Muhammad Syamil Zakaria
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Muhammad Syamil Zakaria
Official Name
Muhammad Syamil, Zakaria
Alternative Name
Zakaria, Muhammad Syamil
Zakaria, M. S.
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Scopus Author ID
57204783753

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  • Publication
    Chip morphology and surface integrity in turning AZ31 magnesium alloy under dry machining and submerged convective cooling
    ( 2023)
    Muhammad Syamil Zakaria
    ;
    Mazli Mustapha
    ;
    Azwan Iskandar bin Azmi
    ;
    Khor Chu Yee
    Magnesium alloys have broad applications, including medical implants and the aerospace sector owing to their great density and high strength-to-weight ratio. Dry cutting is a frequent technique for machining this material. However, it always leads to an excessive rise in temperature due to the absence of cooling at the cutting zone, which affects the machined surface integrity and chip morphology. In this study, chip morphology and surface integrity of the AZ31 magnesium alloy were investigated in the turning process using an internal cooling method called submerged convective cooling (SCC) to overcome the absence of cooling in dry cutting. This method can exploit the advantage of the high specific heat capacity of water as a cooling fluid without any reaction between water and magnesium to create a cooling element in the cutting zone. The chip morphologies and surface integrity were analyzed experimentally with varying cutting speeds under SCC and dry cutting. The experimental results revealed that SCC and dry cutting produced saw-tooth or serrated chip formation. The chips produced in dry cutting were continuous, while SCC was short and discontinuous as a result of a severe crack on the back surface of the chip. It was discovered that the grain refinement layer on the machined samples was thinner under SCC turning. SCC machining increased the microhardness of the AZ31 magnesium alloy by 60.5% from 55 HV to 88.3 HV, while dry turning exhibited a 49% increase in microhardness. The result revealed that surface roughness improved by 10.8%, 9.4% and 4.7% for cutting speeds (V) of 120, 180, and 240 m/min, respectively, under the SCC internal cooling. Based on the result obtained, SCC cutting outperformed dry cutting in terms of chip breakability, grain refinement, microhardness, and surface roughness.
      29  1
  • Publication
    CFD Simulation of Fluid Flow and Heat Transfer of Internal Cooling Channels for Turning Tool
    (Universiti Malaysia Perlis, 2024-12-02)
    Nazmin Ikbar Mohd Piterah
    ;
    Muhammad Syamil Zakaria
    The internal-cooling approach emerged as an alternative in sustainable machining practices due to its multiple benefits. Cooling channels have been applied to cutting inserts to remove heat concentrated in a small area during machining. As a result, these cooling channels are critical in lowering tool temperatures and wear rates. The design of the cooling channel influences the effectiveness of heat management. In the present study, three types of cooling channel designs have been developed to investigate the cooling effect on the insert from the variety of cooling channel profiles. Computational Fluid Dynamics (CFD) is utilized to simulate the cooling effect for all profiles. A temperature reduction has been observed for the internally cooled cutting insert compared to the conventional tool without a cooling channel. The temperature difference is observed when the profile of the channel is varied. In addition, the coolant profile has been observed to be more effective in heat removal when the inlet pressure of the cutting fluid is increased. Through the velocity vector results, it has been determined that the heat transfer rate increases as the flow velocity of coolant within the channel increases. The Turbulence Kinetic Energy (TKE) simulation's value shows that a heat transfer rate enhancement is attained by elevating the TKE value, which depends on the configuration of the coolant flow channel.
      20  3