Mohd Fathullah Ghazli@Ghazali
Thumbnail Image
Preferred name
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

Research Output

Filters

4
4
Reset filters

Settings
Now showing 1 - 4 of 4
Thumbnail Image
Publication

Producing metal powder from machining chips using ball milling process: a review

2023 , Leong Kean Wei , Shayfull Zamree Abd. Rahim , Mohd. Mustafa Al Bakri Abdullah , Allice Yin , Mohd Fathullah Ghazli@Ghazali , Mohd Nazri Omar , Ovidiu NemeÈ™ , Andrei Sandu , Petrica Vizureanu , Abdellah Abdellah

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.

View
Thumbnail Image
Publication

Warpage optimisation using Recycled Polycar-bonates (PC) on Front Panel Housing

2021 , Nur Aisyah Miza Ahmad Tamizi , Shayfull Zamree Abd. Rahim , Abdellah El-hadj Abdellah , Mohd. Mustafa Al Bakri Abdullah , Marcin Nabiałek , Jerzy J. Wysłocki , Bartłomiej Jeż , Paweł Palutkiewicz , Rozyanty Abdul 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.

View
Thumbnail Image
Publication

Optimisation of shrinkage and strength on thick plate part using recycled LDPE materials

2021 , Norshahira Roslan , Shayfull Zamree Abd. Rahim , Abdellah El-hadj Abdellah , Mohd. Mustafa Al Bakri Abdullah , Katarzyna Błoch , Paweł Pietrusiewicz , Marcin Nabiałek , Janusz Szmidla , Dariusz Kwiatkowski , Joel Oliveira Correia Vasco , 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%.

View
Thumbnail Image
Publication

Warpage optimisation using recycled Polycar-bonates (PC) on front panel housing

2021 , Nur Aisyah Miza Ahmad Tamizi , Shayfull Zamree Abd. Rahim , Abdellah El-hadj Abdellah , Mohd. Mustafa Al Bakri Abdullah , Marcin Nabiałek , Jerzy J. Wysłocki , Bartłomiej Jeż , Paweł Palutkiewicz , Rozyanty Abdul 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.

View