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Warpage optimisation on the moulded part with straight drilled and conformal cooling channels using Response Surface Methodology (RSM), Glowworm Swarm Optimisation (GSO) and Genetic Algorithm (GA) optimisation approaches

2021 , Mohd. Hazwan Mohd. Hanid , Shayfull Zamree Abd. Rahim , Joanna Gondro , Safian Sharif , Mohd. Mustafa Al Bakri Abdullah , Azlan Mohd Zain , Abdellah El-hadj Abdellah , Mohd. Nasir Mat Saad , Jerzy J. Wysłocki , Marcin Nabiałek

It is quite challenging to control both quality and productivity of products produced using injection molding process. Although many previous researchers have used different types of optimisation approaches to obtain the best configuration of parameters setting to control the quality of the molded part, optimisation approaches in maximising the performance of cooling channels to enhance the process productivity by decreasing the mould cycle time remain lacking. In this study, optimisation approaches namely Response Surface Methodology (RSM), Genetic Algorithm (GA) and Glowworm Swarm Optimisation (GSO) were employed on front panel housing moulded using Acrylonitrile Butadiene Styrene (ABS). Each optimisation method was analysed for both straight drilled and Milled Groove Square Shape (MGSS) conformal cooling channel moulds. Results from experimental works showed that, the performance of MGSS conformal cooling channels could be enhanced by employing the optimisation approach. Therefore, this research provides useful scientific knowledge and an alternative solution for the plastic injection moulding industry to improve the quality of moulded parts in terms of deformation using the proposed optimisation approaches in the used of conformal cooling channels mould.

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Shrinkage optimisation on the 3D printed part using Full Factorial Design (FFD) optimisation approach

2020-12-18 , Mohd Haidiezul Jamal Ab Hadi , Mohd. Hazwan Mohd. Hanid , Lee W.S. , Gunalan , Najihah N.F. , Fadhli I.

Quality and productivity are both important in 3D printing products and processes. However, it is quite challenging to control the quality and productivity of each product due to several parameters involved in this additive manufacturing process. Most of the parameter settings depend on trial and error techniques which consume a lot of time and material waste. Therefore, in this study, the application of optimization approach which is Full Factorial Design (FFD) approach which has been employed on 3D printed housing part made from Polylactic Acid (PLA) which were printed using Fused Deposition Modelling (FDM) 3D printer to minimize shrinkage on the 3D printed parts. Based on the optimization work, the results showed the performance of FFD approach provides a good dimensional accuracy compared to the drawing specification for the printed part. Therefore, this research provides beneficial scientific knowledge and alternative solution for the additive manufacturing process in industries application to enhance the quality of the 3D printed parts produced using FDM 3D printer machine.

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Determination of moisture content on kenaf via fluidization systems

2020-03-25 , Zainuddin H.H.M. , Mohd Al-Hafiz Mohd Nawi , Kasim M.S. , Mohd. Hazwan Mohd. Hanid , Wan Azani Wan Mustafa , Nik Noriman Zulkepli , Dahham O.S.

Malaysia is a one of tropical forest country in the Southeast Asia and they have a great potential of green agriculture source to be used as a renewable energy. One of this source is a Kenaf that is consist of a core and bast fibers. In this study, biomass which is Kenaf plant was dried using Sherwood M501 air fluid bed dryer. Air fluid bed dryer is one of the fluidization drying process that have potential to be widely used. The current properties in this material used contain the high value of water when produced pellet. Therefore, a study was conducted to determine the characteristics and the percentage of Kenaf focused on moisture loss of Kenaf sample via fluidization drying process. The results of found that during fluidization process the best condition that reduce most of the moisture content of sample is the second condition that applied 4.0 m/s velocity (50% of fan speed), 46°C temperature. Effect of the used of suitable amount of air velocity and temperature would attributed to the physical characteristics change and moisture content value that should be obtained.

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Hybrid mold : Comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC)

2021 , Radhwan Hussin , Safian Sharif , Marcin Nabiałek , Shayfull Zamree Abd. Rahim , Mohd Tanwyn Mohd Khushairi , Jerzy J. Wysłocki , Mohd. Mustafa Al Bakri Abdullah , Mohd. Hazwan Mohd. Hanid , Mohd Azlan Suhaimi , Katarzyna Błoch

The mold-making industry is currently facing several challenges, including new competitors in the market as well as the increasing demand for a low volume of precision moldings. The purpose of this research is to appraise a new formulation of Metal Epoxy Composite (MEC) materials as a mold insert. The fabrication of mold inserts using MEC provided commercial opportunities and an alternative rapid tooling method for injection molding application. It is hypothesized that the addition of filler particles such as brass and copper powders would be able to further increase mold performance such as compression strength and thermal properties, which are essential in the production of plastic parts for the new product development. This study involved four phases, which are epoxy matrix design, material properties characterization, mold design, and finally the fabrication of the mold insert. Epoxy resins filled with brass (EB) and copper (EC) powders were mixed separately into 10 wt% until 30 wt% of the mass composition ratio. Control factors such as degassing time, curing temperature, and mixing time to increase physical and mechanical properties were optimized using the Response Surface Method (RSM). The study provided optimum parameters for mixing epoxy resin with fillers, where the degassing time was found to be the critical factor with 35.91%, followed by curing temperature with 3.53% and mixing time with 2.08%. The mold inserts were fabricated for EB and EC at 30 wt% based on the optimization outcome from RSM and statistical ANOVA results. It was also revealed that the EC mold insert offers better cycle time compared to EB mold insert material.

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Warpage optimisation on front panel housing using straight drilled and conformal cooling channels in injection moulding process

2018 , Mohd. Hazwan Mohd. Hanid

Nowadays, there are various optimisation methods that have been explored by researchers to determine the appropriate setting of processing parameters in the injection moulding process. Based on previous researches, the use of optimisation works has improved the quality of the moulded part produced. Apart from quality, the productivity in the injection moulding process also plays an important role. Therefore, some researchers and manufacturers have introduced the application of conformal cooling channels in injection process which have been proven to improve the quality and productivity of the moulded part due to better uniformity of temperature distribution in the mould as compared to the conventional straight drilled cooling channels. However, the application of optimisation techniques to determine an appropriate setting of processing parameters in previous researches were mainly focused on the conventional straight drilled cooling channels, whereas in conformal cooling channels is still lacking due to the difficulties in mould fabrication. In this study, the application of optimisation technique to improve the warpage on the front panel housing using the conventional straight drilled and Milled Groove Square Shape (MGSS) conformal cooling channels was explored. Simulation studies using Autodesk Moldflow Insight (AMI) 2013 software were conducted to obtain the recommended processing parameters for both types of channels. Then, by selecting cooling time, coolant temperature, packing pressure and melt temperature as the variable parameters, Design of Experiment (DOE) has been constructed using the face-centered, Central Composite Design (CCD) approach. Response Surface Methodology (RSM) was performed to develop mathematical models to employing Glowworm Swarm Optimisation (GSO) and Genetic Algorithm (GA) optimisation approaches in order to determine the appropriate setting of the processing parameters to optimise the warpage defect. Results from experimental works showed that, the performance of MGSS conformal cooling channels is remarkably improved in terms of quality and productivity compared to the straight drilled cooling channels before and after optimisation. GA offers the lowest warpage value, followed by RSM and then GSO for both types of channels. The warpage on the front panel housing was improved by 32.5% (from 0.375 mm to 0.253 mm) and 22.9% (from 0.205 mm to 0.158 mm) using straight drilled and MGSS conformal cooling channels respectively after optimisation using GA, compared to the recommended setting suggested from simulation studies. Next, it was followed by an RSM approach with the improvement of 30.7% and 22% using straight drilled and MGSS conformal cooling channels respectively as compared to the recommended setting suggested from simulation studies. Lastly, the result using GSO approach showed an improvement of 18.7% and 7.3% using straight drilled and MGSS conformal cooling channels respectively when compared to the recommended setting suggested from simulation studies. Therefore, it can be suggested that, this research provides beneficial scientific knowledge and alternative solution for plastic injection moulding industries to enhance the quality of the moulded parts produced using optimisation techniques.

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Analysis of torchlight using engineering analysis tools

2021-05-03 , Mohd. Hazwan Mohd. Hanid , Muhamad Farizuan Rosli , Wan Abdul Rahman Assyahid Wan Ibrahim , Radhwan Hussin , Ahmad S.A.S. , Ting Hua Jui , Nur Ainin Faissal , Nurafzarini Mohd Rusdi , Nor Syahirah Mat Piah

The objective of this paper to improve the design of the torchlight when holding the torchlight and to increase the durability of the torchlight against water by using the float materials. The torchlight also has been analysed using Design for Manufacturing Assembly (DFMA), Failure Modes and Effect Analysis (FMEA), and Sustainability Analysis in order to provide better product.

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Pollutant emission in diesel engine

2020-01-01 , Mohd Al-Hafiz Mohd Nawi , Mohd. Hazwan Mohd. Hanid , Wan Azani Wan Mustafa , Kasim M.S. , Raja Abdullah R.I.

As for the diesel engine, it is well known as one of the largest contributors to environmental pollution, which cause by exhaust emission. Therefore, due to the energy constraint, the rising cost of raw petroleum and environmental change with the expanding request for vitality preservation and environmental protection further enhancement in fuel adaptability and emission reduction in a diesel engine are direly required. The outflows framed are indigent upon the engine configuration, power yield and working burden. The complete ignition of fuel prompts real diminishments in the development of fumes discharges. Complete on combustion will leads a significant mechanical power for the vehicle, which is perfect on the air-fuel mixture. With a specific end goal to diminish NOx and PM arrangement it is important to comprehend the components of its development.

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Full Factorial Design Exploration Approach for Multi-Objective Optimization on the (FDM) 3D Printed Part

2020-09-21 , Mohd Haidiezul Jamal Ab Hadi , Mohd. Hazwan Mohd. Hanid , Soon Lee W. , Gunalan , Fatin Najihah N. , Fadhli I.

In the manufacturing industry, especially in automotive, quality, precision and productivity on the part that produces is crucial. 3D Printing technology offers a significant advantage to the manufacturer because its ability to produce complex geometry and low-cost investment risk compared with injection moulding. However, there are several issues of using this technology in mass scale and of the issue is dimensional accuracy. In this study, the application of optimisation approach which is Full Factorial Design (FFD) approach which has employed on 3D Printed bottom housing part made from Polylactic Acid (PLA) which were printed using Fused Deposition Modelling (FDM) 3D printer in order to minimise shrinkage on 3D printed parts. Based on the optimisation work, the results showed the performance of FFD approach provides a good dimensional accuracy compared to the drawing specification for the printed part. Therefore, this research provides beneficial scientific knowledge and alternative solution for the additive manufacturing process in industries application to enhance the quality of the 3D printed parts produced using FDM 3D printer machine.

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Studies on characteristic of glycerol-kenaf pellet via fluidization drying process toward energy produced

2020-03-25 , Zainuddin H.H.M. , Mohd Al-Hafiz Mohd Nawi , Kasim M.S. , Mohd. Hazwan Mohd. Hanid , Wan Azani Wan Mustafa , Nik Noriman Zulkepli , Dahham O.S.

Glycerol is a co-product compound of biodiesel production that have an interesting heating value. In this study, biomass which is Kenaf plant was mixed with the Glycerol that act as a binder and additives to produce a pellet for energy. Kenaf plant was dried using Sherwood M501 air fluid bed dryer before pelletizing. Air fluid bed dryer is one of the fluidization drying process that have potential to be widely used. The motivation for this study was the material used contain the high value of water and the lower bulk density of pellet. The purpose of this study are to determine the characteristic of Glycerol-Kenaf pellet with a various test. This study will focused on the percentage of Glycerol used, the bulk density of pellet, durability of pellet and the calorific value of pellet. During fluidization process the best condition for the properties of pellet, the pellet which contain 40% Glycerol, 40% Epoxy has been produce a good density and durability. The 50% Glycerol, 30% Epoxy give a high calorific value than 40% Glycerol, 40% Epoxy. Glycerol can react as a binder and additives. Glycerol help to increase the calorific value of the biomass pellet.

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Computational Fluid Dynamics Analysis of Varied Cross-Sectional Areas in Sleep Apnea Individuals across Diverse Situations

2024-01-01 , Faizal W.M. , Khor Chu Yee , Mohamad Suhaimi Shahrin , Mohd. Hazwan Mohd. Hanid , Masniezam Ahmad , Misbah M.N. , Haidiezul A.H.M.

Obstructive sleep apnea (OSA) is a common medical condition that impacts a significant portion of the population. To better understand this condition, research has been conducted on inhaling and exhaling breathing airflow parameters in patients with obstructive sleep apnea. A steady-state Reynolds-averaged Navier–Stokes (RANS) approach and an SST turbulence model have been utilized to simulate the upper airway airflow. A 3D airway model has been created using advanced software such as the Materialize Interactive Medical Image Control System (MIMICS) and ANSYS. The aim of the research was to fill this gap by conducting a detailed computational fluid dynamics (CFD) analysis to investigate the influence of cross-sectional areas on airflow characteristics during inhale and exhale breathing in OSA patients. The lack of detailed understanding of how the cross-sectional area of the airways affects OSA patients and the airflow dynamics in the upper airway is the primary problem addressed by this research. The simulations revealed that the cross-sectional area of the airway has a notable impact on velocity, Reynolds number, and turbulent kinetic energy (TKE). TKE, which measures turbulence flow in different breathing scenarios among patients, could potentially be utilized to assess the severity of obstructive sleep apnea (OSA). This research found a vital correlation between maximum pharyngeal turbulent kinetic energy (TKE) and cross-sectional areas in OSA patients, with a variance of 29.47%. Reduced cross-sectional area may result in a significant TKE rise of roughly 10.28% during inspiration and 10.18% during expiration.