Mohd Fathullah Ghazli@Ghazali
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Mohd Fathullah Ghazli@Ghazali
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Mohd Fathullah, Ghazli@Ghazali
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Fathullah, Mohd
Ghazli, Mohd
Ghazli, M. F.
Ghazali, Mohd Fathullah
Fathullah, G. M.
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57428935900
Researcher ID
AAK-5597-2020

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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%.

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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 Nemeș , 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.

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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.

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Elektronik asas : untuk pelajar mekanikal

2015 , Amarul Talip , Mohd Sazli Saad , Mohd Fathullah Ghazli@Ghazali , Nur Ismalina Haris

Buku ini mengandungi lapan (8) bab kesemuanya di mana ia telah disusun dan mencakupi bab-bab asas yang penting untuk membentuk satu ilmu asas Teknologi Elektrik yang lengkap untuk para pelajar Kejuruteraan Mekanikal. Antara bab-bab tersebut ialah, Asas Kejuruteraan Elektrik, Litar Arus Terus, Litar Arus Ulang-alik, Sistem Tiga Fasa, Elektromagnetik, Pengubah, Mesin Arus Terus dan Mesin Pearuh Tiga Fasa. Di samping itu, buku ini juga diharapkan dapat menjadi rujukan para pelajar dari politeknik khasnya dan institusi pengajian tinggi amnya kerana bilangan buku-buku rujukan yang terdapat dalam Bahasa Melayu adalah terhad. Dalam usaha untuk menambah bilangan buku-buku rujukan yang ditulis dalam Bahasa Melayu, penghasilan buku ini diharapkan dapat membantu pelajar Kejuruteraan khususnya Kejuruteraan Mekanikal untuk lebih memahami dan menguasai Asas Teknologi Elektrik.

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Tool wear and surface evaluation in drilling fly ash geopolymer using HSS, HSS-Co, and HSS-TiN cutting tools

2021 , Mohd Fathullah Ghazli@Ghazali , Mohd. Mustafa Al Bakri Abdullah , Shayfull Zamree Abd. Rahim , Joanna Gondro , Paweł Pietrusiewicz , Sebastian Garus , Tomasz Stachowiak , Andrei Victor Sandu , Muhammad Faheem Mohd. Tahir , Mehmet Erdi Korkmaz , Mohamed Syazwan Osman

This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications

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Geopolymer ceramic application: a review on mix design, properties and reinforcement enhancement

2022 , Nurul Aida Mohd Mortar , Mohd. Mustafa Al Bakri Abdullah , Rafiza Abdul Razak , Shayfull Zamree Abd. Rahim , Ikmal Hakem Aziz , Marcin Nabiałek , Ramadhansyah Putra Jaya , Augustin Semenescu , Rosnita Mohamed , Mohd Fathullah Ghazli@Ghazali

Geopolymers have been intensively explored over the past several decades and considered as green materials and may be synthesised from natural sources and wastes. Global attention has been generated by the use of kaolin and calcined kaolin in the production of ceramics, green cement, and concrete for the construction industry and composite materials. The previous findings on ceramic geopolymer mix design and factors affecting their suitability as green ceramics are reviewed. It has been found that kaolin offers significant benefit for ceramic geopolymer applications, including excellent chemical resistance, good mechanical properties, and good thermal properties that allow it to sinter at a low temperature, 200 °C. The review showed that ceramic geopolymers can be made from kaolin with a low calcination temperature that have similar properties to those made from high calcined temperature. However, the choice of alkali activator and chemical composition should be carefully investigated, especially under normal curing conditions, 27 °C. A comprehensive review of the properties of kaolin ceramic geopolymers is also presented, including compressive strength, chemical composition, morphological, and phase analysis. This review also highlights recent findings on the range of sintering temperature in the ceramic geopolymer field which should be performed between 600 °C and 1200 °C. A brief understanding of kaolin geopolymers with a few types of reinforcement towards property enhancement were covered. To improve toughness, the role of zirconia was highlighted. The addition of zirconia between 10% and 40% in geopolymer materials promises better properties and the mechanism reaction is presented. Findings from the review should be used to identify potential strategies that could develop the performance of the kaolin ceramic geopolymers industry in the electronics industry, cement, and biomedical materials.

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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%.

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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.

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Publication

Tool wear and surface evaluation in drilling fly ash geopolymer using HSS, HSS-Co, and HSS-TiN cutting tools

2021 , Mohd Fathullah Ghazli@Ghazali , Mohd. Mustafa Al Bakri Abdullah , Shayfull Zamree Abd. Rahim , Joanna Gondro , Paweł Pietrusiewicz , Sebastian Garus , Tomasz Stachowiak , Andrei Victor Sandu , Muhammad Faheem Mohd. Tahir , Mehmet Erdi Korkmaz , Mohamed Syazwan Osman

This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications.

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Thermal insulation and mechanical properties in the presence of glas bubble in fly ash geopolymer paste

2021 , Noor Fifinatasha Shahedan , Mohd. Mustafa Al Bakri Abdullah , Norsuria Mahmed , Liew Yun Ming , Shayfull Zamree Abd. Rahim , Ikmal Hakem A Aziz , Aeslina Abdul Kadir , Andrei Victor Sandu , Mohd Fathullah Ghazli@Ghazali

The density, compressive strength, and thermal insulation properties of fly ash geopolymer paste are reported. Novel insulation material of glass bubble was used as a replacement of fly ash binder to significantly enhance the mechanical and thermal properties compared to the geopolymer paste. The results showed that the density and compressive strength of 50% glass bubble was 1.45 g/ ely, meeting the standard requirement for structural concrete. Meanwhile, the compatibility of 50% glass bubbles tested showed that the thermal conductivity (0.898 W/mK), specific heat (2.141 MJ/m3 K), and thermal diffusivity(0.572 mm2/s) in meeting the same requirement. The improvement of thermal insulation properties revealed the potential use of glass bubbles as an insulation material in construction material

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