Mohd Fathullah Ghazli@Ghazali
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Mohd Fathullah Ghazli@Ghazali
Official Name
Mohd Fathullah, Ghazli@Ghazali
Alternative Name
Fathullah, Mohd
Ghazli, Mohd
Ghazli, M. F.
Ghazali, Mohd Fathullah
Fathullah, G. M.
Main Affiliation
Scopus Author ID
57428935900
Researcher ID
AAK-5597-2020

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  • Publication
    Producing Metal Powder from Machining Chips Using Ball Milling Process: A Review
    ( 2023-07-01)
    Leong Kean Wei
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Yin A.T.M.
    ;
    Mohd Fathullah Ghazli@Ghazali
    ;
    Mohd Firdaus Omar
    ;
    Nemeș O.
    ;
    Sandu A.V.
    ;
    Vizureanu P.
    ;
    Abdellah A.E.h.
    In the pursuit of achieving zero emissions, exploring the concept of recycling metal waste from industries and workshops (i.e., waste-free) is essential. This is because metal recycling not only helps conserve natural resources but also requires less energy as compared to the production of new products from virgin raw materials. The use of metal scrap in rapid tooling (RT) for injection molding is an interesting and viable approach. Recycling methods enable the recovery of valuable metal powders from various sources, such as electronic, industrial, and automobile scrap. Mechanical alloying is a potential opportunity for sustainable powder production as it has the capability to convert various starting materials with different initial sizes into powder particles through the ball milling process. Nevertheless, parameter factors, such as the type of ball milling, ball-to-powder ratio (BPR), rotation speed, grinding period, size and shape of the milling media, and process control agent (PCA), can influence the quality and characteristics of the metal powders produced. Despite potential drawbacks and environmental impacts, this process can still be a valuable method for recycling metals into powders. Further research is required to optimize the process. Furthermore, ball milling has been widely used in various industries, including recycling and metal mold production, to improve product properties in an environmentally friendly way. This review found that ball milling is the best tool for reducing the particle size of recycled metal chips and creating new metal powders to enhance mechanical properties and novelty for mold additive manufacturing (MAM) applications. Therefore, it is necessary to conduct further research on various parameters associated with ball milling to optimize the process of converting recycled copper chips into powder. This research will assist in attaining the highest level of efficiency and effectiveness in particle size reduction and powder quality. Lastly, this review also presents potential avenues for future research by exploring the application of RT in the ball milling technique.
      1  11
  • Publication
    Removal of Cu from Printed Circuit Board (PCBs) Leachates using Activated Carbon Derived from Foxtail Palm Fruit
    ( 2020-09-22)
    Maizatul N.N.
    ;
    Mohd Fathullah Ghazli@Ghazali
    ;
    Nik Yusoff N.R.
    Printed circuit boards (PCBs) are the e-waste generated from the end-of-life electronic equipment such as laptops and mobile phone. PCBs contain relatively abundant of valuable metals such as gold and platinum. However, e-waste is considered as an environmental contaminant as it consists plenty of hazardous materials such as cadmium and copper which can pose health threat to human and also environment. It has been reported that PCBs contain a large amount of copper (Cu) in the circuit boards as it is used as a base metal. Moreover, exposure to Cu will lead to adverse impact of human health. Therefore, the objective of the study is to determine the Cu concentration using FAAS and also to remove the Cu from PCBs leachate using activated carbon derived from foxtail palm fruits. In order to remove the Cu, hydrometallurgical process on PCBs will be conducted to leach the metal into solution. Once the metal has been leached to the solution, the metal removal process using activated carbon through adsorption process was conducted. In this study, foxtail palm fruit was tested as an effective low-cost adsorbent for Cu removal. The effect of adsorbent dosage (1 g and 5 g) with fix contact time (40 min) of the prepared activated carbon in selected metal removal were investigated. The Cu in PCBs leachate solution before and after metal removal process were quantified using flame atomic absorption spectrophotometer (FAAS). Result obtained showed that, the percentage removal of Cu was recorded to be higher at high adsorbent dosage which was 14.417% in 5 g dose and 11.219% in 1 g dose. Thus, it can be concluded that the higher the adsorbent dosage used, the greater the percentage removal of Cu metal.
      21  1
  • Publication
    Warpage optimisation using recycled polycar-bonates (PC) on front panel housing
    ( 2021-03-02)
    Tamizi N.A.M.A.
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Abdellah A.E.H.
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Nabiałek M.
    ;
    Wysłocki J.J.
    ;
    Jeż B.
    ;
    Palutkiewicz P.
    ;
    Rozyanty Rahman
    ;
    Mohd. Nasir Mat Saad
    ;
    Mohd Fathullah Ghazli@Ghazali
    Many studies have been done using recycled waste materials to minimise environmental problems. It is a great opportunity to explore mechanical recycling and the use of recycled and virgin blend as a material to produce new products with minimum defects. In this study, appropriate processing parameters were considered to mould the front panel housing part using R0% (virgin), R30% (30% virgin: 70% recycled), R40% (40% virgin: 60% recycled) and R50% (50% virgin: 50% recycled) of Polycarbonate (PC). The manufacturing ability and quality during preliminary stage can be predicted through simulation analysis using Autodesk Moldflow Insight 2012 software. The recommended processing parameters and values of warpage in x and y directions can also be obtained using this software. No value of warpage was obtained from simulation studies for x direction on the front panel housing. Therefore, this study only focused on reducing the warpage in the y direction. Response Surface Methodology (RSM) and Genetic Algorithm (GA) optimisation methods were used to find the optimal processing parameters. As the results, the optimal ratio of recycled PC material was found to be R30%, followed by R40% and R50% materials using RSM and GA methods as compared to the average value of warpage on the moulded part using R0%. The most influential processing parameter that contributed to warpage defect was packing pressure for all materials used in this study.
      2
  • Publication
    Product defect prediction model in food manufacturing production line using multiple regression analysis (MLR)
    ( 2021-07-21)
    Illa I.N.
    ;
    Tan Chan Sin
    ;
    Fadzli R.
    ;
    Safwati Ibrahim
    ;
    Rosmaini Ahmad
    ;
    Mohd Fathullah Ghazli@Ghazali
    This paper aims to develop an improved general mathematical model by focusing on human factors variables that related to the product defect in the manufacturing production line. This is because many studies found that almost 40% of total defects resulted from the operator error and the defects are usually not obvious and neglected. The objective to have defect prediction mathematical model to satisfy as early quality indicator of the manufacturing flow production line and assist the quality control team in manufacturing industries. Thus, the human factor variables will be investigate thoroughly and final model can be used to predict product defect on the line to improve product quality. Product defects quantity are identified and analyzed to determine the potential predictors for developing the mathematical model. A case study is offered that illustrates in a spice packaging semi-automated production line the effect that complexity variables have on assembly quality. By using Minitab, Multiple Regression analysis is conducted to model the relationship between the input variables towards response variables. From the analysis, the predicted data showed reasonable correlation with the observed data improved with adjusted R-Sq from 2.6% to 7.9%. Hence, the regression equation obtain is selected to be the prediction mathematical model for defects based on human factor input variables.
      1  12
  • Publication
    Recent developments in fire retardant glass fibre reinforced epoxy composite and geopolymer as a potential fire-retardant material: A review
    ( 2021-03-29)
    Shahari S.
    ;
    Mohd Fathullah Ghazli@Ghazali
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Mia M.
    ;
    Budi Darmawan V.E.
    Glass fibre reinforced epoxy composites have been used in building area (cold store construction), aeroplanes, land and water vehicles, etc., due to their high-specific rigidity and strength, high damping, great resistance to corrosion, and inferior thermal expansion. Unfortunately, epoxy is flammable whilst releasing a substantial amount of smoke and gases, and therefore presenting a possible risk to lives as well as property. The reduction of their fire risks is normally fulfilled by enhancing the fire performance of composite components including the incorporation of fire retardant (FR) into the polymer matrix and by providing protective FR coatings around the composite. To date, two types of FR have been incorporated into the composite system including additive and reactive FR to improve the fire performance of the composite. This review focuses on the research works over the last ten years in improving fire retardancy of glass fibre reinforced epoxy composite through the incorporation of both types of FR. This work also summarises research works regarding geopolymer which is applied on enhancing fire retardancy of epoxy-based material. Finally, this work presents some future research opportunities as regards to the potential of geopolymer to be utilised as one of FRs to improve fire retardancy of glass fibre reinforced epoxy composite.
      2
  • Publication
    Optimisation of shrinkage and strength on thick plate part using recycled ldpe materials
    ( 2021-04-01)
    Roslan N.
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Abdellah A.E.H.
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Błoch K.
    ;
    Pietrusiewicz P.
    ;
    Nabiałek M.
    ;
    Szmidla J.
    ;
    Kwiatkowski D.
    ;
    Vasco J.O.C.
    ;
    Mohd. Nasir Mat Saad
    ;
    Mohd Fathullah Ghazli@Ghazali
    Achieving good quality of products from plastic injection moulding processes is very challenging, since the process comprises many affecting parameters. Common defects such as warpage are hard to avoid, and the defective parts will eventually go to waste, leading to unnecessary costs to the manufacturer. The use of recycled material from postindustrial waste has been studied by a few researchers. However, the application of an optimisation method by which to optimise processing parameters to mould parts using recycled materials remains lacking. In this study, Response Surface Methodology (RSM) and Particle Swarm Optimisation (PSO) methods were conducted on thick plate parts moulded using virgin and recycled low-density polyethylene (LDPE) materials (100:0, 70:30, 60:40 and 50:50; virgin to recycle material ratios) to find the optimal input parameters for each of the material ratios. Shrinkage in the x and y directions increased in correlation with the recycled ratio, compared to virgin material. Meanwhile, the tensile strength of the thick plate part continued to decrease when the recycled ratio increased. R30 (70:30) had the optimum shrinkage in the x direction with respect to R0 (100:0) material where the shrinkage increased by 24.49% (RSM) and 33.20% (PSO). On the other hand, the shrinkage in the y direction for R30 material increased by 4.48% (RSM) and decreased by 2.67% (PSO), while the tensile strength of R30 (70:30) material decreased by 0.51% (RSM) and 2.68% (PSO) as compared to R0 (100:0) material. Validation tests indicated that the optimal setting of processing parameter suggested by PSO and RSM for R0 (100:0), R30 (70:30), R40 (60:40) and R50 (50:50) was less than 10%.
      2
  • Publication
    Evaluation of shrinkage and weld line strength of thick flat part in injection moulding process
    ( 2021-10-01)
    Nasir S.M.
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Sharif S.
    ;
    Abdellah A.E.h.
    ;
    Mohd Fathullah Ghazli@Ghazali
    ;
    Nik Noriman Zulkepli
    This paper evaluates the shrinkage and strength of weld line using Design of Experiment and Response Surface Methodology in multi-objective optimisation utilising the injection moulding parameters. A simulation process was conducted to determine the recommended setting of injection moulding parameters and the range of the variable parameters. An experimental work was conducted according to the experimental design, where regression models were established to predict the shrinkage and weld line strength. A new set of process parameters setting was found to achieve the optimum shrinkage and weld line strength of the moulded part. The results of shrinkage and weld line strength using an optimal parameter setting after optimisation process were compared with the results obtained using the recommended setting from Autodesk Moldflow Insight software. It was found that the shrinkages in the normal to and parallel to the melt flow directions were reduced by 5.969% and 4.375%, respectively, through the predicted model generated using RSM. On the other hand, the weld line strength improved by 3.758% as compared to the weld line strength obtained from the recommended setting. The shrinkages in both parallel to and normal to the melt flow directions using multi-objective optimisation were reduced by 5.891% and 4.160%, respectively, while the weld line strength was improved by 3.756%, using the combination of the following parameters; 69.93 °C of coolant inlet temperature, 270 °C of melt temperature, 70 MPa of packing pressure and 8 s of cooling time. The predicted errors ranged between 0.2 and 14.5% during the validation experiments. The packing pressure was found to be the most significant parameter affecting the shrinkage in both parallel to and normal to melt flow directions. The coolant inlet temperature on the other hand was the most significant parameter affecting the weld line strength.
      15  1