Jaharah A. Ghani

Jaharah A. Ghani
National University of Malaysia | ukm · Department of Mechanical and Materials Engineering

PhD

About

353
Publications
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5,801
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Publications

Publications (353)
Article
Purpose This study aims to investigate the machining performance of CVD-coated carbide tools by considering most crucial machinability aspects: cutting force, tool life, surface roughness and chip morphology in high-speed hard turning of AISI 4340 alloy steel under a sustainable minimum quantity lubrication (MQL) environment. Design/methodology/ap...
Article
COVID-19 pandemic has affected the activities related to operations management in the manufacturing industry under the scope of production interruption of raw materials and spare parts, labour, logistics, finance as well as supply and demand fluctuation. Manufacturing industry has faced limitation in the import of raw materials and spare parts whic...
Article
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This study investigates the effectiveness of CVD coated carbide inserts in turning hardened AISI 4340 steel at high-machining speed V = 300, 350 m min⁻¹ under sustainable dry cutting environment. Experiments were executed in accordance to Taguchi L4 orthogonal array and crucial machinability aspects tool life, tool wear progression and mechanism, c...
Article
Full-text available
To curtail the negative effects of traditional flood machining, dry cutting using carbide tools has emerged as a prominent alternative for manufacturers, owing to its low cost and phenomenal surface qualities. In line with this view, high-speed machining of high-strength AISI 4340 alloy steel was carried out using multilayer Al2O3/TiCN-CVD and TiAl...
Article
Sustainable manufacturing has become a critical concern across various industries, including aerospace, automotive, and services. It involves the creation of manufactured products through economically sound processes that minimize negative environmental impacts while conserving energy and natural resources. Additionally, sustainable manufacturing a...
Article
The material M303 is commonly used in the fabrication of machinery, automotive components, locomotive axle housings, and injection moulds. It is a stainless martensitic chromium steel known for its high strength, wear resistance, and corrosion resistance. The primary purpose of this study is to investigate the machinability of M303 under cryogenic...
Article
The hybrid S-phase layer was formed on the surface of an austenitic stainless steel by the thermomechanical heat treatment, which was carried out at a low temperature (475 °C). The thickness of the layer depends on the methane (CH4) gas content in the heat treatment chamber. The microstructure of the layer contains plenty of microstructural defects...
Chapter
Hybrid manufacturing, a pioneering concept in modern industry, combines various manufacturing methods to achieve unparalleled performance and versatility. By seamlessly integrating diverse technologies, it overcomes limitations of individual techniques while leveraging their strengths. This review explores recent progress in hybrid manufacturing, i...
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The paper describes the method to identify chatter in low-cutting-speed operations. It is based on vibration and surface roughness measurements. Tool chatter is the self-excited relative motion between the cutting tool and work piece. Tool chatter leads to poor surface quality and tool wear. The LMS Scadas testing system and accelerometer were used...
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Sustainable machining practices including dry cutting, cryogenic cooling (Cryo), and minimum quantity lubrication (MQL) techniques play an essential role in minimizing the extensive utilization of mineral-based cutting fluids, which can harm our ecology and health. However, the insufficient cooling and lubrication competencies of these eco-friendly...
Article
This present study explored using minimum quantity lubrication (MQL) as a sustainable solution for machining. A bubble bursting atomization (BBA) system was created using theory of inventive problem solving (teoriya resheniya izobretatelskikh zadach, TRIZ) and computational fluid dynamics (CFD) simulations. TRIZ was chosen as it offers problem-solv...
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This study presents the result of surface roughness (SR) during milling AISI 4340 under sustainable machining techniques of minimum quantity lubrication (MQL) and cryogenic using liquid nitrogen (LN2). Along with MQL, Treated Recycled Cooking Oil (TRCO) using waste Palm Oil is used to promote a greener cutting condition. Taguchi L9 orthogonal array...
Chapter
The forces that are acting on a tool throughout the process of metal cutting are extremely important. An understanding of these forces can help to estimate the power required when cutting, as well as helping to ensure the subsequent structures are free from vibration and are adequately rigid. Several techniques have been utilised to model the respo...
Article
This study focused on the development and testing of a stationary dynamometer using force-sensing elements capable of measuring three axes of cutting force during milling operations. The force-sensing element was based on the Maltese cross-beam concept but has been improved and modified to increase sensitivity and reduce interference or cross-talk...
Article
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This paper investigates the correlation between surface roughness of Inconel 718 and tool edge condition of ball nose inserts when milled at high speed. The cutting parameters were varied as follows; cutting speed: 120–140 m/min, feed rate: 0.15–0.25 mm/tooth, and axial depth of cut: 0.3–0.7 mm. For a sustainable machining approach, the experimenta...
Article
A three dimensional computational fluid dynamic (CFD) analysis was conducted to understand the hydrodynamic performance of a dimple texture produced using recently invented low-cost dynamic-assisted tooling (DAT) in the machining process. Five different area ratios, α r of 0%, 1.63%, 3.26%, 6.53%, and 9.80%, and three different sliding speeds repre...
Article
This study presents an experimental investigation on tool wear mechanisms in dry and cryogenic machining when milling AISI H13 steel with varying cutting-edge radius. The aim was to study the effect of cutting-edge radius on the wear mechanism of rounded cutting-edge radius of an uncoated carbide cutting tool under dry and cryogenic machining. Unco...
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Magnesium alloy AZ91D is used extensively in the automotive industry because of its high strength-to-weight ratio. Typically, components produced using the alloy are required to have good surface finish and to contribute to high productivity but require long cutting times. Cryogenic cooling is an environmentally friendly technology which has been p...
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Finding an alternate solution for supplanting the existing conventional lubricant in machining is a challenge. This work narrows the search down to the use of nano-cutting fluids, as they exhibit excellent properties such as high thermal conductivity and good lubricity. A technical analysis of the performance of hybrid nano-cutting fluids in the en...
Article
M303 is a corrosion resistant martensitic chromium steel offering excellent toughness, corrosion, and wear resistance, characterized by improved machinability and polish ability. It is widely utilized in industries such as in mould and die making, machinery and automotive equipment, bearing housing, and tooling. Recently, this material has also bee...
Article
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The main focus of this work was the design and development of a cross-beam force transducer for use in the construction of a tri-axial dynamometer. This dynamometer would be able to measure the cutting force along all three axes simultaneously during turning operations. The force transducer was built on the concept of the Maltese cross-beam, but it...
Article
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Inconel 718 is widely used in components under harsh conditions. The abrasiveness of the carbide particles, poor heat conductivity and built-up edge (BUE) formation are common issues which warrant further investigation. In this work, the failure mode of a TiAlN/AlCrN-coated tungsten carbide (WC) tool during milling of Inconel 718 using different lu...
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Jatropha curcas, has been established as a plant whose seeds contain a relatively high percentage of oil that is suitable for biodiesel production, among other industrial applications. Seed oil properties of J. curcas may vary depending on soils, age of plant, genotype of the plant, and agro-climatic conditions of a specific geographical region. St...
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Ti6Al4V alloy is widely used in aerospace and medical applications. It is classified as a difficult to machine material due to its low thermal conductivity and high chemical reactivity. In this study, hybrid intelligent models have been developed to predict surface roughness when end milling Ti6Al4V alloy with a Physical Vapor Deposition PVD coated...
Article
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The purpose of this review is to present an up-to-date description of our knowledge of the technology in the production of nano-sized aerosols (NAs). In this review, the methods and mechanisms of each atomization systems will be discussed. The elements which will be discussed include operational factors, system improvements, pros and cons of the at...
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Sustainable and green machining technologies have become a welcomed topic in the manufacturing industries. One of the emerging sustainable technologies is minimum quantity lubrication (MQL). In this study, the optimisation and study of the bubble-bursting atomisation system applied to MQL machining is carried out through the computational fluid dyn...
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Metalworking Fluids (MWFs) are extensively used to achieve a smoother machining operation, a better surface finish, and a longer tool life. Unfortunately, mineral-based metalworking fluids have negative impacts on the workers as well as the environment. This study focuses on the application of bio-MWF from treated recycled cooking oil (TRCO) in mac...
Article
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Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal arr...
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Cryogenic technique is the use of a cryogenic medium as a coolant in machining operations. Commonly used cryogens are liquid nitrogen (LN2) and carbon dioxide (CO2) because of their low cost and non-harmful environmental impact. In this study, the effects of machining conditions and parameters on the wear mechanism were analysed in the milling proc...
Article
This study experimentally investigates the influence of cryogenic CO2 and dry cutting conditions on the performance of multi-coated PVD tungsten carbide ball nose inserts during high-speed milling of Inconel 718. The areas of focus were the tool life, surface roughness and wear mechanisms. For the cryogenic CO2, a new cooling method approach was ap...
Article
Cutting force is vital in machining nickel-based superalloys due to their excellent mechanical properties, thus creating difficulty in cutting. In the current scenario of metal machining, milling processes require high spindle speed and low chip load, which result in a low cutting force. However, low chip load not only result in low cutting force b...
Article
Purpose This research aims to present the characteristics of dimple structure which was fabricated using a turning machine, where the characteristics include sizes, shapes, area ratio and aspect ratio. This research aims at filling the gap in the machining parameters of previous research in producing dimple by using turning process with the aid of...
Conference Paper
Full-text available
This paper presents the surface roughness of aluminium silicon alloy (AlSi) matrix composite reinforced with aluminium nitride (AlN) using three types of carbide inserts. Experiments were conducted at various cutting speeds, feed rates and depth of cut according to the Taguchi method , using a standard orthogonal array L27 Signal-to-noise(S/N) rati...
Conference Paper
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This paper presents a study on the chip formation in the milling process of Al-SiC/AlN MMC. The focus this study is the effect of the cutting parameter towards the morphology and the microstructure of the chip. Al-SiC/AlN MMC reinforced with the aluminium nitride (AlN) particle is a new-generation material that is appropriate to be used in the manu...
Conference Paper
Full-text available
Metal matrix composites (MMCs) attract considerable attention as a result from its ability in providing a high strength, high modulus, high toughness, high impact properties, improving wear resistance and providing good corrosion resistance compared to unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been widely used in various indus...
Article
This paper presents the experimental investigations to identify the effect of different machining parameters on the microstructure and microhardness alterations beneath the machined surface of Inconel 718. The high-speed milling experiments were conducted using PVD multi-coated ball nose carbide inserts, under cryogenic CO2 condition at controlled...
Article
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It is known that the functional performance of a surface can be improved by introducing a dimple structure. Dimple structured surface has stunningly benefited tribological performance in many ways, such as in reducing friction and increasing load capacity. This paper presents an analysis of coefficient of friction (COF) and load capacity using comp...
Article
Autonomous manufacturing allows the system to distinguish between a mild, normal and total failure in tool condition. K-means clustering has become the most applied algorithm in discovering classes in an unsupervised scenario. Nevertheless, the algorithm is sensitive to the initial centroids giving various solution every time the system updating. R...
Preprint
The purpose of this paper is to investigate the effect of cutting parameters on surface roughness, flank wear and chip formation using CBN tools under the conditions of turning of difficult-to-cut material, Ti6Al4V titanium alloy. Using the signal-to-noise (S / N) ratio, the Taguchi method is used to analyze the impact of cutting parameters on opti...
Chapter
Recent studies have reported the advantages of cryogenic machining in producing superior surface roughness (Ra) when applied in metal cutting. This study shows the application of Box-Behnken Response Surface Methodology (RSM) to analyze the effect of milling parameters; cutting speed, feed rate, axial depth of cut (DOC) and radial DOC on the Ra of...
Article
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Sustainable manufacturing Minimum quantity lubrication (MQL) Cryogenic Dry machining Machinability of AISI 4340 Hybrid lubrication Machining with AISI 4340 usually involves an excessive consumption of cutting oil to ensure a good surface finish and to extend the tool life. Accordingly, three highly sustainable and green cooling techniques that cons...
Article
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Hardened layers are commonly required for automotive components after their production using a machining process in order to enhance the service life of these components. This study investigates the possibility of producing a nanostructured machined surface which can increase the hardness of the machined surface by varying the machining parameters...
Article
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In this work, AISI 4340 alloy was machined using PVD tungsten multilayer TiAlN/AlCrN coated carbide inserts under two different cutting environments: cryogenic cooling using liquid nitrogen (LN) and dry cutting condition. The experiments were performed at varying cutting parameters of cutting speed: 200–300 m/min, feed rate: 0.15–0.30 mm/tooth, axi...
Article
The automotive industry is looking to adopt environmentally-friendly machining processes for automotive components. This study intends to investigate the machining parameters affecting the machinability of hypereutectic Al-Si alloys in the context of surface roughness and tool life via a DLC coated face milling cutter inserted under dry cutting con...
Article
Achieving sustainable machining is in demand nowadays and it is in line with the rise of global eco-awareness and rigorous regulations by the authorities to prevent from further damaging the environment and its constituents. One of the sustainable solutions extensively explored over the years is machining with minimum quantity lubrication system. N...
Article
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This paper presents a statistical analysis to investigatethe correlation between cutting forces and surface roughness values in turning process. Although the correlation of machining processes has been widely studied in metal cutting, it still presents a challenge as surface roughness has to be considered for product quality and it is hard to ensur...
Article
Recent trends in metal cutting shows the increasing of demand at the global stage for the application of eco-friendly machining approaches in order to eliminate the adverse effects of conventional cutting fluids. Thus, this experimental work was conducted to evaluate the performance of sustainable cooling techniques of cryogenic carbon dioxide (CO2...
Article
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Research on cutting force revealed that the cutting force decreases as cutting speed increases, which is in line with Salomon’s Theory. However, the fundamental behaviour was never clearly explained because most studies had focused on increasing the cutting speed by increasing spindle speed without retaining the rate of chip load. On that note, the...
Chapter
Surface integrity of machined subsurface is an important aspect in any machining process especially in high accuracy demand industries like aerospace. As is known, Inconel 718 is a difficult to machine material and in most cases, Inconel 718 will be resulting an excessive heat generated at the cutting zone which can causes rapid tool wear, damage o...
Article
This paper presents a chatter detection technique based on the stability of the measured Ra and Rz values of process damping and surface roughness in low cutting speed activities. In practice, process damping during machining procedures is hard to predict and identify due to the model and technique of limitation. The impact of cutting conditions on...
Article
This paper presents the optimization in machining processes on the cutting parameters for the S45C in turning process using the response surface method (RSM). The experimental work conducted investigates the influence of cutting parameters on statistical analysis of signals and surface quality. The paper also presents a statistical analysis of sign...
Article
Purpose The purpose of this study is to investigate wear mechanisms of a multi-layered TiAlN/AlCrN-coated carbide tool during the milling of AISI 4340 steel under cryogenic machining. Design/methodology/approach The wear progression was measured using a toolmaker microscope and an optical microscope. Later, a field emission scanning electron micro...
Article
Full-text available
This study presents the tool life optimization of carbide coated ball nose milling inserts using high-speed milling Inconel 718 under cryogenic CO2 environment. A total of 29 experiments were conducted based on Box-Behnken Response Surface Methodology using the 4 factors; cutting speed (Vc: 120-140 m/min), feed rate (Fz: 0.15-0.25 mm/tooth), axial...
Article
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Machining significantly influences surface integrity, metallurgical structure, grain size and thereby the mechanical, chemical and physical properties of the component. The presented investigation concentrates on grain refinement in turning of AISI 4340 alloy steel in dry and cryogenic turning. With cutting temperatures below 950 °C, the resulted s...
Article
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This paper presents a stability analysis to predict regenerative vibration during turning process. Although the stability of machining process has been widely studied in metal cutting it still presents a challenge as surface roughness, tool wear and productivity have to be considered. If the tool is vibrating as it removes material, these vibration...
Article
Purpose The purpose of this study is to present the tool life optimization of carbide-coated ball nose milling inserts when high-speed milling of Inconel 718 under cryogenic CO 2 condition. The main aims are to analyze the influence level of each cutting parameter on the tool life and to identify the optimum parameters that can lengthen the tool li...
Article
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This present paper deals with the chip segmentation in ball nose end milling process of Inconel 718 for turbine blades. It deals with characterizing the chip morphologies and microstructure investigations under minimum quantity lubrication (MQL) condition. In this study, the effects of cutting speed (Vc), radial depth of cut (WoC), and axial depth...
Article
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Purpose This study aims to simulate the influence of surface texturing produced via turning process toward pressure distribution and load capacity generation using computational fluid dynamics (CFD). Design/methodology/approach The dimple geometry was obtained via turning process, to be used for future application on piston skirt surfaces. Two cas...
Article
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In order to identify the influence of different cutting parameters on cutting force under cryogenic cooling assistance, this paper presents an experimental investigation on the influence by high-speed milling Inconel 718 using carbide coated ball nose milling inserts. For Design of Experiment (DOE), Box-Behnken Response Surface Methodology (RSM) wi...
Article
This paper details an investigation into the performance of PVD tungsten carbide coated ball nose milling inserts when conducting high-speed cutting of Inconel 718 under eco-friendly machining methods of cryogenic carbon dioxide (CO2) and dry cutting conditions. The experiments were performed at varying cutting parameters of; cutting speed: 120–140...
Article
Dimples is an important structure in the context of surface texturing due to its role in improving the heat transfer while minimizing wear and friction on sliding mechanical components. In this study, various sizes and shapes of dimple structures were fabricated on a cylindrical surface of a hyper eutectic aluminum silicon alloy (A390) using the tu...
Article
Full-text available
This paper presents a new statistical-based method of cutting tool wear progression in a milling process called Z-rotation method in association with tool wear progression. The method is a kurtosis-based that calculates the signal element variance from its mean as a measurement index. The measurement index can be implicated to determine the severit...
Article
Increasing demands to cost down in production brings to the implementation of unattended machining in most manufacturing industries. Since tool breakage and uncontrolled wear are the most unwanted characteristic in machining process which lessening a tool life, an automatic detection of flank wear is vital in an unmanned turning operation. In the p...
Article
Full-text available
This paper presents a new statistical-based method of cutting tool wear progression in a milling process called Z-rotation method in association with tool wear progression. The method is a kurtosis-based that calculates the signal element variance from its mean as a measurement index. The measurement index can be implicated to determine the severit...
Article
Titanium carbonitride (TiCN) is a popular hard coating for carbide cutting tools in various applications. The properties of TiCN are within its composition and can be controlled by maintaining the C–N ratio within the coating to a certain level. This paper studied the influence of carbon content and coating composition within TiCxN1−x coatings with...
Article
Titanium carbonitride (TiCN) is a popular hard coating for carbide cutting tools in various applications. The properties of TiCN are within its composition and can be controlled by maintaining the C-N ratio within the coating to a certain level. This paper studied the influence of carbon content and coating composition within TiC x N 1−x coatings w...
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Full-text available
Background: Religious obligation helps people to develop mental health by creating internal commitment to special rules. This meta-analysis aimed to determine the relationship between religious orientation and anxiety among college students. Methods: Major scientific databases including PubMed, Web of Science, Science Direct, EBSCO, ProQuest and P...
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Nowadays the quality of machined surface has become the main problem due to the demand rate of life span, performance, and reliability of a machined product. The study of the component’s surface integrity is an important aspect of avoiding failure. The purpose of this research is to investigate the effect of milling parameters on cutting temperatur...