1
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Ishfaq K, Sana M, Waseem MU, Ashraf WM, Anwar S, Krzywanski J. Enhancing EDM Machining Precision through Deep Cryogenically Treated Electrodes and ANN Modelling Approach. Micromachines (Basel) 2023; 14:1536. [PMID: 37630072 PMCID: PMC10456530 DOI: 10.3390/mi14081536] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/23/2023] [Revised: 07/17/2023] [Accepted: 07/21/2023] [Indexed: 08/27/2023]
Abstract
The critical applications of difficult-to-machine Inconel 617 (IN617) compel the process to be accurate enough that the requirement of tight tolerances can be met. Electric discharge machining (EDM) is commonly engaged in its machining. However, the intrinsic issue of over/undercut in EDM complicates the achievement of accurately machined profiles. Therefore, the proficiency of deep cryogenically treated (DCT) copper (Cu) and brass electrodes under modified dielectrics has been thoroughly investigated to address the issue. A complete factorial design was implemented to machine a 300 μm deep impression on IN617. The machining ability of DCT electrodes averagely gave better dimensional accuracy as compared to non-DCT electrodes by 13.5% in various modified dielectric mediums. The performance of DCT brass is 29.7% better overall compared to the average value of overcut (OC) given by DCT electrodes. Among the non-treated (NT) electrodes, the performance of Cu stands out when employing a Kerosene-Span-20 modified dielectric. In comparison to Kerosene-Tween-80, the value of OC is 33.3% less if Kerosene-Span-20 is used as a dielectric against the aforementioned NT electrode. Finally, OC's nonlinear and complex phenomena are effectively modeled by an artificial neural network (ANN) with good prediction accuracy, thereby eliminating the need for experiments.
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Affiliation(s)
- Kashif Ishfaq
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, Pakistan (M.U.W.)
| | - Muhammad Sana
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, Pakistan (M.U.W.)
| | - Muhammad Umair Waseem
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, Pakistan (M.U.W.)
| | - Waqar Muhammad Ashraf
- Sargent Centre for Process Systems Engineering, Department of Chemical Engineering, University College London, Torrington Place, London WC1E 7JE, UK
| | - Saqib Anwar
- Industrial Engineering Department, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia;
| | - Jaroslaw Krzywanski
- Department of Advanced Computational Methods, Jan Dlugosz University in Czestochowa, 42-200 Czestochowa, Poland
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2
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Rehman M, Yanen W, Mushtaq RT, Ishfaq K, Zahoor S, Ahmed A, Kumar MS, Gueyee T, Rahman MM, Sultana J. Erratum: Publisher Correction: Additive manufacturing for biomedical applications: a review on classification, energy consumption, and its appreciable role since COVID-19 pandemic. Prog Addit Manuf 2023; 8:1. [PMID: 38625358 PMCID: PMC9851585 DOI: 10.1007/s40964-023-00405-y] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 04/17/2024]
Abstract
[This corrects the article DOI: 10.1007/s40964-022-00373-9.].
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Affiliation(s)
- Mudassar Rehman
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890 Pakistan
| | - Wang Yanen
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - Ray Tahir Mushtaq
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - Kashif Ishfaq
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890 Pakistan
| | - Sadaf Zahoor
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890 Pakistan
| | - Ammar Ahmed
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - M. Saravana Kumar
- Graduate Institute of Manufacturing Technology, National Taipei University of Technology, Taipei, 10608 Taiwan
| | - Thierno Gueyee
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - Md Mazedur Rahman
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - Jakia Sultana
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
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3
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Rehman M, Yanen W, Mushtaq RT, Ishfaq K, Zahoor S, Ahmed A, Kumar MS, Gueyee T, Rahman MM, Sultana J. Additive manufacturing for biomedical applications: a review on classification, energy consumption, and its appreciable role since COVID-19 pandemic. Prog Addit Manuf 2022; 8:1-35. [PMID: 38625342 PMCID: PMC9793824 DOI: 10.1007/s40964-022-00373-9] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/10/2021] [Accepted: 12/08/2022] [Indexed: 05/27/2023]
Abstract
The exponential rise of healthcare problems like human aging and road traffic accidents have developed an intrinsic challenge to biomedical sectors concerning the arrangement of patient-specific biomedical products. The additively manufactured implants and scaffolds have captured global attention over the last two decades concerning their printing quality and ease of manufacturing. However, the inherent challenges associated with additive manufacturing (AM) technologies, namely process selection, level of complexity, printing speed, resolution, biomaterial choice, and consumed energy, still pose several limitations on their use. Recently, the whole world has faced severe supply chain disruptions of personal protective equipment and basic medical facilities due to a respiratory disease known as the coronavirus (COVID-19). In this regard, local and global AM manufacturers have printed biomedical products to level the supply-demand equation. The potential of AM technologies for biomedical applications before, during, and post-COVID-19 pandemic alongwith its relation to the industry 4.0 (I4.0) concept is discussed herein. Moreover, additive manufacturing technologies are studied in this work concerning their working principle, classification, materials, processing variables, output responses, merits, challenges, and biomedical applications. Different factors affecting the sustainable performance in AM for biomedical applications are discussed with more focus on the comparative examination of consumed energy to determine which process is more sustainable. The recent advancements in the field like 4D printing and 5D printing are useful for the successful implementation of I4.0 to combat any future pandemic scenario. The potential of hybrid printing, multi-materials printing, and printing with smart materials, has been identified as hot research areas to produce scaffolds and implants in regenerative medicine, tissue engineering, and orthopedic implants.
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Affiliation(s)
- Mudassar Rehman
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890 Pakistan
| | - Wang Yanen
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - Ray Tahir Mushtaq
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - Kashif Ishfaq
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890 Pakistan
| | - Sadaf Zahoor
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890 Pakistan
| | - Ammar Ahmed
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - M. Saravana Kumar
- Graduate Institute of Manufacturing Technology, National Taipei University of Technology, Taipei, 10608 Taiwan
| | - Thierno Gueyee
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - Md Mazedur Rahman
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
| | - Jakia Sultana
- Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xian, 710072 China
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Ishfaq K, Rehman M, Wang Y. Toward the Targeted Material Removal with Optimized Surface Finish During EDM for the Repair Applications in Dies and Molds. Arab J Sci Eng 2022. [DOI: 10.1007/s13369-022-07006-x] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/31/2022]
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Harris M, Mohsin H, Potgieter J, Ishfaq K, Archer R, Chen Q, De Silva K, Guen MJL, Wilson R, Arif KM. Partial Biodegradable Blend with High Stability against Biodegradation for Fused Deposition Modeling. Polymers (Basel) 2022; 14:polym14081541. [PMID: 35458292 PMCID: PMC9027655 DOI: 10.3390/polym14081541] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/12/2022] [Revised: 04/02/2022] [Accepted: 04/07/2022] [Indexed: 02/04/2023] Open
Abstract
This research presents a partial biodegradable polymeric blend aimed for large-scale fused deposition modeling (FDM). The literature reports partial biodegradable blends with high contents of fossil fuel-based polymers (>20%) that make them unfriendly to the ecosystem. Furthermore, the reported polymer systems neither present good mechanical strength nor have been investigated in vulnerable environments that results in biodegradation. This research, as a continuity of previous work, presents the stability against biodegradability of a partial biodegradable blend prepared with polylactic acid (PLA) and polypropylene (PP). The blend is designed with intended excess physical interlocking and sufficient chemical grafting, which has only been investigated for thermal and hydrolytic degradation before by the same authors. The research presents, for the first time, ANOVA analysis for the statistical evaluation of endurance against biodegradability. The statistical results are complemented with thermochemical and visual analysis. Fourier transform infrared spectroscopy (FTIR) determines the signs of intermolecular interactions that are further confirmed by differential scanning calorimetry (DSC). The thermochemical interactions observed in FTIR and DSC are validated with thermogravimetric analysis (TGA). Scanning electron microscopy (SEM) is also used as a visual technique to affirm the physical interlocking. It is concluded that the blend exhibits high stability against soil biodegradation in terms of high mechanical strength and high mass retention percentage.
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Affiliation(s)
- Muhammad Harris
- Massey Agrifood Digital Lab, Massey University, Palmerston North 4410, New Zealand; (J.P.); (R.W.)
- Industrial and Manufacturing Engineering Department, Rachna College of Engineering and Technology, Gujranwala 52250, Pakistan
- Correspondence:
| | - Hammad Mohsin
- Department of Polymer Engineering, National Textile University, Faisalabad 37610, Pakistan;
| | - Johan Potgieter
- Massey Agrifood Digital Lab, Massey University, Palmerston North 4410, New Zealand; (J.P.); (R.W.)
| | - Kashif Ishfaq
- Industrial and Manufacturing Engineering Department, University of Engineering and Technology, Lahore 54890, Pakistan;
| | - Richard Archer
- School of Food and Advanced Technology, Massey University, Palmerston North 4410, New Zealand; (R.A.); (Q.C.)
| | - Qun Chen
- School of Food and Advanced Technology, Massey University, Palmerston North 4410, New Zealand; (R.A.); (Q.C.)
| | - Karnika De Silva
- Faculty of Engineering, University of Auckland, Auckland 1023, New Zealand;
| | | | - Russell Wilson
- Massey Agrifood Digital Lab, Massey University, Palmerston North 4410, New Zealand; (J.P.); (R.W.)
| | - Khalid Mahmood Arif
- Department of Mechanical and Electrical Engineering, SF&AT, Massey University, Auckland 0632, New Zealand;
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6
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Harris M, Mohsin H, Naveed R, Potgieter J, Ishfaq K, Ray S, Guen MJL, Archer R, Arif KM. Partial Biodegradable Blend for Fused Filament Fabrication: In-Process Thermal and Post-Printing Moisture Resistance. Polymers (Basel) 2022; 14:polym14081527. [PMID: 35458281 PMCID: PMC9025397 DOI: 10.3390/polym14081527] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/23/2022] [Revised: 04/03/2022] [Accepted: 04/07/2022] [Indexed: 02/01/2023] Open
Abstract
Despite the extensive research, the moisture-based degradation of the 3D-printed polypropylene and polylactic acid blend is not yet reported. This research is a part of study reported on partial biodegradable blends proposed for large-scale additive manufacturing applications. However, the previous work does not provide information about the stability of the proposed blend system against moisture-based degradation. Therefore, this research presents a combination of excessive physical interlocking and minimum chemical grafting in a partial biodegradable blend to achieve stability against in-process thermal and moisture-based degradation. In this regard, a blend of polylactic acid and polypropylene compatibilized with polyethylene graft maleic anhydride is presented for fused filament fabrication. The research implements, for the first time, an ANOVA for combined thermal and moisture-based degradation. The results are explained using thermochemical and microscopic techniques. Scanning electron microscopy is used for analyzing the printed blend. Fourier transform infrared spectroscopy has allowed studying the intermolecular interactions due to the partial blending and degradation mechanism. Differential scanning calorimetry analyzes the blending (physical interlocking or chemical grafting) and thermochemical effects of the degradation mechanism. The thermogravimetric analysis further validates the physical interlocking and chemical grafting. The novel concept of partial blending with excessive interlocking reports high mechanical stability against moisture-based degradation.
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Affiliation(s)
- Muhammad Harris
- Massey Agrifood Digital Lab, Massey University, Palmerston North 4410, New Zealand;
- Industrial and Manufacturing Engineering Department, Rachna College of Engineering and Technology, Gujranwala 52250, Pakistan
- Correspondence: or engr.harris@.uet.edu.pk
| | - Hammad Mohsin
- Department of Polymer Engineering, National Textile University, Faisalabad 37610, Pakistan;
| | - Rakhshanda Naveed
- Industrial and Manufacturing Engineering Department, University of Engineering and Technology, Lahore 54890, Pakistan; (R.N.); (K.I.)
| | - Johan Potgieter
- Massey Agrifood Digital Lab, Massey University, Palmerston North 4410, New Zealand;
| | - Kashif Ishfaq
- Industrial and Manufacturing Engineering Department, University of Engineering and Technology, Lahore 54890, Pakistan; (R.N.); (K.I.)
| | - Sudip Ray
- New Zealand Institute for Minerals to Materials Research, Greymouth 7805, New Zealand;
| | | | - Richard Archer
- School of Food and Advanced Technology, Massey University, Palmerston North 4410, New Zealand;
| | - Khalid Mahmood Arif
- Department of Mechanical and Electrical Engineering, SF&AT, Massey University, Auckland 0632, New Zealand;
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Ishfaq K, Asad M, Harris M, Alfaify A, Anwar S, Lamberti L, Scutaru ML. EDM of Ti-6Al-4V under Nano-Graphene Mixed Dielectric: A Detailed Investigation on Axial and Radial Dimensional Overcuts. Nanomaterials (Basel) 2022; 12:nano12030432. [PMID: 35159777 PMCID: PMC8837981 DOI: 10.3390/nano12030432] [Citation(s) in RCA: 11] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/31/2021] [Revised: 01/20/2022] [Accepted: 01/22/2022] [Indexed: 02/04/2023]
Abstract
Ti-6Al-4V is considered a challenging material in terms of accurate machining. Therefore, electric discharge machining (EDM) is commonly engaged, but its low cutting rate depreciates its use. This issue is resolved if graphene nanoparticles are mixed in the dielectric. However, the control over the sparking phenomenon reduces because of the dispersion of graphene particles. Subsequently, the machined profile’s geometric accuracy is compromised. Furthermore, the presence of nanographene induces different sparks along axial and radial cutting orientations. This aspect has not been comprehensively examined yet and dedicatedly targeted in this study to improve the quality of EDM process for Ti-6Al-4V. A total of 18 experiments were conducted under Taguchi’s L18 design considering six parameters namely, electrode type, polarity, flushing time, spark voltage, pulse time ratio, and discharge current. The aluminum electrode proved to be the best choice to reduce the errors in both the cutting orientations. Despite the other parametric settings, negative tool polarity yields lower values of axial (ADE) and radial errors (RDE). The developed optimal settings ensure 4.4- and 6.3-times reduction in RDE and ADE, respectively. In comparison to kerosene, graphene-based dielectric yields 10.2% and 19.4% reduction in RDE and ADE, respectively.
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Affiliation(s)
- Kashif Ishfaq
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 548900, Pakistan;
- Correspondence: (K.I.); (M.L.S.)
| | - Muhammad Asad
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 548900, Pakistan;
| | - Muhammad Harris
- Industrial and Manufacturing Engineering Department, Rachna College of Engineering and Technology, Gujranwala 52250, Pakistan;
| | - Abdullah Alfaify
- Industrial Engineering Department, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia; (A.A.); (S.A.)
| | - Saqib Anwar
- Industrial Engineering Department, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia; (A.A.); (S.A.)
| | - Luciano Lamberti
- Dipartimento di Meccanica, Matematica e Management, Politecnico di Bari, 70125 Bari, Italy;
| | - Maria Luminita Scutaru
- Department of Mechanical Engineering, Transilvania University of Brasov, B-dul Eroilor No 29, 500036 Brasov, Romania
- Correspondence: (K.I.); (M.L.S.)
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8
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Harris M, Potgieter J, Ishfaq K, Shahzad M. Developments for Collagen Hydrolysate in Biological, Biochemical, and Biomedical Domains: A Comprehensive Review. Materials (Basel) 2021; 14:2806. [PMID: 34070353 PMCID: PMC8197487 DOI: 10.3390/ma14112806] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/28/2021] [Revised: 05/19/2021] [Accepted: 05/19/2021] [Indexed: 01/11/2023]
Abstract
The collagen hydrolysate, a proteinic biopeptide, is used for various key functionalities in humans and animals. Numerous reviews explained either individually or a few of following aspects: types, processes, properties, and applications. In the recent developments, various biological, biochemical, and biomedical functionalities are achieved in five aspects: process, type, species, disease, receptors. The receptors are rarely addressed in the past which are an essential stimulus to activate various biomedical and biological activities in the metabolic system of humans and animals. Furthermore, a systematic segregation of the recent developments regarding the five main aspects is not yet reported. This review presents various biological, biochemical, and biomedical functionalities achieved for each of the beforementioned five aspects using a systematic approach. The review proposes a novel three-level hierarchy that aims to associate a specific functionality to a particular aspect and its subcategory. The hierarchy also highlights various key research novelties in a categorical manner that will contribute to future research.
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Affiliation(s)
- Muhammad Harris
- Massey Agrifood (MAF) Digital Labs, Massey University, Palmerston North 4410, New Zealand;
- Industrial and Manufacturing Engineering Department, Rachna College of Engineering and Technology, Gujranwala 52250, Pakistan;
| | - Johan Potgieter
- Massey Agrifood (MAF) Digital Labs, Massey University, Palmerston North 4410, New Zealand;
| | - Kashif Ishfaq
- Industrial and Manufacturing Engineering Department, University of Engineering and Technology, Lahore 54890, Pakistan;
| | - Muhammad Shahzad
- Industrial and Manufacturing Engineering Department, Rachna College of Engineering and Technology, Gujranwala 52250, Pakistan;
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9
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Ahmed N, Rehman AU, Ishfaq K, Naveed R, Moiduddin K, Umer U, E Ragab A, Al-Zabidi A. Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin. Materials (Basel) 2020; 13:ma13204523. [PMID: 33053899 PMCID: PMC7601468 DOI: 10.3390/ma13204523] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/13/2020] [Revised: 09/20/2020] [Accepted: 09/21/2020] [Indexed: 11/30/2022]
Abstract
Titanium-aluminium-vanadium (Ti 6Al 4V) alloys, nickel alloys (Inconel 718), and duraluminum alloys (AA 2000 series) are widely used materials in numerous engineering applications wherein machined features are required to having good surface finish. In this research, micro-impressions of 12 µm depth are milled on these materials though laser milling. Response surface methodology based design of experiment is followed resulting in 54 experiments per work material. Five laser parameters are considered naming lamp current intensity (I), pulse frequency (f), scanning speed (V), layer thickness (LT), and track displacement (TD). Process performance is evaluated and compared in terms of surface roughness through several statistical and microscopic analysis. The significance, strength, and direction of each of the five laser parametric effects are deeply investigated for the said alloys. Optimized laser parameters are proposed to achieve minimum surface roughness. For the optimized combination of laser parameters to achieve minimum surface roughness (Ra) in the titanium alloy, the said alloy consists of I = 85%, f = 20 kHz, V = 250 mm/s, TD = 11 µm, and LT = 3 µm. Similarly, optimized parameters for nickel alloy are as follows: I = 85%, f = 20 kHz, V = 256 mm/s, TD = 8 µm, and LT = 1 µm. Minimum roughness (Ra) on the surface of aluminum alloys can be achieved under the following optimized parameters: I = 75%, f = 20 kHz, V = 200 mm/s, TD = 12 µm, and LT = 3 µm. Micro-impressions produced under optimized parameters have surface roughness of 0.56 µm, 2.46 µm, and 0.54 µm on titanium alloy, nickel alloy, and duralumin, respectively. Some engineering applications need to have high surface roughness (e.g., in case of biomedical implants) or some desired level of roughness. Therefore, validated statistical models are presented to estimate the desired level of roughness against any laser parametric settings.
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Affiliation(s)
- Naveed Ahmed
- Department of Industrial Engineering, College of Engineering and Architecture, Al Yamamah University, Riyadh 11512, Saudi Arabia;
| | - Ateekh Ur Rehman
- Department of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (A.E.R.); (A.A.-Z.)
- Correspondence:
| | - Kashif Ishfaq
- Department of Industrial and Manufacturing Engineering, University of Engineering & Technology, Lahore 54890, Pakistan; (K.I.); (R.N.)
| | - Rakhshanda Naveed
- Department of Industrial and Manufacturing Engineering, University of Engineering & Technology, Lahore 54890, Pakistan; (K.I.); (R.N.)
| | - Khaja Moiduddin
- Advance Manufacturing Institute, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (K.M.); (U.U.)
| | - Usama Umer
- Advance Manufacturing Institute, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (K.M.); (U.U.)
| | - Adham E Ragab
- Department of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (A.E.R.); (A.A.-Z.)
| | - Ayoub Al-Zabidi
- Department of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; (A.E.R.); (A.A.-Z.)
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Ishfaq K, Ali MA, Ahmad N, Zahoor S, Al-Ahmari AM, Hafeez F. Modelling the Mechanical Attributes (Roughness, Strength, and Hardness) of Al-alloy A356 during Sand Casting. Materials (Basel) 2020; 13:ma13030598. [PMID: 32012844 PMCID: PMC7040807 DOI: 10.3390/ma13030598] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/13/2019] [Revised: 01/20/2020] [Accepted: 01/23/2020] [Indexed: 11/30/2022]
Abstract
Sand-casting is a well established primary process for manufacturing various parts of A356 alloy. However, the quality of the casting is adversely affected by the change in the magnitude of the control variables. For instance, a larger magnitude of pouring velocity induces a drop effect and a lower velocity increases the likelihood of cold-shut and mis-run types of defects. Similarly, a high pouring temperature causes the formation of hot tears, whereas a low temperature is a source of premature solidification. Likewise, a higher moisture content yields microcracks (due to gas shrinkages) in the casting and a lower moisture content results in the poor strength of the mold. Therefore, the appropriate selection of control variables is essential to ensure quality manufactured products. The empirical relations could provide valuable guidance in this regard. Additionally, although the casting process was optimized for A356 alloy, it was mostly done for a single response. Therefore, this paper aimed to formulate empirical relations for the contradictory responses, i.e., hardness, ultimate tensile strength and surface roughness, using the response surface methodology. The experimental results were comprehensively analyzed using statistical and scanning electron microscopic analyses. Optimized parameters were proposed and validated to achieve castings with high hardness (84.5 HB) and strength (153.5 MPa) with minimum roughness (5.8 µm).
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Affiliation(s)
- Kashif Ishfaq
- Department of Industrial and Manufacturing Engineering, University of Engineering & Technology, Lahore 54890, Pakistan
- Correspondence: ; Tel.: +923224998308
| | - Muhammad Asad Ali
- Department of Industrial Engineering, University of Engineering and Technology, Taxila 47080, Pakistan
| | - Naveed Ahmad
- Department of Industrial and Manufacturing Engineering, University of Engineering & Technology, Lahore 54890, Pakistan
- Industrial Engineering Department, College of Engineering and Architecture, Al-yamamah University, Riyadh 11421, Saudi Arabia
| | - Sadaf Zahoor
- Department of Industrial and Manufacturing Engineering, University of Engineering & Technology, Lahore 54890, Pakistan
| | - Abdulrahman M. Al-Ahmari
- Industrial Engineering Department, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia
| | - Faisal Hafeez
- Department of Industrial Engineering, University of Engineering and Technology, Taxila 47080, Pakistan
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Ishfaq K, Ahmad N, Jawad M, Ali MA, M Al-Ahmari A. Evaluating Material's Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses. Materials (Basel) 2019; 12:ma12121940. [PMID: 31212883 PMCID: PMC6631865 DOI: 10.3390/ma12121940] [Citation(s) in RCA: 21] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/25/2019] [Revised: 05/13/2019] [Accepted: 06/03/2019] [Indexed: 12/02/2022]
Abstract
Stainless steel (SS 304) is commonly employed in industrial applications due to its considerable corrosion resistance, thermal resistance, and ductility. Most of its intended applications require the formation of complex profiles, which justify the use of wire electrical discharge machining (WEDM). However, its high thermal resistance imposes a limitation on acquiring adequate surface topography because of the high surface tension of the melt pool, which leads to the formation of spherical modules; ultimately, this compromises the surface quality. Furthermore, the stochastic nature of the process makes it difficult to optimize its performance, especially if more than one conflicting response is involved, such as high cutting speed with low surface roughness and kerf width. Therefore, this study aimed to comprehensively investigate the interaction of SS 304 and WEDM, with a prior focus on simultaneously optimizing all the conflicting responses using the Taguchi-based grey relational approach. Analysis of variance (ANOVA) revealed that the current was the most significant parameter for cutting speed and kerf, whereas roughness, voltage (45%), drum speed (25.8%), and nozzle offset distance (~21%) were major contributing factors. SEM micrographs showed that optimal settings not only ensured simultaneous optimization of the conflicting responses but also reduced the number and size of spherical modules.
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Affiliation(s)
- Kashif Ishfaq
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, Pakistan.
| | - Naveed Ahmad
- Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, Pakistan.
| | - Muhammad Jawad
- Department of Industrial Engineering, University of Engineering and Technology, Taxila 47080, Pakistan.
| | - Muhammad Asad Ali
- Department of Industrial Engineering, University of Engineering and Technology, Taxila 47080, Pakistan.
| | - Abdulrahman M Al-Ahmari
- Raytheon Chair for Systems Engineering, Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia.
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