Zailani Zainal Abidin
Thumbnail Image
Preferred name
Zailani Zainal Abidin
Official Name
Zailani, Zainal Abidin
Alternative Name
Zailani, Zainal A.
Zailani, Z. A.
Zailani, Zainal Abidin
Main Affiliation
Scopus Author ID
57214460223
Researcher ID
CKM-8563-2022

Research Output

Filters

24 1
9 2
24
Reset filters

Settings
Now showing 1 - 10 of 24
  • Publication
    Effect of tool engagement on cutting force for different step over in milling aisi p20 tool steel
    ( 2021-01-01)
    Roshaliza Hamidon
    ;
    Mohamed N.I.
    ;
    Saravanan R.
    ;
    Azmi H.
    ;
    Zailani Zainal Abidin
    ;
    Mohd Fathullah Ghazli@Ghazali
    In mold production, end milling with tool path strategies is required for the process known as pocket operation. Different step overs involve depending on the type of tool path strategy used. Thus, different engagement will occur and leads to fluctuation of cutting force due to different step over during the process. However, most of study before focused on the effect of cutting speed, feed rate and depth of cut only in machining AISI P20. Thus, in this study, step over will be considered as one of the factor to improve machining force. The objective of this study are to evaluate the effect of cutting parameters and step over on cutting force and to study the behavior of cutting force for different tool engagement. A series of milling operation was carried out by varying cutting speed and feed rate. However, the depth of cut was set to 0.25 mm for each run. Step over with 100%, 75% and 50% were selected in this study. L27 Taguchi and S/N ratio were used to determine the significant factors that influence the result. Within the range of cutting parameters selected, feed rate were found to be the most significant parameters that influence cutting force. The highest cutting force found for 100% step over compared to 75% and 50% step over. According to the result, cutting force increased as the step over increased. In can be concluded that, step over is one of the important cutting parameter that affected machining output.
  • Publication
    Investigation on delamination factor (Fd) of kenaf fibre reinforced plastic composite materials under drilling process
    ( 2024-03-07)
    Azmi Harun
    ;
    Hassan C.H.C.
    ;
    Mohd Al-Hafiz Mohd Nawi
    ;
    Zailani Zainal Abidin
    Natural Fibre Reinforced Plastic Composite material that the Kenaf Fibre are used to reinforce to the polymer matrix to improve its mechanical properties. It is environmentally friendly and low cost as compare to non-biodegradable material. It is also widely used in Aerospace, Automotive and Furniture industry. Drilling process plays an important role in fabrication in these industries. However, some defects often occur on the Natural Fibre Reinforced Plastic Composite during drilling process. The major damage is delamination that are found on the surface of the composite in drilling process. This damage reduces the mechanical properties of the composite. Therefore, the objective of this study is to investigate and minimize the delamination by using Response Surface Methodology (RSM). Cutting speed and feed rate are found significant to delamination in this study. The higher the previous researchers investigate the cutting speed with low feed rate, the lower the delamination. Therefore, the conclusion of this study is high cutting speed with low feed rate improve the mechanical quality of composite.
  • Publication
    Machinability of nickel-titanium shape memory alloys under dry and chilled air cutting conditions
    ( 2023-06-01)
    Zailani Zainal Abidin
    ;
    Mativenga P.T.
    Nickel-titanium (NiTi) shape memory alloys (SMAs) undergo phase transformation between austenitic and martensitic phases in response to applied thermal or mechanical stress, resulting in unique properties and applications. However, machinability often becomes challenging due to property and temperature sensitivity attributes. The use of chilled air to influence machinability in macro-milling was investigated in this study. Other than that, differential scanning calorimetry (DSC) was used to determine the temperature of phase transformation. The results showed that milling with chilled air and minimal lubrication significantly improved machining performance by reducing tool wear and burr formation. Moreover, surface quality has also improved significantly. A notable discovery is that the machining process can change the critical conditions for phase transition, enabling new performance capability of tuning material hysteresis.
  • Publication
    Tribological Behaviour of Graphene Nanoparticles as an Additive in Vegetable Based Oil
    ( 2024-04-19)
    Noor N.Z.M.
    ;
    Zailani Zainal Abidin
    ;
    Zain M.Z.M.
    ;
    Norshah Aizat Shuaib
    Friction between cutting tool and workpiece generates heat, which can shorten tool life and impair the quality of machined parts. Thus, the use of appropriate lubricants is required to mitigate these issues. In this research, the use of different weight concentration of graphene nanoparticles (0.1 %, 0.5 % and 1.0 %) to augment commercially available vegetable-based oil, LB3000 was investigated using tribological test. Their performances were evaluated in form of the coefficient of friction, wear scar diameter, kinematic viscosity and thermal conductivity. Higher concentration of graphene was found to be more effective in terms of lowering coefficients of friction, reducing wear scar diameter, and improving kinematic viscosity and thermal conductivity. This study clearly demonstrates that a suitable combination of graphene nanoparticles in oil can improve tribological behaviour as well as lubrication performance.
  • Publication
    Effect of milling parameter and fiber pull-out on machinability kenaf fiber reinforced plastic composite materials
    ( 2021-01-01)
    Azmi H.
    ;
    Haron C.H.C.
    ;
    Roshaliza Hamidon
    ;
    Zailani Zainal Abidin
    ;
    Lih T.C.
    ;
    Yuzairi A.R.
    ;
    Sanusi H.
    Milling surface quality normally depends on the value of surface roughness and delamination factor. The milling parameters, which are cutting tool geometry and fiber pull-out, are the major factors affecting the value of surface roughness and delamination factor in milling kenaf fiber reinforced plastic composite. The objectives of this research are to study the effects of milling parameters, to evaluate the fiber behavior, and to determine the optimum conditions for a range of milling parameters in order to minimize surface roughness (Ra) and delamination factor (Fd) using response surface methodology (RSM). RSM with central composite design (CCD) approach was used to conduct a non-sequential experiment and analyzed the data from the measurements of surface roughness and delamination factor. This study focused on the investigation of relationship between the milling parameters and their effects on kenaf reinforced plastic composite materials during cutting process. Kenaf composite panels were fabricated using vacuum assisted resin transfer molding (VARTM) method that was pressurized below 15 psi using a vacuum pressure. The results showed that the optimum parameters for better surface roughness and delamination factor were cutting speed of 16 Vm/min, feed rate of 0.1 mm/tooth, and depth of cut of 2.0 mm. The feed rate and cutting speed are expected to be the biggest contributors to surface roughness and delamination factor. Finally, different cutting tool geometries also influenced the fiber pull-out that affect surface roughness and delamination factor in milling kenaf fiber reinforce plastic composite materials.
  • Publication
    Experimental investigation on the microdefects formation due to the electrical discharge coating process: A fractional factorial design
    ( 2024-03-07)
    Ahmad Fairuz Mansor
    ;
    Azwan Iskandar Azmi
    ;
    Zailani Zainal Abidin
    ;
    Zain M.Z.M.
    Electrical discharge coating (EDC) is a well-known technique among researchers for modification of metallic surfaces. This process is capable of producing a hard coating layer, biocompatible and high corrosion resistance at low operating cost. Unfortunately, the process develops unfavourable microcracks and porosity on the substrate surface attributed by heat generation. Thus, in this study, the effect of several parameters to the microdefects' formation was investigated through an experimental work based on fractional factorial design. This work was conducted on a nickel-titanium (NiTi) shape memory alloy by varying the EDC parameters, namely; polarity, discharge duration, peak current, pulse interval, gap voltage and additive Ti nano powder concentration in deionized water (DI water). ANOVA results exhibited that the discharge duration has dominated the microcracks and porosity fraction on the substrate surface due to the impact of high intensity of discharge energy. Although, the Ti nano powder mixed in the DI water had capability to reduce the microcracks formation, the porosity fraction during at high gap voltage setting was elevated with the Ti nano powder mixed.
  • Publication
    Optimisation of cutting performance in drilling of aluminium alloy 7075 involving chilled air cooling under Taguchi method
    (Semarak Ilmu Publishing, 2025)
    Muhammad Hisyamuddin Rosli
    ;
    Zailani Zainal Abidin
    ;
    Norshah Afizi Shuaib
    ;
    Muhammad Zikry Zainuddin
    ;
    Adel Ali Azawqari
    The use of lightweight Aluminium Alloy 7075 (AA7075) in aerospace and automotive industries is increasing due to its exceptional properties, such as high strength, good fatigue resistance, and excellent strength-to-weight ratio. However, this alloy is difficult to machine due to high ductility and heat generation during cutting. Cutting fluids are commonly used to deal with these problems, although they raise environmental concerns. The research aims to enhance drilling efficiency for AA7075, considering environmental impacts, through a greener method, a chilled air system. Their impact on tool wear and cutting force was evaluated through spindle speed, feed rate, and nozzle types by adopting the Taguchi method. Chisel edge wear was discovered to be a major contributor to tool wear. Lower feed rate and slower spindle speed using dual nozzle yielded better tool wear and cutting force performance. These findings provide feasible recommendations for industry practitioners seeking to employ eco-friendly chilled air systems to achieve optimal drilling efficiency for this type of material.
  • Publication
    Effect of Small Corner Radius in Cold Punching of 22MnB5 Die-Quenched Boron Steel Sheets
    ( 2022-01-01)
    Jaafar H.
    ;
    Tajul L.
    ;
    Zamzuri M.
    ;
    Zailani Zainal Abidin
    ;
    Murad M.N.
    ;
    Hamedon Z.
    The effect of small corner radius in punching process of ultra-high strength category of steel i.e. 22MnB5 die-quenched boron steel was investigated. Although the die-quenched steel sheet can reach superior strength of above 1500 MPa, the ductility of the steel sheet is low, making punching process totally challenging. Punching of hole at 22MnB5 boron steel commonly carried out in hot condition prior to die-quenching and usually needed for complex tools for preheating, punching, transferring, and cooling the part. Inaccurate of hole dimension after quenching is inevitable due to the change of grain structure during cooling. In this study, a pre-hardened 22MnB5 boron steel sheet is punched under a small clearance in a normal cold condition. The small corner radius disperses the stress concentration at the punch edge and thus increases the material flow during initial stage of the punch penetration. The action of small clearance between punch and die reduce the tensile stress and therefore, the initiation of crack is delayed. The quality of the sheared edge surface was improved with the high percentage of area cover with the burnished surface.
      2  21
  • Publication
    Chilled Air System and Size Effect in Micro-milling of Nickel−Titanium Shape Memory Alloys
    ( 2020-03-01)
    Zailani Zainal Abidin
    ;
    Tarisai Mativenga P.
    ;
    Harrison G.
    Although Nickel-Titanium Shape Memory Alloys (NiTi SMAs) are used in a variety of applications due to their shape memory and superelasticity properties, their features of high ductility, temperature sensitivity, and strong work hardening render these materials difficult to machine. The viability of a new approach in improving the machinability through temperature control using chilled air system application was investigated. Differential scanning calorimetry was used to characterise material response to thermal loads. Microstructure phase identification was evaluated with X-ray diffraction. Micro-milling tests were performed using chilled air system and benchmarked to dry cutting and the use of minimum quantity lubricant (MQL). To augment lubrication, chilled air was also applied concurrently with MQL. Results indicated that the application of chilled air reduced cutting temperature and minimised burr height, while their simultaneous application with MQL further improved the machinability. Further investigation was conducted to explore the influence of the ploughing mechanism on machining performance and product quality. The results pointed to higher feed per tooth producing better outcomes. This paper puts forward a new hypothesis that the machinability could be improved by inhibiting or locking in phase transformation through temperature control, and optimising chip thickness, one of the principal parameters of size effect.
      1  18
  • Publication
    Influence of Size Effect on Cutting Edge Rounding and Surface Roughness in Micro-Milling of Ti-6Al-4V
    ( 2020-07-09)
    Fakirin Ismail I.
    ;
    Norshah Afizi Shuaib
    ;
    Zailani Zainal Abidin
    ;
    Abdul Rahim I.
    ;
    Heinemann R.
    The quality of cutting depends most on the cutting tool condition. Towards having a good quality finish, cutting tolerance becomes a major concern, especially when machining at micro-scale where highly precise cutting is desired. This research investigates the size-effect during the micro-milling of Ti-6Al-4V under dry condition where the observations were made on cutting edge rounding (CER) and workpiece surface roughness. The result showed that the lower the feed rate, the greater rounding on the cutting edges were observed. Similar trend in result was obtained when measuring the surface roughness. The best feed rate for both observations was at 60 mm/min, where this setting has brought the mechanism to shearing, as the ratio between undeformed chip thickness and cutting edge radius started at 1.
      2  20