bluuebunny/crossref_metadata_2025 huggingface dataset:
Dry Sliding Behaviour of AlCrN and TiN Coatings
Authors: Liew W.Y.H. , Dayou Sebastian , Ismail M. Azlan Bin , Siambun Nancy J. , Dayou Jedol
Published: October 2012

This paper examines the friction behaviour of AlCrN and TiN PVD coatings in atmospheric air and vacuum using a ball-on-disc and a reciprocating tribotesters. Comparative study on the coating sliding in air and in high vacuum environment provides important insight on the effect of oxidation on the friction behaviour of the coatings. Other important factors such as load, sliding velocity, temperature effects on the frictional behaviour of these coatings were also investigated. In the ball-on-disc tests carried out in vacuum, (i) TiN gave lower coefficient of friction (COF) than AlCrN, indicating that TiN was more lubricous, (ii) higher speed resulted in lower COF, and (iii) the COF of both coatings were lower than that produced in air. In ambient air, (i) AlCrN gave lower COF than TiN with high wear debris retention on the sliding interface due to the effect of oxidation, and (ii) higher speed resulted in lower COF, similar to that observed in vacuum. In the reciprocating tests, at low load, increasing the temperature from room temperature to 150 °C resulted in a reduction in the COF. However, at high load, the temperature virtually did not affect the COF. Higher nominal load resulted in lower COF while higher speed resulted in higher COF.
Surface Modification by EDM Using Co-Cr Sintered Powder Metallurgy Electrode
Authors: Khan Ahsan Ali , Ndaliman Mohammed Baba , Mohammad Yeakub Ali , Mansor Mas Hafizah Bt , Idrus Nurul Ain Bt
Published: October 2012

In this investigation, the powder metallurgy (PM) electrode developed from cobalt (Co) and chromium (Cr) powders was used in electrical discharge machining (EDM). This new Co-Cr sintered electrode was used to machine mild steel workpiece with kerosene dielectric fluid. The main objective is to modify its surface characteristics and secure increased surface hardness. The EDM variables of peak current, pulse duration and pulse interval were applied to investigate these surface properties. Scanning electron microscopy (SEM) / energy dispersive X-ray (EDX) spectroscopy analysis confirmed migration of electrode materials (Co and Cr) onto the EDMed surface. Improved hardness was obtained on the mild steel, the highest being 85.3 HRB. Thus, the Co-Cr electrode introduced into the EDM has the capability of modifying the mild steel surface.
Effect of Time Depositions on Electrodeposited Cobalt-Iron Nanocoating
Authors: Abdullah Wan Normimi Roslini , Hyie Koay Mei , Resali Nor Azrina , Tong Chong Wen
Published: October 2012

Cobalt-Iron (CoFe) nanocrystalline coatings are successfully prepared in 30, 60 and 90 minutes time depositions using electrodeposition method. The effect of time deposition towards crystallographic structure, elemental composition, surface morphology, microhardness and corrosion behaviour of CoFe coatings were investigated. The CoFe nanocrystalline coatings were deposited on stainless steel substrate at pH 3 environment. The grain sizes of the coatings are in the range of 57.88 to 70.18 nm. The CoFe nanocrystalline coating prepared at 90 minutes deposition achieves the highest microhardness of 290 HV. This coating also exhibits the lowest corrosion rate with 1.086 mpy. It is found that the increment of time deposition improves the microhardness and corrosion behavior of CoFe nanocrystalline coatings.
Effect of Voltage and Suspension Medium on Titania (TiO2) Film Prepared by Electrophoretic Deposition (EPD)
Authors: Aziz Siti Alwani A. , Tumiry Muhamad Nazeri , Taib Hariati
Published: October 2012

The electrophoretic deposition (EPD) technique was applied in order to produce titanium dioxide (TiO2) coating on stainless steel. Voltages of 2V, 4V, 6V and 8V and two types of TiO2 suspensions; (i) acidic (pH 4) and (ii) alkaline (pH 8) were used. Depositions were carried out for duration of 10 minutes. The TiO2 coatings phases, morphologies, thicknesses and weight were analysed. It was found that thickness and weight of coatings produced using both acidic and alkaline TiO2 suspensions increased proportionally. However, from the uniform and dense morphology of coatings, acidic TiO2 suspension was observed to yield better TiO2 depositions through the EPD technique.
Synthesis and Characterization of Zinc Oxide Nanostructured by Electrochemical Deposition Method
Authors: Rodzi A.S. , Berhan M.N. , Rusop M.
Published: October 2012

Zinc Oxide (ZnO) nanostructured was successfully synthesis by electrochemical deposition method. In this paper present the ZnO nanorods growth in a zinc nitrate/hexamethylenetetramine solution at 90°C with different potential applied. The effect of the growth process was investigated by the cyclic voltametric curve and the current-time curve. The structural of ZnO nanorods evidence that it has single crystalline, a wurtzite crystal structure with markedly preferential orientation along (001) direction was measured x-ray diffraction. The observation of ZnO nanorods was measured on field emission scanning electron microscopy that diameter of ZnO rods were below than 100 nm sizes. Uv-Vis spectrophotometer used to determine the transparency of ZnO nanorods through the UV light. The ZnO nanorods show the average transmittance (<90%) for all potential applied. The piezoelectric property of ZnO nanorods were measuring connected with two electrodes to the metal contact on the film that was driven by an ultrasonic wave. The piezoelectric output current was gained and characteristics curve have been illustrated for different voltage with constant driving frequency of ultrasonic wave at 40 kHz.
Effect of RF Power on the Formation and Morphology Evolution of ZnO Nanostructured Thin Films
Authors: Sin N.D.M. , Mamat Mohamad Hafiz , Musa Mohamed Zahidi , Ahmad S. , Abdul Aziz A. , Rusop Mahmood Mohamad
Published: October 2012

The effect of RF power on the formation and morphology evolution of ZnO nanostructured thin films deposited by magnetron sputtering are presented. This project focused on electrical, optical and structural properties of ZnO thin films. The effect of variation of RF power at 50 watt-250 watt at 200 °C on glass substrate of the ZnO thin films was investigated. The thin films were examined for electrical properties and optical properties using two point probe current-voltage (I-V) measurement (Keithley 2400) and UV-Vis-NIR spectrophotometer (JASCO 670) respectively. The structural properties were characterized using field emission scanning electron microscope (FESEM) (JEOL JSM 7600F) and atomic force microscope (AFM) (Park System XE-100). The IV measurement indicated that at RF power 200 watt the conductivity of ZnO thin film show the highest. All films show high UV absorption properties using UV-VIS spectrophotometer (JASCO 670). The root means square (rms) roughness for ZnO thin film were about 4 nm measured using AFM. The image form FESEM observed that transformation of structure size started to change as the RF power increase.
Dielectric Properties of PVDF-TrFE/PMMA: TiO2 Multilayer Dielectric Thin Films
Authors: Lyly Nyl Ismail , Mohd Wahid Mohamad Hafiz , Habibah Zulkefle , Herman Sukreen Hana , Mahmood Mohamad Rusop
Published: October 2012

This paper reports on the dielectric properties of multilayer PVDF-TrFE/PMMA:TiO2 thin film. Two samples were fabricated on ITO substrates; one with PVDF-TrFE only and another PMMA:TiO2 on PVDF-TrFE on (PVDF-TrFE/PMMA:TiO2). Both samples were produced by spin coating method. Dielectric properties were characterized using impedance spectroscopic. Dielectric constant, k, capacitance and dielectric loss, tan δ values of PMMA:TiO2/PVDF-TrFE were measured in the frequency range 0 – 50 kHz. The result for dielectric loss did not show any significant different between the samples with and without nanocomposite PVDF-TrFE layer. However, the dielectric constant are affected when depositing a nanocomposite PVDF-TrFE layer on PMMA:TiO2. The dielectric constant is decreased by 0.3 from 7.9 to 7.6.
Friction Coefficient of Polymer and Composite Materials Sliding against Stainless Steel
Authors: Nuruzzaman Dewan Muhammad , Chowdhury Mohammad Asaduzzaman
Published: October 2012

An endeavor has been made to study and compare the friction coefficient of different polymer and composite materials. Experiments were carried out when stainless steel 304 (SS 304) pin slides on different types of composite and polymer materials such as cloth reinforced ebonite (commercially known as gear fiber), glass fiber reinforced plastic (glass fiber), nylon and polytetrafluoroethylene (PTFE). Experiments were conducted at normal load 5, 7.5, 10 N, sliding velocity 0.5, 0.75, 1 m/s and relative humidity 70%. Variations of friction coefficient with the duration of rubbing at different normal loads and sliding velocities were investigated. Results show that friction coefficient varies with duration of rubbing, normal load and sliding velocity. In general, friction coefficient increases with the increase in normal load and sliding velocity for all the tested materials except nylon. At identical operating conditions, the magnitudes of friction coefficient are different for different polymer and composite materials.
Deposition on SS 316 at Different Gas Flow Rates Using Thermal CVD
Authors: Chowdhury Mohammad Asaduzzaman , Nuruzzaman Dewan Muhammad
Published: October 2012

A hot filament thermal chemical vapor deposition (CVD) reactor was used to deposit solid thin films on stainless steel 316 (SS 316) substrates at different flow rates of natural gas. The variation of thin film deposition rate with the variation of gas flow rate has been investigated experimentally. During experiment, the effect of gap between activation heater and substrate on the deposition rate has also been observed. Results show that deposition rate on SS 316 increases with the increase in gas flow rate. It is also observed that deposition rate increases with the decrease in gap between activation heater and substrate within the observed range. In addition, friction coefficient and wear rate of SS 316 sliding against SS 304 under different normal loads are also investigated before and after deposition. The experimental results reveal that improved friction coefficient and wear rate are obtained after deposition as compared to that of before deposition.
Structural Properties of Deposited ZnO Thin Films on Flexible Substrates at Various Substrate Temperatures and RF Power
Authors: Sauki Nur Sa’adah Muhamad , Herman Sukreen Hana , Ani Mohd Hanafi , Mohamad Rusop Mahmood
Published: October 2012

ZnO thin films were deposited on Teflon substrates by RF magnetron sputtering at different substrate temperature and different RF power. In this work, we investigated the dependence of the deposition rate and also the ZnO physical and electrical properties on the substrate temperature and RF power. It is observed that the deposition rate increased as the temperature and RF power increased. FE-SEM images confirmed that microstructure of the thin films consists of nanoparticles. XRD data confirmed that the ZnO thin films at various RF power and substrate temperature have (002) structure.
A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel
Authors: Jasni N.A.H. , Lajis Mohd Amri
Published: October 2012

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.
Influence of Post Annealing Temperature on the Properties of ZnO Films Prepared by RF Magnetron Sputtering
Authors: Ahmad Samsiah , Sin N.D.M. , Berhan M.N. , Rusop Mahmood Mohamad
Published: October 2012

Zinc Oxide (ZnO) films were prepared on unheated glass substrate by radio frequency (RF) magnetron sputtering technique and post deposition annealing of the ZnO thin film were performed at 350, 400, 450 and 500°C. Post annealing temperature was found to improve the structural and electrical characteristics of the deposited films. The structural properties of the films were carried out by the surface profiler, X-Ray diffraction (XRD), atomic force microscopy (AFM) and field emission scanning electron microscope (FESEM) while the electrical properties were measured using current voltage (I-V) probe measurement system. All samples exhibit the (002) peak and the sample annealed at 500°C gives the highest crystalline quality, highest Rms roughness (1.819 nm) and highest electrical conductivity (3.28 x 10-3 Sm-1).
The Effect of Camphor Oil Amounts on the Properties of Amorphous Carbon Thin Films by Thermal Chemical Vapor Deposition
Authors: Kamaruzaman Dayana , Fadzilah A.N. , Rusop Mohamad
Published: October 2012

Amorphous carbon thin films have been deposited by a simple Thermal Chemical Vapor Deposition (CVD) with varying the amount of natural precursor (camphor oil) onto the glass substrates. In this work, we have investigated the effect of different amount of camphor oil on the evolution of electrical conductivity and the optical and structural properties of amorphous carbon thin films. The amorphous carbon thin films were characterized by using current-voltage (I-V) measurement, UV-VIS-NIR spectroscopy and Raman spectroscopy. The current-voltage (I-V) study reveals that the highest electrical conductivity was deposited at 3 ml camphor oil. The optical band gap is almost unchanged with the increase of camphor oil amount. Raman result indicates that amorphous carbon thin films consists a mixture of sp2 and sp3 bonded carbon atoms.
Fundamental Study on the Carbonization Characteristics of Low Rank Coal Under Low Temperature and its Application on Traditional Blacksmith
Authors: Khairil Khairil , Irwansyah Irwansyah , Edhy Hamdani Sarwo , Rizal Samsul
Published: October 2012

The fundamental study on carbonization characteristic of low rank coal under low temperature was investigated by using a laboratorium scale electric furnace. In this experiment, the mass decreasing fraction of coal during carbonization, the bahaviour of volatile matter and the changes of fixed carbon as well as gas composition during carbonization was carried out. The effect of fixed carbon content in fuel on iron quality is also investigated. The experimental method for investigation of low rank coal carbonization characteristic was selected by variation of the carbonization temperature and nitrogen was introduced as a carrier gas. The experimental result shows that the mass decreasing fraction of coke was increased with the carbonization period. The fixed carbon content in coke was increased with the carbonization temperature. The gas composition during carbonisation shows consist of argon (Ar), carbon monoxide (CO) and methane (CH4). It shows that the CO gas is dominated of the amoung them. It is shown that the iron surface hardness may affect on carburizing media.
The Application of Reverse Engineering Tools and Rapid Prototyping Technology in Developing Automotive Components
Authors: Way Yusof , Kamarudin Muhammad Ridhuan , Salimi Noor Iliana Mohd
Published: October 2012

The important of Reverse Engineering (RE) and Rapid Prototyping (RP) process in the automotive sector has made the knowledge of its operation vital to engineers and designers. The purpose of this research is to apply and implement the RE and RP process and also integrate advance quality tools in the development of automotive components. The advance quality tools that been implemented are Quality Function Deployment (QFD) and Failure Mode Effect Analysis (FMEA). To produce the final products, a machine that works under Fused Deposition Modeling (FDM) principle is used. A manual window crank as the automotive component has been selected as the product for this paper and application. Before continuing the fabrication of product, the design improvement of the target product to a better product level is done through the QFD and FMEA as the advance quality tools. The analysis from QFD and FMEA tool is then translated into the design and product development.
Laser Sintering for the Fabrication of Architectural Models
Authors: Eyers Daniel Roy , Soe Shwe Pyi , Yusmawiza Wan Ahmad
Published: October 2012

Additive Manufacturing technologies are widely employed in the production of models for a range of industries. However, to-date little explicit research attention has examined the way in which the Laser Sintering technologies can be used in the specific application of architectural models. To evaluate the suitability of the process, this research develops a SWOT analysis of the Laser Sintering technologies for this application, highlighting not only the current advantages and disadvantages, but also future opportunities and threats which can be observed. From this assessment, the paper demonstrates the use of LS through the implementation of a four-stage model, supported by two examples of commercially produced architectural models.
Hole Making Process of Carbon Fiber Reinforced Polymer (CFRP) Using End Mill Cutting Tool
Authors: Rahim Erween Abdul , Mohid Z. , Mat K.C. , Jamil M.F.M. , Koyasu R. , Sasahara H.
Published: October 2012

This paper presents an alternative way of producing a hole by using a helical milling concept on a carbon fiber reinforced polymer (CFRP). Delamination is a major problem associated with making a hole by drilling on the CFRP. This study focused on helical milling technique using a vertical machining center in order to produce a hole. Various levels of cutting parameter such as cutting speed, feed rate and depth of cut have been chosen to observe the effect of trust force, delamination and surface roughness. The result will be used to determine on which cutting parameters give the best hole quality that will achieved by this new approached.
Moisture and Humidity Effects on the ABS Used in Fused Deposition Modeling Machine
Authors: Mohd Halidi Siti Nur Amalina , Abdullah Jamaluddin
Published: October 2012

The environment seems to have an effect on Acrylonitrile-Butadiene-Styrene (ABS) which consequently causes physical, morphological and thermal stability changes to the polymer. Not only that, these changes may have caused nozzle blockage on the liquefier of the Fused Deposition Modeling (FDM) rapid prototyping machine. Experiments are conducted to support and verify whether ABS does affect the blockage. It has been observed that physical changes may have not caused nozzle clogging.
Fragmentation Analysis of OG-7 Warhead Using AUTODYN SPH Solver
Authors: Abdalla Mohammed A.
Published: October 2012

In this paper an OG-7 warhead was modeled using Autodyn SPH solver. The results were compared with the pit test and analyzed by Held’s formula for fragments mass distribution. The results of Autodyn SPH showed good agreement considering of the effects of the mass losses and fragments impact during the pit test.
Monitoring of Fatigue Damage Using Ultrasonics and Finite Element Analysis
Authors: Hrairi Meftah , Mohammad Masturah , Ismail Siti Maisara
Published: October 2012

This study investigated the initiation and propagation of cracks until fracture of aluminum alloy 7075 under cyclic loadings. Tests were conducted to generate fatigue failures from 1×103 to 4×104 cycles at 10 Hz. Nondestructive ultrasound technique was used to detect the presence of any crack as well as its growth. Finite element analysis was conducted in order to assess the ability to predict fatigue crack initiation behavior. The results obtained from the fatigue test were compared to those obtained using ANSYS and a good agreement between the two was observed.
Modeling of a Turning Tool Holder with Finite Elements and Simulation of it Free Vibration Frequencies
Authors: Jaafar I.H. , Dawood Mohamed Shaik , Wazir I. A. , Amin A.K.M. Nurul , Shah Q.H.
Published: October 2012

Chatter is an unwanted phenomenon in metal cutting that involves violent vibrations of the cutting tool resulting in marked reduction in tool-life and increased roughness of the cut surface. Researchers have shown that chatter occurs due to resonance of the machine-tool-work system‘s natural frequency with that of the secondary saw teeth chip formation. This work investigates the modeling and free vibration analysis of a SANDVIK steel turning tool holder (DSSNR2525M12) set at 50, 70, 100, and 120 mm overhang, with a SANDVIK COROMANT titanium nitride coated carbide insert. The simulated free vibration data is compared to those obtained via experiments. The results show a correlation between simulated and experimentally obtained data for the tool holder set at the 50 and 70 mm. However there is a large discrepancy in results for the 100 and 120 mm overhang cases. This latter difference is unavoidable, due to the experimental test setup whereby the tool holder is clamped within the fixture with only 2 pins as opposed to the more rigid boundary condition applied to the finite element model, whereby the whole holder length within the carriage is rigidly supported at the element nodes. Hence the discrepancy is accentuated as the overhang is increased. This study is part of an ongoing research that aims at modeling and simulating the turning process itself, with the ultimate goal of providing off-line simulation and prediction of chatter.
Vibration Investigation of a Quarter Car with Nonlinear Shock Absorber Model
Authors: Darsivan Fadly Jashi , Faris Waleed F.
Published: October 2012

The paper discusses the response and the accuracy of a quarter car model with a non-linear damping force. The non-linear shock absorber model was a result of an experiment that was conducted earlier and the mathematical model was verified. Based on this model simulation responses of the sprung and unsprung masses between a linear and the non-linear damper were compared. The wheel of the quarter car model was excited by a road profile and according to the results the non-linear quarter model showed responses which were not depicted and captured by the linear model.
A Method for Predicting the Chemical Composition of Recycled Aluminum Alloys
Authors: Mahfoud Musbah , Ayyagari Prasad
Published: October 2012

The present paper describes a method for predicting the imminence (hereafter referred as ‘quality’) of the chemical composition of a recycled alloy to that of a standard alloy of aluminum recycled alloy made from aluminum scrap (used automotive components). The present method allows the chemical composition of a recycled alloy to be predicted. The method has been validated experimentally, and the results obtained showed that the composition of the recycled alloy was close to that of the predicted one. These findings indicate that the present method can be successfully used for any other recycled alloys to predict the alloy composition based on the in-coming scrap alloys. In this work, the chemical composition of a synthesized recycled alloy was compared to an ASTM standard alloy with the nearest composition. It was found that the two compositions were very comparable. A deviation factor has been defined in order to understand the quality of the recycled alloy obtained with reference to the ASTM alloy.
Dynamic Modeling and Simulation of Waste Energy Harvesting System for Urban Car
Authors: Fadhilah A.R. , Rahman A.
Published: October 2012

Single cylinder engine is capable of reducing harmful emission to the environment due to reduction in fuel consumption. On the other side, supercharger is known to be able to boost air to substantially improve the fuel economy of passenger cars. However, some amount of power is required by supercharger, thus reducing the efficiency of the engine. For improving the engine efficiency, waste heat energy from coolant is transferred to the boosted air before it flows into the combustion chamber. The system which functions as heat transfer is known as Waste Energy Harvesting System (WEHS). This system has been developed in order to supply enough boosted air for creating massive turbulence effect and auto oxidation to burn 100% of fuel with very short time. WEHS will contribute to reduce power loss due to heat release from the engine as well as reduce power consumed by the supercharger.
Experimental Study of Helical Milling on CFRP (Carbon Fibre Reinforced Polymer) for the Hole Making Process
Authors: Rahim Erween Abdul , Mohid Zazuli , Jamil M.F.M. , Mat K.C. , Koyasu R. , Sasahara Hiroyuki
Published: October 2012

Generate borehole by helical milling process may be used effectively since accurate location of the hole may be secured by means of the feed screw graduations. Fiber delamination which is the main defect occurred during hole making process on carbon fiber reinforced polymer (CFRP) were investigate throughout an experimental study. Effects of thrust force (Fz), delamination factor (Fd) and surface roughness are evaluated. Objective of the experiment are to find best cutting parameter and tool design suitable to performed helical milling operation on CFRP. Two types of end mill with 4 flutes were used and results are evaluated. It was found that tool design 2-1 has higher performance on CFRP.
“321” Program in Bandung State Polytechnic for Manufacturing for Better Operations Management Understanding
Authors: Ananto Gamawan
Published: October 2012

In ‘Bandung State Polytechnic for Manufacturing’ (POLMAN) Bandung as a vocational education institution, Production Base Education (PBE) is already implemented for years. Through this concept students are doing practical jobs that inquired by real customer from industries, with the Quality-Cost-Delivery (QCD) necessity as well. The student practical program schedule is made structurally, combined with theory and other needed contents according the planned competency for each study program in 3 years (6 semesters). Therefore, so far 2 weeks for practical and 1 week theory alternately is arranged and ran well. Students will then learn all about process and transformation of raw material to product included assembly, but they seem not enough experienced in Operation Management and integrating the related manufacture activities. There are feedbacks that POLMAN graduates have adequate capability in technical matters like designing, machining, fabrication etc. but few skills in managing could still be improved. In 321 program idea, students will get the first 3 semesters for basic matters needed, the next 2 semesters in integrated continually project program and the last 1 semester for finalization and the additional enrichment items. With this program, students will more concern and get better understanding in project handling comprehensively, integrating all related planning, relevancies among one process to others in order handling and manufacture activities, and be realized in controlling the milestone of supply chain component entities like vendor, logistic, production, sales and customer. The consequences in market and project matter preparation of course has to be highly anticipated.
Preliminary Investigations on the Reduction of Foot Pressure Measurement and Muscle Activity with Different Insole Materials
Authors: Ahmad Anis , Jaafar Roseleena , Omar A.R. , Hasim Mokhtar , Ali Masalina A.M. , Halim I.
Published: October 2012

Standing for long periods of time has been recognized as a potential contributor to muscle fatigue. When a person is performing activities in prolonged standing and wearing ineffective material of shoe insole, not only lead to muscle fatigue but can even cause injuries in the long term. The objective of this study is to determine the effects of two types of shoe insole materials; Ethylene Vinyl Acetate (EVA) and a combination of polyurethane (PU) and poron on muscle activity and foot pressure. The analysis of muscle fatigue was performed using surface electromyography (sEMG) while pressure under the foot was measured using FScan device. Results of comparison found that the two types of shoe insole materials showed significant difference (p-value < 0.05) in electromyography signals (µV) in the left and right gastrocnemius muscle while there are significant reductions on the peak pressure measured from the foot pressure measurement. It can be concluded that the combination of PU and poron is an effective material to be used a shoe insole for a person who is exposed to prolonged periods of standing.
Productivity Study and Line Balancing of GGMG & CALICO Production Line
Authors: Mustafa Hartini , Yusoff Ahmad Razlan , Ismail M. Yusoff
Published: October 2012

Assembly line balancing is assumed to have fixed task within specified task time during the initial stage of the mass production. The problem of current case study of this assembly line was the production line cannot meet the expected output plan with imbalance station cycle time. In this paper, productivity study and line balancing is applied to improve production line of GGMG & CALICO. The desired cycle time defined using the Standard Time Data (STD) which required the person to perform assign task till completion by defining the performance rating of person. The proposed solution proved by the implementation analysis conducted in the research. The results showed that the productivity of production line which is tremendously increased within 50% after implementation. There are six factors identified during the study which are bottleneck stations, workpiece flow, line layout, ergonomic, resource assignment and buffer allocation.
Workforce Assignment into Large-Sized Virtual Cells Using Learning Vector Quantization (LVQ) Approach
Authors: Murali R.V.
Published: October 2012

Much has been reported in literature on virtual cell formation problems while a limited work is reported on worker assignments. Virtual Cellular Manufacturing Systems (VCMS) have come into existence, replacing traditional Cellular Manufacturing Systems (CMS), to meet highly dynamic production conditions in terms of demand, production lots, processing times, product mix and production sequences. Although the problem of worker assignment and flexibility in cell based manufacturing environments has been studied and analyzed in plenty using various heuristics/mathematical models, application of Artificial Neural Networks (ANN), adapted from the biological neural networks, is the recent development in this field exploiting the ability of ANN to work out mathematically-difficult-to-solve problems. In this attempt, the previous work of the author has been further developed and an attempt has been made to apply Learning Vector Quantization (LVQ) approach into worker assignment problems for higher order virtual cells i.e., three cells configurations and analyze the suitability of LVQ approach in terms of successful classification rate and simulation parameters for a number of VCMS periods.
The Study on Production Performances of Part Transporter in Flexible Manufacturing System by Using Simulation Method
Authors: Iqbal Mohammad , Purnomo Muhammad Ridwan Andi , Imra Muhammad Ammar Bin Mohd , Konneh Mohamed , Karim A.N. Mustafizul
Published: October 2012

Material handling is one of major components in Flexible Manufacturing System (FMS). Any improvement of material handling capability is to affect the performance of the whole system. This paper discusses the simulation study on the effect of part arrival rate and dispatching rules to the average waiting time and production rate of the FMS. The facilities of the system were modeled into simulation environment by using Arena Simulation Software. The production parameters such as machine processing times, part transportation speed and type of products were put into the model to represent the behaviors of the real system. Two rules have been considered in the study, i. e. first come first served (FCFS), and shortest processing time (SPT). Average waiting time and productivity were taken into account as performance measures of the system. The result of the study showed that SPT rule gives shorter average waiting time and higher productivity. Based on this result, the SPT rules would be used to control part transporter in order to have a better performance of the FMS.
Solving Multiple Routes Travelling Salesman Problem Using Modified Genetic Algorithm
Authors: Andi Purnomo Muhammad Ridwan , Iqbal Mohammad , Sufa Mila Faila
Published: October 2012

The multiple routes travelling salesman problem (mrTSP) is an extension of the well-known travelling salesman problem (TSP), where there are several points clusters to be visited by salesman. The problem to be solved is how to define the best route in every cluster and initial position of each routes as interconnection points for the salesman. In this paper, modified genetic algorithm (mGA) is proposed in order to solve the mrTSP problem. In the proposed mGA, new heuristic algorithm for crossover and mutation operator based on local shortest path algorithm is proposed in order to assist the mGA to improve 'best solution so far'. Numerical examples are also given to test the performance of proposed mGA when solving mrTSP. The result of the study shows that the mGA is superior compared to conventional GA.
Electro-Discharge Machining of SUS 304 Stainless Steel with TaC Powder-Mixed Dielectric
Authors: Zain Zakaria Mohd , Ndaliman Mohammed Baba , Khan Ahsan Ali , Mohammad Yeakub Ali
Published: October 2012

Powder-mixed dielectric fluid is one of the innovations of electro-discharge machining (EDM) which seeks to improve the process outputs by addition of powders to the dielectric during machining. In the present study, the influence of TaC powder in kerosene dielectric fluid on EDM process outputs was investigated. Experiments were conducted with the outputs as material removal rate (MRR), surface roughness (Ra) and micro-hardness. During the EDM, the discharge current was varied between 2.5 and 6.5 A, while powder concentration ranges between 5.0 and 15.0 g/l. Results indicate that the highest MRR of 0.38 g/min was obtained with TaC concentration of 15 g/l at the current of 6.5 A. TaC powder addition does not affect both the MRR and Ra at lower current. However, the level of micro-hardness attained was influenced by TaC powder concentration in dielectric fluid, the highest being 1,040 Hv with 5.0 g/l at the current of 2.5 A.
Economic Scenario of Cellulase Enzyme Production Using Palm Oil Mill Effluent (POME)
Authors: Karim A.N. Mustafizul , Hamdan M.A.H. , Alam Md Zahangir , Iqbal Mohammad
Published: October 2012

This paper presents an analysis on the economic suitability of a large scale plant for the production of cellulase enzyme from Palm Oil Mill Effluent (POME). Based on the data and other relevant information gathered from indigenous operation of a lab and a pilot scale bio-reactors (30L and 300L capacities), a predicted evaluation of economic aspects of enzyme production with a 3000L bioreactor has been made. Factors such as the initial price and installation cost, the expenses for raw materials, operation and maintenance of the plant, overhead, utilities, logistics etc. were considered. Enzyme output from the proposed bioreactor was estimated depending on the optimum operational conditions established by the small scale investigation. Net present value (NPV) of the project was evaluated by using the discounted cash-flow analysis. With a conservative view of 5% escalation of recurring costs and a target of 70% capacity utilization an NPV of MYR 2,5 million was found to be achievable for a 10% discount rate and a plant life of 10 years,. Economic scenario developed for 50-100% range capacity utilization indicating the NPV can be helpful in making decisions for implementation of such plants. Thus production of cellulase enzyme from POME using a 3000L bioreactor is found to be economically attractive.
Applying Value Stream Mapping for Productivity Improvement of a Metal Stamping Industry
Authors: Karim A.N. Mustafizul , Jaafar A.A.B. , Abdullah M.A.I. , Haque M. , Mohammad Yeakub Ali , Azline S.A.
Published: October 2012

To sustain in business by meeting the customer expectations with limited resources under tight schedule is a great challenge for high volume manufacturing industry. In this respect Value Stream Mapping (VSM) plays an important role as a strategic tool in streamlining the processing operations and enhances capacity utilization. This study has been conducted on application of VSM in a make-to-order metal stamping company engaged in production of different stamped parts of which the LCD TV frame is a significant one. Based on the product flow analysis, a current state VSM has been constructed using pertinent data collected from the production floor. Analysis of recorded videos and time studies were performed in order to figure out the scope of improvements in framing the future state map (FSM) in the context of cycle time reduction and line balancing efficiency. As observed from the FSM, the efficiency of production line is possible to be significantly increased from about 48% to more than 93% vis-à-vis a reduced batch completion cycle time. Thus it is obvious that with minor adjustments in the system in line with the findings of the study, the industry can make a substantial improvement in their operational efficiency.
The Implementation of Lean Manufacturing in Malaysian Automotive Industry
Authors: Fakhri S. Ahmad , Hafiz J. Muhammad , Rahman Mohamed Abdul
Published: October 2012

The study was conducted to investigate the level of implementation of lean manufacturing (LM) in Malaysian automotive industry. A number of survey methodologies were utilized to ensure reliability of the results of this study. Thirteen areas have been identified as typical workplaces implementing lean manufacturing. The study also investigated the benefits gained and obstacles faced by manufacturers in implementing the system. The frequency and tendency of applying lean tools in manufacturing environment have also been ranked.
Cost Based Process Optimization by Incrementally Changing the Cutting Data during Sustainable Machining
Authors: Schultheiss Fredrik , Lundqvist Bengt , Ståhl Jan Eric
Published: October 2012

All companies strive towards lowering their manufacturing costs. Few companies do however succeed in continuously improving their production after the launch of a new production process. This article introduces a method for companies having an established technology to optimize their production in terms of part cost without disrupting the normal, day-to-day production. By incrementally chancing the process parameters such as for example cutting data as a function of the originally selected values, it is possible to optimize the production process. This is closely related to the lean production philosophy and long term sustainability which strives towards efficient use of resources and involvement of all employees in improving the production process. In the case study presented in this article it was found that by adding extra sulfur to the cutting fluid it was possible to decrease the part cost. By using the proposed method the company was able to decrease the part cost when manufacturing a specific part with approximately 5 %.
Analysis of End Crack in Boiler Tube
Authors: Begum Shahida , Karim A.N. Mustafizul , Nainar Mohamed Ansari M. , Sevah Sukhana
Published: October 2012

Boiler tube failures usually result in frequent forced outages, and ultimately in costly extended outages for major tubing replacement in a plant. There are several failure modes that may occur in a boiler tube, i.e. stress-corrosion cracking, pitting, water-side corrosion, fire-side corrosion, fatigue failure, overheating, dissimilar metal weld fatigue, mechanical fatigue and erosion. In this research the failure modes of boiler and its end cracks due to the dissimilar metal weld is analyzed. Hence data are collected and explored to determine the cause of failure and as a solution ceramic ferrule is suggested. The use of ceramic ferrule in boiler tube can eliminate the crack occurrence or delay the process due to thermal properties. The prevention of crack will reduce frequent maintenance and thus the cost of operation can be minimized.
Design and Fabrication of Active Vibration Isolation System for Free Space Optics Communication
Authors: Turahim Khairiah K. , Muthalif Asan G.A. , Rahim Syazwani A.
Published: October 2012

Free Space Optics (FSO) communication is a technology widely used today. It involves transmission of data from a transmitter to a receiver. In order to achieve successful data transmission, a continuous alignment between the transmitter and receiver telescope is needed. If not, misalignment will happen due to certain factors. Vibration at the transmitter or the receiver is one of the factors that contribute to misalignment. In this work, active vibration isolation (AVI) system is designed and fabricated in order to improve the performance of the transmitter and receiver in an FSO link. First, a virtual prototype is designed. Then a real prototype is fabricated to implement AVI. The result after applying a controller to the AVI system shows 33.1% reduction in amplitude of displacement of the top plate, in other words reduction in amplitude of vibration.
A Study of Fatigue Life of Kenaf Fibre Composites
Authors: Abdullah Abdul Hakim , Alias Siti Khadijah , Abdan Khalina , Ali Aidy
Published: October 2012

Towards green material, fatigue life of unidirectional kenaf fibre reinforced epoxy composites was investigated made from the hand-layout technique. The composites were subjected to tension-tension fatigue loading at stress ratio of 0.5 and 5 Hz of frequency. Fibre content ratios were found to affect fatigue life on the low cycle fatigue regime strongly as illustrated with stress level versus cycles to failure. It is found that kenaf fibre reinforced epoxy composites with higher fibre content posses higher load carrying capacity and degradation rates.
Tool Wear Analysis in End Milling of Advanced Ceramics with TiAlN and TiN Coated Carbide Inserts
Authors: Reddy M. Mohan , Gorin Alexander , Abou-El-Hossein Khaled A. , Sujan D. , Mohammad Yeakub Ali , Maleque Md Abdul
Published: October 2012

Advanced ceramic materials are difficult to machine by conventional methods due to the brittle nature and high hardness. The appropriate selection of cutting tool and cutting conditions may help to improve machinability by endmilling. Performance of TiAlN and TiN coated carbide tool insert in end milling of machinable glass ceramic has been investigated. Several dry cutting tests were performed to select the optimum cutting parameters for the endmilling in order to obtain better tool life. In this work, a study was carried out on the influence of cutting speed, feed rate and axial depth of cut on tool wear.The technique of design of experiments (DOE) was used for the planning and analysis of the experiments. Tool wear prediction model was developed using Response surface methodology.The results indicate that tool wear increased with increasing the cutting speed and axial depth of cut. Effect of feed rate is not much significant on selected range of cutting condition
Tensile Strength of Weld Joint Produced by Spinning Friction Welding of Round Aluminum A6061 with Various Chamfer Angles
Authors: Irawan Yudy Surya , Wirohardjo Marsoedi , Ma’arif Mochamad Syamsul
Published: October 2012

Tensile strength of Aluminum A6061 joint produced by spinning friction welding (SFW) with various chamfer angles was studied. Tensile strength test specimens that have weld joint part at their centers were machined from spinning friction welded base metals. SFW specimens were prepared by making various chamfer angles of 15, 30, 45, 60, 75 degree and without chamfer angle on both contact-surfaces of base materials. It was found that chamfer angle affected tensile strength of weld joint of Aluminum A6061. Base materials with chamfer angle of 30 degree resulted in specimen that had the maximum tensile strength of friction weld joint. From the result of macrostructure evaluation, it was found that high strength in these specimens was due to the maximum area of fully plasticized zone, minimum porosity and minimum area of heat-affected zone.
Analysis of Thermal Stress Intensity Factors for Edge Cracked Bimaterial System
Authors: Hrairi Meftah , Ali Arafath , Rizk Abd El Fattah
Published: October 2012

The thermo elastic edge-cracking problem in bimaterial systems subjected to convective heating is considered. The medium is assumed to be insulated on one surface and exposed to sudden convective heating on another surface containing the edge crack. Superposition and uncoupled quasi-static thermoelasticity principles are adopted to formulate the problem. Thermal stress distribution and stress intensity factor values had been determined using the finite element software ANSYS for two different bi-material systems containing edge crack normal to the interface.
Diode Characteristics of Nanocomposited MEH-PPV: I-MWNTs with Different Types of Metal Contact Organic Solar Cells
Authors: Saad Puteri Sarah Mohamad , Zahid F.S.S. , Rusop M.
Published: October 2012

This paper investigates the performance of organic solar cells by using different types of metal contact. The metal contacts that have been chosen are Ag, Au and Pt. The different work function of the metals will influence the efficiency of the organic solar cells. From the results it can be seen that the absorbance value is quite high around 0.5 which absorb more photon when it is illuminated. The efficiency of the device using Pt shows the highest efficiency which is 10.62x10-3% followed by Au with 8.01x10-4% and Ag 1.25x10-4%.
Parallel Manipulator for Auto Tracking System: Virtual Prototyping Using LabVIEW- Solidworks
Authors: Ramli Zalifah , Muthalif Asan G.A. , Shafie Amir A. , Antong Hasmawati
Published: October 2012

Free-space optics (FSO) communication is a technology that uses light to transmit data through free space. The most important part in FSO communication is the alignment between transmitter and telescope’s receiver. However, since the transmission medium of FSO is atmosphere, it will give misalignment between the transceivers. Hence, auto tracking system is required to solve the problem between the transmitter and receivers. The 3-RPS parallel manipulator has been designed as an auto tracking system for the alignment between transceivers. First, a prototype of the system is designed in SolidWorks and integrated with LabVIEW software to perform virtual prototyping. Then, the result of virtual prrotyping is discussed.
Design and Develop the Jig and Fixtures for HLV 30 Piercing Machine
Authors: Haji Che Daud Mohd Radzi , Abdul Nasir Mohamad Faizal Bin
Published: October 2012

HLV 30 Piercing Machine produced by SMG Pressen, an engineering company from Germany that exercising the task of piercing of LPG cylinder for valving process. This particular machine is used by LPG cylinder production plant, and one of them is Keloil LPG Cylinders Sdn. Bhd. This research project intend to study how this piercing process affects the production quality of the LPG gas and also to develop and design the new jig and fixture for this machine to get the accurate tolerance for the piercing process and decrease the index of rejection of the cylinder. In this research, we try to analyze the production data and try to make a new design of fixtures for this machine to get the better result and performance for this machine.