szymon Wojciechowski, Tadeusz Mikolajczyk, Wojciech Kapłonek. Improvement of machinability of Ti and its alloys using cooling-lubrication techniques: a review and future prospect. Journal of Materials Research and Technology. 2021; 11 ():719-753.

Chicago/Turabian Style

Danil Yu. Pimenov; Mozammel Mia; Munish K. Gupta; Alisson R. Machado; Ítalo V. Tomaz; Murat Sarikaya; Szymon Wojciechowski; Tadeusz Mikolajczyk; Wojciech Kapłonek. 2021. "Improvement of machinability of Ti and its alloys using cooling-lubrication techniques: a review and future prospect." Journal of Materials Research and Technology 11, no. : 719-753.

Journal article
Published: 16 January 2021 in Metals
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In this paper, the investigation of chip formation of aluminum alloy in different machining strategies (i.e., micro and macro cutting) is performed to develop a holistic view of the chip formation phenomenon. The study of chip morphology is useful to understand the mechanics of surface generation in machining. Experiments were carried out to evaluate the feed rate response (FRR) in both ultra-precision micro and conventional macro machining processes. A comprehensive study was carried out to explore the material removal mechanics with both experimental findings and theoretical insights. The results of the variation of chip morphology showed the dependence on feed rate in orthogonal turning. The transformation of discontinuous to continuous chip production—a remarkable phenomenon in micro machining—has been identified for the conventional macro machining of Al alloy. This is validated by the surface crevice formation in the transition region. Variation of the surface morphology confirms the phenomenology (transformation mechanics) of chip formation.

ACS Style

M. Azizur Rahman; Shahnewaz Bhuiyan; Sourav Sharma; Mohammad Saeed Kamal; M. M. Musabbir Imtiaz; Abdullah AlFaify; Trung-Thanh Nguyen; Navneet Khanna; Shubham Sharma; Munish Kumar Gupta; Saqib Anwar; Mozammel Mia. Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy. Metals 2021, 11, 159 .

AMA Style

M. Azizur Rahman, Shahnewaz Bhuiyan, Sourav Sharma, Mohammad Saeed Kamal, M. M. Musabbir Imtiaz, Abdullah AlFaify, Trung-Thanh Nguyen, Navneet Khanna, Shubham Sharma, Munish Kumar Gupta, Saqib Anwar, Mozammel Mia. Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy. Metals. 2021; 11 (1):159.

Chicago/Turabian Style

M. Azizur Rahman; Shahnewaz Bhuiyan; Sourav Sharma; Mohammad Saeed Kamal; M. M. Musabbir Imtiaz; Abdullah AlFaify; Trung-Thanh Nguyen; Navneet Khanna; Shubham Sharma; Munish Kumar Gupta; Saqib Anwar; Mozammel Mia. 2021. "Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy." Metals 11, no. 1: 159.

Journal article
Published: 04 January 2021 in Metals
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The quest for advanced cooling/lubrication approaches for energy-efficient, eco-benign, and cost-effective sustainable machining processes is garnering attention in academia and industry. Electrical and embodied energy consumption plays an important role in reducing CO2 emissions. In the present study, new empirical models are proposed to assess sustainable indicators. The embodied energy, environmental burden, and cost of coolant/lubricant have been added in the proposed models. Initially, optimal levels of minimum quantity lubrication (MQL) oil flow rate, liquid LN2 flow rate, air pressure, and nanoparticle concentration were found. Based on optimal technological parameters, experiments were performed under the same cutting conditions (machining parameters) for MQL and cryogenic LN2-assisted external turning of Ti6-Al-4V titanium alloy. The electric power and energy consumption, production time/cost, and CO2 emissions were assessed for a unit cutting-tool life. Later, specific responses were measured and compared between both cooling and lubrication approaches. Results showed that hybrid Al-GnP nanofluid consumed 80.6% less specific cumulative energy and emitted 88.7% less total CO2 emissions. However, cryogenic LN2 extended tool life by nearly 70% and incurred 4.12% less specific costs with 11.1% better surface quality. In summary, after Energy–Economy–Ecology–Engineering technology (4E)-based analysis, cryogenic LN2 is sustainable economically but not environmentally and there is a need to improve the sustainable production of LN2 at an industrial scale to achieve environmental sustainability. The present study provides useful information to establish clean machining processes.

ACS Style

Aqib Mashood Khan; Saqib Anwar; Muhammad Jamil; Mustafa M. Nasr; Munish Kumar Gupta; Mustafa Saleh; Shafiq Ahmad; Mozammel Mia. Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy. Metals 2021, 11, 88 .

AMA Style

Aqib Mashood Khan, Saqib Anwar, Muhammad Jamil, Mustafa M. Nasr, Munish Kumar Gupta, Mustafa Saleh, Shafiq Ahmad, Mozammel Mia. Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy. Metals. 2021; 11 (1):88.

Chicago/Turabian Style

Aqib Mashood Khan; Saqib Anwar; Muhammad Jamil; Mustafa M. Nasr; Munish Kumar Gupta; Mustafa Saleh; Shafiq Ahmad; Mozammel Mia. 2021. "Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy." Metals 11, no. 1: 88.

Journal article
Published: 03 January 2021 in Materials
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The necessity to progress towards sustainability has inspired modern researchers to examine the lubrication and cooling effects of vegetable oils on conventional metal cutting operations. Consequently, as an eco-friendly vegetable product, castor oil can be the right choice as Minimum quantity lubrication (MQL) base fluid. Nonetheless, the high viscosity of castor oil limits its flowability and restricts its industrial application. Conversely, palm oil possesses superior lubricity, as well as flowability characteristics. Hence, an attempt has been made to improve the lubrication behavior of castor oil. Here, six castor-palm mixtures (varying from 1:0.5–1:3) were utilized as MQL-fluid, and the values of machining responses viz. average surface roughness, specific cutting energy, and tool wear were evaluated. Furthermore, an integrated Shannon’s Entropy-based Technique for order preference by similarity to ideal solution (TOPSIS) framework was employed for selecting the most suitable volume ratio of castor-palm oil mixture. The rank provided by the TOPSIS method confirmed that 1:2 was the best volume ratio for castor-palm oil mixture. Afterward, a comparative analysis demonstrated that the best castor-palm volume fraction resulted in 8.262 and 16.146% lowering of surface roughness, 5.459 and 7.971% decrement of specific cutting energy, 2.445 and 3.155% drop in tool wear compared to that of castor and palm oil medium, respectively.

ACS Style

Binayak Sen; Munish Kumar Gupta; Mozammel Mia; Danil Yurievich Pimenov; Tadeusz Mikołajczyk. Performance Assessment of Minimum Quantity Castor-Palm Oil Mixtures in Hard-Milling Operation. Materials 2021, 14, 198 .

AMA Style

Binayak Sen, Munish Kumar Gupta, Mozammel Mia, Danil Yurievich Pimenov, Tadeusz Mikołajczyk. Performance Assessment of Minimum Quantity Castor-Palm Oil Mixtures in Hard-Milling Operation. Materials. 2021; 14 (1):198.

Chicago/Turabian Style

Binayak Sen; Munish Kumar Gupta; Mozammel Mia; Danil Yurievich Pimenov; Tadeusz Mikołajczyk. 2021. "Performance Assessment of Minimum Quantity Castor-Palm Oil Mixtures in Hard-Milling Operation." Materials 14, no. 1: 198.

Review article
Published: 27 December 2020 in Journal of Manufacturing Processes
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A well-acknowledged role of cutting fluids in any cutting operation has made them inevitable to utilize regarding the provision of adequate cooling and lubrication. Mineral-based cutting fluids are common practice in the industry; however, they are not suitable for our ecology and health. Therefore, there is a need to implement sustainable cooling/lubrication system that helps the environment and improves the machinability of light weight alloys. This review is presenting the machining and sustainability characteristics of minimum quantity lubrication (MQL), nanofluids-MQL, Ranque-Hilsch vortex tube MQL (RHVT + MQL), cryogenic-MQL as alternative to flood cooling applications in the cutting of light-weight materials. It can be stated that MQL advancements can offer clear guidelines to implement hybrid cooling techniques to improve heat transfer, lubrication, and sustainable implementations.

ACS Style

Murat Sarikaya; Munish Kumar Gupta; Italo Tomaz; Mohd. Danish; Mozammel Mia; Saeed Rubaiee; Mohd Jamil; Danil Yu Pimenov; Navneet Khanna. Cooling techniques to improve the machinability and sustainability of light-weight alloys: A state-of-the-art review. Journal of Manufacturing Processes 2020, 62, 179 -201.

AMA Style

Murat Sarikaya, Munish Kumar Gupta, Italo Tomaz, Mohd. Danish, Mozammel Mia, Saeed Rubaiee, Mohd Jamil, Danil Yu Pimenov, Navneet Khanna. Cooling techniques to improve the machinability and sustainability of light-weight alloys: A state-of-the-art review. Journal of Manufacturing Processes. 2020; 62 ():179-201.

Chicago/Turabian Style

Murat Sarikaya; Munish Kumar Gupta; Italo Tomaz; Mohd. Danish; Mozammel Mia; Saeed Rubaiee; Mohd Jamil; Danil Yu Pimenov; Navneet Khanna. 2020. "Cooling techniques to improve the machinability and sustainability of light-weight alloys: A state-of-the-art review." Journal of Manufacturing Processes 62, no. : 179-201.

Original article
Published: 09 December 2020 in The International Journal of Advanced Manufacturing Technology
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This study presents a two-fold investigation on precision end-milling of stainless steel (AISI 316L). First, the impact of end-milling variables (cutting speed and feed rate) on the surface quality (surface roughness, microhardness, and surface morphology) was analyzed. The best surface quality with surface roughness (Ra) 0.65 ± 0.02 μm was observed for cutting speed of 140 m/min and 0.025 mm/tooth of feed rate. Microhardness was increased with increment in cutting speed. Second, the impact of surface roughness (Ra) on the stress corrosion cracking under two different mediums, i.e., body solutions (Hank’s solution) and 1 M hydrochloric acid solution, was studied. The investigations showed that the samples with higher surface roughness values were more prone to stress corrosion cracking.

ACS Style

Muhammad Yasir; Mohd Danish; Mozammel Mia; Munish Kumar Gupta; Murat Sarikaya. Investigation into the surface quality and stress corrosion cracking resistance of AISI 316L stainless steel via precision end-milling operation. The International Journal of Advanced Manufacturing Technology 2020, 112, 1065 -1076.

AMA Style

Muhammad Yasir, Mohd Danish, Mozammel Mia, Munish Kumar Gupta, Murat Sarikaya. Investigation into the surface quality and stress corrosion cracking resistance of AISI 316L stainless steel via precision end-milling operation. The International Journal of Advanced Manufacturing Technology. 2020; 112 (3-4):1065-1076.

Chicago/Turabian Style

Muhammad Yasir; Mohd Danish; Mozammel Mia; Munish Kumar Gupta; Murat Sarikaya. 2020. "Investigation into the surface quality and stress corrosion cracking resistance of AISI 316L stainless steel via precision end-milling operation." The International Journal of Advanced Manufacturing Technology 112, no. 3-4: 1065-1076.

Journal article
Published: 07 December 2020 in Metals
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The hardened tool steel AISI O1 has increased strength, hardness, and wear resistance, which affects the complexity of the machining process. AISI O1 has also been classified as difficult to cut material hence optimum cutting parameters are required for the sustainable machining of the alloy. In this work, the effect of feed peer tooth (fz), cutting speed (vc), cutting of depth (ap) on surface roughness (Ra, Rt), cutting force (Fx, Fy), cutting power (Pc), machining cost (Ci), and carbon dioxide (Ene) were investigated during the slot milling process of AISI O1 hardened steel. A regression analysis was carried out on the obtained experimental results and the induction of nonlinear mathematical equations of surface roughness, cutting force, cutting power, and machining cost with a high coefficient of determination (R2 = 90.62–98.74%) were deduced. A sustainability assessment model is obtained for optimal and stable levels of design variables when slot milling AISI O1 tool steel. Stable indicators to ensure personal health and safety of operation, P1 values were set to “1” at a cutting speed of 20 m/min or 43.3 m/min and “2” at a cutting speed of 66.7 m/min or 90 m/min. It is revealed that for eco-benign machining of AISI O1, the optimum parameters of 0.01 mm/tooth, 20 m/min, and 0.1 mm should be adopted for feed rate, cutting speed, and depth of cut respectively.

ACS Style

Angelos P. Markopoulos; Nikolaos E. Karkalos; Mozammel Mia; Danil Yurievich Pimenov; Munish Kumar Gupta; Hussein Hegab; Navneet Khanna; Vincent Aizebeoje Balogun; Shubham Sharma. Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel. Metals 2020, 10, 1650 .

AMA Style

Angelos P. Markopoulos, Nikolaos E. Karkalos, Mozammel Mia, Danil Yurievich Pimenov, Munish Kumar Gupta, Hussein Hegab, Navneet Khanna, Vincent Aizebeoje Balogun, Shubham Sharma. Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel. Metals. 2020; 10 (12):1650.

Chicago/Turabian Style

Angelos P. Markopoulos; Nikolaos E. Karkalos; Mozammel Mia; Danil Yurievich Pimenov; Munish Kumar Gupta; Hussein Hegab; Navneet Khanna; Vincent Aizebeoje Balogun; Shubham Sharma. 2020. "Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel." Metals 10, no. 12: 1650.

Journal article
Published: 26 November 2020 in Materials
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The article shows that noncontact measurement techniques can be an important support to X-ray-based methods when examining the surface condition of modern circulated coins. The forms and degrees of wear of such coins, affecting their utility values, qualifying them as a legal tender in a given country, can be measured and analyzed, among other things, using advanced high-accuracy optical profilometry methods. The authors presented four analyses carried out for reverses and obverses of round coins (1 zloty, 1 franc, 50 bani, 5 pens) characterized by different degrees of surface wear. All of the coins were measured using 3D optical profilometers (Talysurf CLI 2000 and S neox) representing two generations of these types of systems. The obtained results confirm the validity of the applied high-accuracy measurement systems in conjunction with dedicated software in the presented applications. Examples of the analyses carried out can be a significant source of information on the condition of coins in the context of maintaining their functional properties (selection of appropriate wear–resistant alloys and correctness of the production process).

ACS Style

Wojciech Kapłonek; Tadeusz Mikolajczyk; Danil Yurievich Pimenov; Munish Kumar Gupta; Mozammel Mia; Shubham Sharma; Karali Patra; Marzena Sutowska. High-Accuracy 3D Optical Profilometry for Analysis of Surface Condition of Modern Circulated Coins. Materials 2020, 13, 5371 .

AMA Style

Wojciech Kapłonek, Tadeusz Mikolajczyk, Danil Yurievich Pimenov, Munish Kumar Gupta, Mozammel Mia, Shubham Sharma, Karali Patra, Marzena Sutowska. High-Accuracy 3D Optical Profilometry for Analysis of Surface Condition of Modern Circulated Coins. Materials. 2020; 13 (23):5371.

Chicago/Turabian Style

Wojciech Kapłonek; Tadeusz Mikolajczyk; Danil Yurievich Pimenov; Munish Kumar Gupta; Mozammel Mia; Shubham Sharma; Karali Patra; Marzena Sutowska. 2020. "High-Accuracy 3D Optical Profilometry for Analysis of Surface Condition of Modern Circulated Coins." Materials 13, no. 23: 5371.

Journal article
Published: 23 November 2020 in Energies
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Sustainability assessments of cooling/lubrication-assisted advanced machining processes has been demanded by environment control agencies because it is an effective management tool for improving process sustainability. To achieve an effective and efficient sustainability evolution of machining processes, there is a need to develop a new method that can incorporate qualitative indicators to create a quantifiable value. In the present research work, a novel quantifiable sustainability value assessment method was proposed to provide performance quantification of the existing sustainability assessment methods. The proposed method consists of three steps: establishing sustainable guidelines and identifying new indicators, data acquisition, and developing an algorithm, which creates the Overall Performance Assessment Indicator (OPAI) from the sustainability assessment method. In the proposed algorithm, initially, both quantitative and qualitative sustainability indicators are normalized. After weight assignment and aggregation, the OPAI is obtained. The developed algorithm was validated from three literature case studies, and optimal cutting parameters were obtained. The present methodology provides effective guidelines for a machinist to enhance process performance and achieve process optimization. The study also offers a relationship between sustainable and machining metrics for the support of industrial sustainability.

ACS Style

Aqib Mashood Khan; Saqib Anwar; Munish Kumar Gupta; Abdullah AlFaify; Saqib Hasnain; Muhammad Jamil; Mozammel Mia; Danil Yurievich Pimenov. Energy-Based Novel Quantifiable Sustainability Value Assessment Method for Machining Processes. Energies 2020, 13, 6144 .

AMA Style

Aqib Mashood Khan, Saqib Anwar, Munish Kumar Gupta, Abdullah AlFaify, Saqib Hasnain, Muhammad Jamil, Mozammel Mia, Danil Yurievich Pimenov. Energy-Based Novel Quantifiable Sustainability Value Assessment Method for Machining Processes. Energies. 2020; 13 (22):6144.

Chicago/Turabian Style

Aqib Mashood Khan; Saqib Anwar; Munish Kumar Gupta; Abdullah AlFaify; Saqib Hasnain; Muhammad Jamil; Mozammel Mia; Danil Yurievich Pimenov. 2020. "Energy-Based Novel Quantifiable Sustainability Value Assessment Method for Machining Processes." Energies 13, no. 22: 6144.