Sanusi Hamat
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Preferred name
Sanusi Hamat
Official Name
Sanusi, Hamat
Alternative Name
Hamat, S.
Hamat, Sanusi
Sanusi, H.
Main Affiliation
Scopus Author ID
57004964400
Researcher ID
ABB-5094-2020

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Effect of kenaf fiber loading on the tensile properties of 3D printing PLA filament

2023-01-01 , Lau H.Y. , Mohd Sabri Hussin , Sanusi Hamat , Muhamad Saifuldin Abdul Manan , Ibrahim M. , Hafizawati Zakaria

As know Polylactic acid (PLA) is a popular and widely used thermoplastic material used in fused filament fabrication (FDM) due to its biodegradability and biocompatibility. As PLA was identified as a brittle material, reinforcement was used to enhance the properties of the PLA. This paper aims to study the effect of using various kenaf volume ratios on the tensile properties of the 2003D PLA filament for 3D printing. The study began by extruding 2003D grade PLA pellet from Ingeo NatureWorks into a single filament extruder machine with an extrusion temperature of 190 °C and a screw rate of 7 rpm. The 90° raster angle of line infill pattern with 100 % infill density were used for the 3D printing specimens. Mechanical test standards such as ASTM D638, was used for tensile testing to analyse the quality of the extruded PLA single filament. As result, the with kenaf fibre loading of 15 % shows the optimum tensile properties among the filler loading, hence it is proven that the tensile properties of the was indeed being enhanced by the additional of the kenaf fibre as reinforcement.

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Design and Mechanical Analysis on a Compact Bicycle Loader for a Small Cubic Centimeter Motorcycle

2021-01-01 , Mohd Sabri Hussin , Sanusi Hamat , Syamir Alihan Showkat Ali

This paper presents the finite element and fluid-flow analysis on the behavior of a new compact bicycle loader design used for a small cubic centimeter motorcycle. The bicycle loader in the current market comes with various sizes and design which mostly applicable to the large-scale vehicles, namely car and motorcycle with higher cubic centimeter engines. The study aims to design a new compact bicycle loader specifically for small cubic centimeter motorcycles with greater loading capability and security. The finite element analysis was performed using the ABAQUS and ANSYS software to better understand the static and dynamic response of the bicycle loader relating to static and fatigue strengths with specific loads. The fluid-flow to structure analysis has also been carried out using the XFlow Computational Fluid Dynamic software to demonstrate the flow behavior and effect on the bicycle loader with different motorcycle speed. The fatigue analysis was carried out to analyze the structural performance of the bicycle loader. Factors like fatigue life, safety factor, biaxiality indication and fatigue response are plotted for the bicycle loader and the fatigue performance is predicted using the data obtained. The results of the stress distribution show that the maximum von-Mises stress obtained from is about 31.7 MPa, well within the yield strength if the mild steel material. The results show that the highest stress distribution occurs at the mounting part of the bicycle loader, with equivalent stress of 50.29 MPa. The results show that there are no permanent deformations occurred in the bicycle loader during the fatigue test and fulfils the minimum safety requirements needed. The fluid flow analysis show that a strong recirculation region occurs at the front of the motorcycle, bicycle headset and suspension fork and downstream of the bicycle tires, however, no obvious flow disturbance is observed in the vicinity of the bicycle loader.

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Experimental and finite element modeling of partial infill patterns for thermoplastic polymer extrusion 3D printed material using elasto-plastic method

2020-10-26 , Mohd Sabri Hussin , Sanusi Hamat , Syamir Alihan Showkat Ali , Muhammad Aiman Ahmad Fozi , Yuzairi Abdul Rahim , Mohd Syedi Imran Mohd Dawi , Darsin M.

Fused Deposition Modeling is known as one of the 3D printing technology where it used a thermoplastic filament to produce a prototype or a 3D part. FDM will print out the 3D part, layer by layer on the platform of the 3D printer from bottom to top using the extruded molten thermoplastic. However, there is no information about the volume enclosed by the boundary surface of the 3D part by commonly used model data format such as STL file, since the volume enclosed can be completely or partially filled. Therefore, the study and research have been carried out to investigate the strength of the 3D part affected by the design of the infill pattern where three methods being used which are design, experiment and simulation. The 3D parts were designed using CATIA V5 following the ASTM D638 for tensile test and ASTM D695 for compression test. The 3D design was then being printed using the Fused Deposition Modeling (FDM) technique for experimental purposes and to perform the quasi-static test. Furthermore, the 3D printed with infill pattern test data were then being imported to ABAQUS/Explicit software for non-linear finite element analysis using elasto-plastic approach. The best infill patterns that exhibit a better strength after the 100% fill part is the 30% fill Lines pattern. It can be concluded that the average percentage error of stress and strain values between experimental test and simulations in tensile and compression for all specimens is below than 10%.

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Tensile Properties of 3D Printed Recycled PLA Filament: A Detailed Study on Filament Fabrication Parameters

2023-10-01 , Sanusi Hamat , Ishak M.R. , Salit M.S. , Yidris N. , Syamir Alihan Showkat Ali , Mohd Sabri Hussin , Maliki Ibrahim , Asmawi Sanuddin

Polylactic acid (PLA), a biodegradable and biocompatible thermoplastic commonly utilized in 3D Printing filaments, undergoes changes in properties upon recycling. The objective was to elucidate the role of extrusion temperature and screw speed in modulating the quality of recycled PLA filament, as well as in controlling its dimensional attributes. Recycled PLA pellets (3D850D) were extruded using a single filament extruder machine within an extrusion temperature range of 145°C to 165°C and a screw speed varying from 2 rpm to 6 rpm. The extruded filaments were subsequently 3D printed into specimens adopting a 0° raster angle, line infill pattern, and a 100 percent infill density, then tested as per ASTM D638 mechanical standards. The study revealed a profound influence of extrusion parameters on the filament's ultimate tensile strength, yield strength, and diameter. Optimal extrusion conditions-155°C and 5 rpm-resulted in maximum mechanical strengths, while the parameters yielding filament diameters closest to commercial standards were identified as 5 rpm and 155°C. These results under-score the possibility of optimizing the recycled PLA filament's properties through adept control of extrusion parameters. Consequently, this investigation supports the potential use of recycled PLA filament in the 3D printing industry as a sustainable and performance-efficient material, offering a tangible step towards environmentally friendly additive manufacturing practices.

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The Effects of Self-Polymerized Polydopamine Coating on Mechanical Properties of Polylactic Acid (PLA)–Kenaf Fiber (KF) in Fused Deposition Modeling (FDM)

2023-06-01 , Sanusi Hamat , Syamir Alihan Showkat Ali , Salit M.S. , Yidris N. , Showkat Ali S.A. , Mohd Sabri Hussin , Muhamad Saifuldin Abdul Manan , Muhamad Qauyum Zawawi Ahamad Suffin , Maliki Ibrahim , Ahmad Nabil Mohd Khalil

This research examines the impact of self-polymerized polydopamine (PDA) coating on the mechanical properties and microstructural behavior of polylactic acid (PLA)/kenaf fiber (KF) composites in fused deposition modeling (FDM). A biodegradable FDM model of natural fiber-reinforced composite (NFRC) filaments, coated with dopamine and reinforced with 5 to 20 wt.% bast kenaf fibers, was developed for 3D printing applications. Tensile, compression, and flexural test specimens were 3D printed, and the influence of kenaf fiber content on their mechanical properties was assessed. A comprehensive characterization of the blended pellets and printed composite materials was performed, encompassing chemical, physical, and microscopic analyses. The results demonstrate that the self-polymerized polydopamine coating acted as a coupling agent, enhancing the interfacial adhesion between kenaf fibers and the PLA matrix and leading to improved mechanical properties. An increase in density and porosity was observed in the FDM specimens of the PLA–PDA–KF composites, proportional to their kenaf fiber content. The enhanced bonding between kenaf fiber particles and the PLA matrix contributed to an increase of up to 13.4% for tensile and 15.3% for flexural in the Young’s modulus of PLA–PDA–KF composites and an increase of up to 30% in compressive stress. The incorporation of polydopamine as a coupling agent in the FDM filament composite led to an improvement in tensile, compressive, and flexural stresses and strain at break, surpassing that of pure PLA, while the reinforcement provided by kenaf fibers was enhanced more by delayed crack growth, resulting in a higher strain at break. The self-polymerized polydopamine coatings exhibit remarkable mechanical properties, suggesting their potential as a sustainable material for diverse applications in FDM.

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FINITE ELEMENT ANALYSIS ON STRUCTURAL BEHAVIOUR OF GEOPOLYMER REINFORCED CONCRETE BEAM USING JOHNSON-COOK DAMAGE IN ABAQUS

2022-01-01 , Nurul Aida Mohd Mortar , Mohd. Mustafa Al Bakri Abdullah , Kamarudin Hussin , Rafiza Abd Razak , Sanusi Hamat , Ahmad Humaizi Hilmi , Noorfifi Natasha Shahedan , Li L.Y. , Ikmal Hakem Abdul Aziz

This paper details a finite element analysis of the behaviour of Si-Al geopolymer concrete beam reinforced steel bar under an impulsive load and hyper velocity speed up to 1 km/s created by an air blast explosion. The initial torsion stiffness and ultimate torsion strength of the beam increased with increasing compressive strength and decreasing stirrup ratio. The study involves building a finite element model to detail the stress distribution and compute the level of damage, displacement, and cracks development on the geopolymer concrete reinforcement beam. This was done in ABAQUS, where a computational model of the finite element was used to determine the elasticity, plasticity, concrete tension damages, concrete damage plasticity, and the viability of the Johnson-Cook Damage method on the Si-Al geopolymer concrete. The results from the numerical simulation show that an increase in the load magnitude at the midspan of the beam leads to a percentage increase in the ultimate damage of the reinforced geopolymer beams failing in shear plastic deformation. The correlation between the numerical and experimental blasting results confirmed that the damage pattern accurately predicts the response of the steel reinforcement Si-Al geopolymer concrete beams, concluded that decreasing the scaled distance from 0.298 kg/m3 to 0.149 kg/m3 increased the deformation percentage.

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Design and structural analysis of 3D-printed modular furniture joints

2020-12-18 , Muhammad Aiman Ahmad Fozi , Sanusi Hamat , Mohd Haidiezul Jamal Ab Hadi , Cheong H.Y.

Modular furniture joint defined as a connection used to connect two or more wood pieces to produce furniture with multiple functions. Notofusy furniture joint made from plywood was less expensive. However, during the manufacturing process, it was occasionally caused tear-out of wood fibre. Therefore, this research has been carried out to investigate and compare the existing material and Fused Deposition Modelling (FDM) fabrication method on the designed modular furniture joint. Finite Element Analysis (FEA) of elasto-plastic method from ABAQUS CAE software and three-point bending test were used to evaluate the structural analysis of designed modular furniture joint. In this research, the final concept selected was able to withstand load up to 730 kg and it only weights 113.59 g. The long-term goal for this research was to evaluate the possibility of producing end products using FDM technology. It was found that FDM contributed to cost effective in low volume production. In this research, the material focused were Acrylonitrile Butadiene Styrene (ABS) and Polyethylene Terephthalate (PETG). However, future studies can be conducted to evaluate the possibility of using other 3D printing materials.

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Finite element analysis on structural behaviour of geopolymer reinforced concrete beam using Johnson-Cook Damage in ABAQUS

2022 , Nurul Aida Mohd Mortar , Mohd. Mustafa Al Bakri Abdullah , Rafiza Abdul Razak , Kamarudin Hussin , Sanusi Hamat , Ahmad Humaizi Hilmi , Noorfifi Natasha Shahedan , Long Yuan Li , Ikmal Hakem A. Aziz

This paper details a finite element analysis of the behaviour of Si-Al geopolymer concrete beam reinforced steel bar under an impulsive load and hyper velocity speed up to 1 km/s created by an air blast explosion. The initial torsion stiffness and ultimate torsion strength of the beam increased with increasing compressive strength and decreasing stirrup ratio. The study involves building a finite element model to detail the stress distribution and compute the level of damage, displacement, and cracks development on the geopolymer concrete reinforcement beam. This was done in ABAQUS, where a computational model of the finite element was used to determine the elasticity, plasticity, concrete tension damages, concrete damage plasticity, and the viability of the Johnson-Cook Damage method on the Si-Al geopolymer concrete. The results from the numerical simulation show that an increase in the load magnitude at the midspan of the beam leads to a percentage increase in the ultimate damage of the reinforced geopolymer beams failing in shear plastic deformation. The correlation between the numerical and experimental blasting results confirmed that the damage pattern accurately predicts the response of the steel reinforcement Si-Al geopolymer concrete beams, concluded that decreasing the scaled distance from 0.298 kg/m3 to 0.149 kg/m3 increased the deformation percentage.

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Biodegradable natural fiber polymer composite as future 3D printing feedstock

2023 , Sanusi Hamat , Mohamad Ridzwan Ishak , Mohd Sapuan Salit , Noorfaizal Yidris

The key advantages of 3D printing are its capability to produce complex structures and rapid prototyping. This has contributed to the development of modern material processing methods over the past years for industrial tasks and needs. However, the development of biodegradable feedstock for 3D printing filament and enhanced natural fiber as reinforcement filler to improve mechanical properties and biodegradation is still not fully explored. Also, there have been alarming concerns around the world about the use of non-biodegradable resources during 3D printing that could threaten the sustainable environment. This review discusses the types of biodegradable polymers, natural fibers with their properties and applications, the development method for non-biodegradable and biodegradable polymer composites obtained through fused filament fabrication (FFF). Finally, the challenges and future opportunities associated with 3D printing feedstock of biodegradable polymer composites are reviewed and analyzed.

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Effects on Ply Orientation of Kevlar/Epoxy for Ballistic Impact in Bulletproof Vest Using Non-linear Finite Element Analysis

2021-01-01 , Sanusi Hamat , Mohd Sabri Hussin , Syamir Alihan Showkat Ali , Maliki Ibrahim

The bulletproof vest is vital equipment to stop bullets from penetrating the body. The vest comes with a ballistic panel that can absorb the energy from the ballistic impact. Due to excellent impact resistance and high strength-to-weight ratio, Kevlar fibers composites are widely used for designing a ballistic panel in bulletproof vest body armor to avoid penetration. In this study, the research aims to investigate the ballistic impact behavior on a ballistic panel of Kevlar/Epoxy by using different fibers ply orientation to increase the ballistic impact performance. A finite element analysis using non-linear dynamic simulation was developed in commercial software Abaqus/Explicit to analyze the performance of impact characteristics in penetration depth, damage criteria, and energy-absorbing capacity. The simulation results show that the fibers ply orientation sequence of [0/90/0/90]2sym with 4 mm panel thickness has produced the highest energy absorption of 1523.7 J with least depth penetration of 2.12 mm for the 9 mm bullet traveling at 358 m/s and produce a lowest Hashin’s damage criteria with the value of 0.40. The finding shows that the ply orientation of Kevlar/Epoxy composite ballistic panel has excellent potential in bulletproof body armor application for minimizing the effect of blunt force trauma with less expensive materials usage and light weight ballistic panel.

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