Journal of Advanced Manufacturing Technology (JAMT)

Table of Content Vol 18 No 3 (2024)

M.H.F. Md Fauadi — 2024-12-23

Table of Content Vol 18 No 3 (2024)

EFFECT OF PROCESS PARAMETERS ON TENSILE STRENGTH OF 3D PRINTED PLA PARTS

N.P. Lee — 2024-12-23

Additive Manufacturing (AM), known as 3D printing, has transformed industrial production through precise layer-by-layer material deposition. However, the primary issue often encountered during the fabrication of parts using Fused Deposition Modeling (FDM) is the inferior mechanical characteristics resulting from processing parameters. This study investigates the effect and interaction of various process parameters (infill density, temperature, layer height) on the tensile strength of 3D-printed PLA parts using Analysis of Variance (ANOVA). Utilizing a fractional factorial design, four-parameter runs with three factors at two levels each were created. The main plot effect indicates that infill density and print temperature are the most significant factors, and the interaction plots reveal a notable correlation between printing temperature and layer height. A linear regression model has been developed to predict the tensile strength. The selected process parameters influence the strength, but only infill density (85.03%) and print temperature (8.8%) are statistically significant. The microstructure analysis showed a good agreement between the experimental and statistical data, where 100% infill density at different temperatures and layer height settings offer excellent interlayer adhesion and fewer voids than the 50% infill density. The presented methodology can be used as a pre-processing approach to optimize desired mechanical properties in material extrusion 3D printing.

NOVEL FOUR-DIMENSIONAL PRINTING OF 3D-PRINTED ABS VIA ELECTRON BEAM IRRADIATION

M.I. Shueb — 2024-12-23

The proliferation of electronic devices has given rise to electromagnetic interference (EMI), which can cause malfunction in electronic devices and disrupt wireless communication systems. Polymers in their pure form exhibit limited EMI shielding properties due to their inherently low electrical conductivity. A promising approach to address this limitation is found in four-dimensional (4D) printing, which can manipulate the intrinsic characteristics of 3D-printed objects in response to external stimuli, such as electron beam (EB) irradiation. This paper investigated the effects of electron beam irradiation (0, 125, 250 kGy) on the thermal, electrical, and mechanical properties of 3D-printed ABS samples. In addition, it evaluates the influence of EB irradiation on the shielding effectiveness (SE). Both tensile strength and modulus showed a slight decrease with the increase of EB dosage. Contrarily, thermogravimetric analysis (TGA) results indicated an improvement in thermal stability with EB irradiation. EB irradiation causes polymer chains to undergo chain scission, where the polymer backbone is broken, leading to a decrease in the mechanical properties. While chain scission might reduce tensile strength due to a weakened polymer structure, it may simultaneously increase thermal stability because shorter polymer chains are less susceptible to degradation at elevated temperatures. Moreover, a slight increase in SE value at a certain frequency is observed in the EB irradiated 3D-printed ABS. The increase in SE might be attributed to the decrease in porosity due to formation of crosslinked networks induced by EB radiation. The findings suggest that both crosslinking and chain scission take place upon EB irradiation of 3D printed ABS in this particular dosage range. Most significantly, this study demonstrates a promising method for improving the properties of 3D printed ABS intended for use in EMI shielding applications.

OPTIMIZATION OF SINGLE POINT INCREMENTAL FORMING (SPIF) PROCESS PARAMTERS ON SPRINGBACK OF DISSIMILAR FRICTION STIR WELDED ALUMINIUM ALLOYS BLANK USING TAGUCHI METHOD

K.A.H.A. Razak — 2024-12-23

Single-point incremental forming (SPIF) is a die-free sheet metal-forming approach where various profiles can be produced distinctively. However, geometrical defects such as a springback occur during the process and are difficult to control, hence causing assembly errors. This issue becomes more critical for sheets that consist of dissimilar metal joints joined together using the friction stir welding process. This paper investigated the effect of single-point incremental forming (SPIF) parameters such as rotational speed, feed rate, step size, and wall angles on the springback. In this study, a truncated cone profile made of AA 6061 and AA 5052 was studied. The Taguchi method was utilised to identify the most significant effects and optimal SPIF process parameters. The results showed that the wall angle had the most significant effect on the springback compared to others. Based on the ANOVA, the percentage contribution of wall angle was the highest for both sides, which are 93.63% and 89.68%, respectively, compared to other parameters.

THE INFLUENCE OF LASER POWER AND SCAN SPEED ON THE MICROSTRUCTURE, DISTORTIONS, AND MECHANICAL PROPERTIES IN THE L-PBF OF Ti-6Al-4V

G. Pollara — 2024-12-23

Laser powder bed fusion (L-PBF) has gained a lot of interest for its ability to build complex geometries with freedom of design. The wrong choice of process parameters like laser power (P) and scan speed (v) can result in parts with low ductility, pores, and distortion. In the literature, the influence of P and v on the quality of the printed part in terms of porosity defects, distortion, and mechanical properties has been widely explored. However, to obtain functional parts without defects it is crucial to consider different aspects simultaneously. This paper aimed to fill the lack of knowledge in the literature about the combined effect of laser power and scan speed on microstructure and distortions and their influence on mechanical properties. In this frame, tensile tests, microstructural, density, and distortion measurements were carried out to study the effect of P and v on mechanical strength, ductility, density, and distortion for Ti-6Al-4V parts produced with L-PBF. Three levels of P and v were analyzed in a range of 340-380 W and 1400-1600 mm/s, respectively. From the experimental analysis, a big influence of P on the ultimate tensile strength (UTS) and density was observed. Ductility, instead, was more affected by the v. Overall, high P and v resulted in significant distortions due to the increase in thermal gradient and cooling rate. Furthermore, porosity acted as a stress-relieving factor, and as a consequence, samples with high porosity showed less distortion.

HYGROTHERMAL ANALYSIS OF HYBRID ELECTRICALLY CONDUCTIVE ADHESIVE AT OPTIMAL MICRO-NANO FILLERS RATIO

Z. Adnan — 2024-12-27

Recent advancements have significantly advanced hybrid electrically conductive adhesive (HECA) as a pivotal polymer-based interconnector in electronic packaging. However, the durability of these materials remains uncertain, particularly under severe thermal and humid conditions, where current literature provides limited explanation. This paper evaluates the reliability of epoxy-based HECA formulations by varying micro-nano ratios of silver micro-flakes and multiwalled carbon nanotubes (AgMF-MWCNT), ranging from 0.07 to 0.27. The study subjects these formulations to hygrothermal exposure at 85°C and 85% relative humidity over a 3 week ageing period. The evaluation employs gravimetric measurement for water absorption, four-point probe testing for electrical conductivity, lap shear testing for mechanical strength, and scanning electron microscopy (SEM) for morphological analysis. Results show the most favorable ratios are 0.07 and 0.17, which achieve the best electrical and mechanical properties respectively. Upon hygrothermal ageing, anomalous behavior was found in water absorption as weight loss occurs after the first week of ageing. SEM reveals that cracks, delamination, filler pull-out, and filler-matrix debonding were observed on the fractured surface of HECA. In summary, the HECA formulation with a 0.17 ratio demonstrates optimal reliability across all evaluated parameters, underscoring its potential for robust electronic packaging applications.

A FACTORIAL EXPERIMENTAL DESIGN METHOD FOR ANALYSING CORROSION RATE OF AISI 316L STAINLESS STEEL IN SELECTED TROPICAL FRUIT JUICE MEDIA

Y. Yusuf — 2024-12-23

The utilisation of AISI 316L stainless steel in kitchenware is widespread due to its exceptional strength and remarkable corrosion resistance. Nevertheless, the susceptibility of stainless steel to corrosion from regularly utilised cooking substances, such as fruit juice, remains uncertain. Hence, it is crucial to assess the impact of frequently utilised fruit juice mediums on the corrosion resistance of 36L stainless steel kitchen equipment. The weight-loss method will be employed to assess the impact of the corrosion resistance quality of 316L stainless steel on specific tropical liquids (lime, tamarind, and pineapple). Measurements were conducted every 8 days over a period of 40 days. The experiment was designed and the data were analysed using experimental design (DOE) and variance analysis (ANOVA) methodologies. The results of this study indicate that tamarind juice had the highest corrosion rate of 0.4775mmyear^{− 1}, followed by lime juice, while pineapple juice had the lowest corrosion rate of 0.0075mmyear^{− 1}. The corrosion rates exhibited a maximum value during the initial week of the experiment, followed by a progressive decline over the course of time. This study also introduced a regression equation that includes the three distinct mediums studied.

OPTIMISING CUTTING PARAMETERS OF AISI H13 TO REDUCE TOOL WEAR AND SURFACE ROUGHNESS IN THE LATHE CNC MACHINING PROCESS

T. Norfauzi — 2024-12-23

This study evaluates tool wear and surface roughness (Ra) using carbide cutting tools at various cutting speeds (Vc), feed rates (Fr), and a high constant cutting depth of 1 mm on AISI H13 using a computer numerically controlled (CNC) lathe. When the machining parameters are not matched correctly, the machining performance decreases, increasing tool wear and Ra. This study aims to obtain the most suitable machine parameters for machining AISI H13. In addition, the study reveals the wear mechanism of the cutting tool effect for various machining parameters. The experiments were conducted at 100–200 m/min Vc, a 0.05–0.10 mm/rev Fr, and a constant cut depth of 1 mm (hard turning). The results show that 170 m/min Vc at 0.05 mm/rev Fr produces the lowest flank wear than other Vc. For 0.10 mm/rev Fr, the lowest flank wear was 140 m/min Vc and increased significantly by 57% when Vc was increased to 200 m/min Vc. This cutting speed causes severe damage to the cutting tool, such as chipping, notching, built-up edge (BUE), and flaking. The result for the overall Ra shows that the combination between 0.05 mm/rev Fr and 140 m/min Vc gives the best machining parameter, 0.24 um. This study reveals the impact of machining parameters on AISI H13 and the implications for wear characteristics and surface roughness.

PRODUCT REDESIGN BASED ON USER EXPERIENCE, COMPLAINT, AND FAILURE ANALYSIS

A.I. Juniani — 2024-12-23

User experience is a critical factor of product quality, especially for a manufacturer which launches product redesign similar to those of its competitors in the same market. Redesign in product development is necessary for the manufacturing industry to withstand competition. Every product would be customized to meet customer needs. Customer satisfaction is essential, and avoiding customer dissatisfaction is critical. Customers have the possibility of receiving a faulty item and subsequently lodging a complaint. Users' unfavorable experiences with a product could be used as feedback to improve its design. Product redesign begins with the identification of functional components. Customer needs are generally utilized to prioritize functional components, whereas complaints and failure modes, which are also crucial for improving product reliability, are often overlooked. This study utilized customer requirements, complaints, and failure analysis to determine the critical components of a two-burner stove. The method accomodates the failure mode and effect analysis (FMEA) and the Kano model to improve product failure and bolster customer satisfaction. Results of the implementation framework indicated that pan support is could not attach tightly. The dented main body, a hard-to-assemble body plate, and a hard-to-assemble side plate are the top three priorities to be redesigned.

SUPER TWISTING SLIDING MODE CONTROLLER FOR PRECISE BALL SCREW DRIVEN XY POSITIONING MILLING TABLE

M. Maharof — 2024-12-23

Servo drive system in positioning control requires precision, stability, and robustness against system non-linearity, un-modeled system dynamics, and input disturbance. A robust controller in a servo motor control system will realised these requirements. The objective of the work presented in this paper was to design and evaluate the performances of a Super Twisting Sliding Mode Controller (ST-SMC) for control of a ball screw driven milling table under the influence of input force disturbance. The ST-SMC control law design parameters; l, L and W were selected using the heuristics method. The controller performances were analysed numerically using MATLAB and Simulink software based on the magnitude of the root mean square (RMSE) of the tracking errors. Reference signals with amplitude of 1 mm, 2 mm, and 3 mm at frequency of 2 Hz were selected as input signal with a random filtered white noise as the input disturbance. In case of the x-axis, results showed the precision of ST-SMC with near zero RMSE values of 0.0012 mm, 0.0093 mm, and 0.0259 mm respectively. For disturbance rejection, the percentage variation in RMSE values for cases with and without the input noise ranged from 1.5% to 29.2% compared to 15% to 42% in the case of cascade P/PI controller. The performance of the ST-SMC is to be further extended for multiple types input disturbance rejection.

COMPARISON OF MACHINING AND WEAR PERFORMANCE OF 22MnB5 BORON STEEL AND HIGH-SPEED STEEL CUTTING TOOLS ON 6061 ALUMINIUM ALLOY

M.R. Fairuz — 2024-12-23

In an effort to utilize a robust material for friction-resistant applications, high-strength and high-hardness 22MnB5 boron steel is widely employed. Its unique properties make it thinner and lighter while retaining high strength, making it suitable for demanding tasks. This study evaluates the performance of 22MnB5 boron steel as a cutting tool for machining aluminum alloy Al 6061 and compares it with high-speed steel (HSS). A round piece of 22MnB5 boron steel, specified as RNGN 120300, was laser-cut and tested in CNC turning with cutting speeds of 200 to 300 m/min, a feed rate of 0.1 mm/rev, and a depth of cut of 0.5 mm. Results indicate that 22MnB5 boron steel outperforms HSS in machining Al 6061, offering tool life improvements of 5% to 11%. The wear mechanism for 22MnB5 boron steel was primarily abrasive at lower cutting speeds, while built-up edges at increased cutting speeds led to adhesive wear in the form of a tribolayer.

EFFECT OF APPLIED VOLTAGE ON ELECTROPHORETIC DEPOSITION OF NANO-HYDROXYAPATITE COATING ON BIODEGRADABLE AZ31 MAGNESIUM ALLOY AND ITS CORROSION PROPERTIES

C.Y. Chong — 2024-12-23

Magnesium alloys have recently gained attention among researchers due to their excellent biodegradability. However, rapid corrosion of Mg AZ31 alloys may cause an implant to fail before the bone has been fully restored. This study aimed to enhance corrosion resistance of Mg AZ31 alloy. In this study, hydroxyapatite (HA) powder coatings were prepared by using electrophoretic deposition (EPD) technique on AZ31 alloy for orthopaedic application. In this research, the voltage applied by EPD was increased from 10V to 50V. Coating morphologies, coating structures and corrosion properties were studied. FESEM observation was conducted on the formation of cracks, agglomeration and particle distribution. Corrosion test was performed by using an immersion test. Meanwhile, potentiodynamic test was evaluated by using pH value measurement and Tafel extrapolation. The presence of HA had successfully increased the corrosion resistance of bare AZ31. Through the FESEM observation, applied voltage of 20V had the highest corrosion resistance and least defects found amongst samples. Moderate applied voltage of 20V revealed the least defects and uniform coating layer because of charged particles attraction and repulsion to form a self-arrangement and high packing deposited layer. Therefore, the corrosion properties were increased by acting as an effective barrier to the corrosive environment.

A UNIVERSAL DESIGN METHOD BASED ON MOTION ANALYSIS BY USING MOTION CAPTURE AND MUSCULOSKELETAL MODEL: CASE STUDY OF PRODUCT SHELF HEIGHT

Y. Shimizusawa — 2024-12-23

In recent years, many companies have focused on the concept of universal design (UD) to design products that can be easily used by users of diverse body characteristics in order to develop products that take user diversity into consideration. This study proposes the UD method that takes into account physical load in order to realize the design that is easy to use for as many people as possible, which is one of the concepts of UD. The actual motions during product use are measured by using motion capture, and the motions are applied to the musculoskeletal model for motion analysis to evaluate the load on the user’s body. This analysis results in deriving the user-friendly solution for each group and aggregating them to derive the UD solution that can be used by as many people as possible with a less physical load. The effectiveness of the proposed method is demonstrated by applying it to the design problem of a shelf height.

SECURE INDUSTRIAL IOT DATA AGGREGATION IN THE MANUFACTURING INDUSTRY USING LIGHTWEIGHT HOMOMORPHIC ENCRYPTION SCHEME

M.R. Baharon — 2024-12-23

The rise of the Industrial Internet of Things (IIoT) has revolutionised manufacturing by enhancing efficiency, automation, and data-driven decision-making. However, this advancement presents serious security and privacy challenges, particularly concerning data leaks and unauthorised access. The extensive data sharing among IIoT devices increases their susceptibility to security breaches, which could expose sensitive information and result in financial and physical harm. Moreover, IIoT devices often face resource constraints, such as limited computational power, memory, and battery life, which complicates the implementation of robust security measures. This study focuses on data leakage, unauthorised access, and cyber risks to examine the security issues inherent in IIoT systems. Additionally, it also examined the effect of resource constraints and privacy concerns on the integration of IIoT with Industry 4.0. Recent studies have proposed various solutions to enhance data security and integrity, including homomorphic encryption and blockchain frameworks. In response, this study proposed a novel lightweight homomorphic encryption scheme to address critical vulnerabilities and improve overall security in industrial systems. The encryption scheme was designed and rigorously tested as part of this approach, with findings demonstrating significant improvements in data privacy and system efficiency. The results underscore the importance of robust security measures to ensure the safe and reliable operation of IIoT systems.

AN AUTOMATED DATA LOGGER SYSTEM FOR REAL-TIME MONITORING AND ANOMALY DETECTION IN INDUSTRIAL IOT ENVIRONMENT

N. Harum — 2024-12-23

In Industrial Internet-of-Things, a data logger must possess critical features such as real-time data acquisition, scalable storage capabilities, robust anomaly detection, and efficient dashboard integration for user-friendly monitoring, ensuring comprehensive data management and system reliability across industrial environments. Nevertheless, current data loggers offer very little data storage, have few intelligent features, and frequently have an interface that is difficult to use. Additionally, these loggers struggle with efficient data management, leading to storage issues and poor user experience. The integration of Industrial Internet of Things technology facilitates efficient mass data collection by enabling seamless connectivity and real-time monitoring. In this work, a system that features a user-friendly dashboard, enhanced with Grafana for advanced data visualization and management, built on Node-RED for flexible and streamlined development was proposed. A Raspberry Pi was chosen as a gateway due to its capability to process real-time data and send the data to the database. The system is capable of reading data from multiple sensors, which is stored in InfluxDB, a reliable time-series database. Moreover, the dashboard supports factory workflow and environmental monitoring from any location. The system also alerts users when an anomaly is detected, enabling proactive management and timely response. The anomaly message was sent directly from Raspberry Pi to reduce processing time, as demonstrated in the performance test results. The developed product underwent user evaluation, scoring grade A in usability testing with an impressive score of 91.25%, indicating a high level of user satisfaction and effectiveness.

MULTI-CRITERIA DECISION-MAKING MODEL ON CLOSE-OPEN MIXED VEHICLE ROUTING PROBLEM FOR MIDDLE-MILE DELIVERY OPTIMISATION

S. Nirwan — 2024-12-23

Middle-Mile Delivery (MMD) is perceived to carry less importance in supply chain management and has the least potential for improvement, prompting many companies to skip this step in logistics. Although MMD is studied as part of the Vehicle Routing Problem (VRP), it receives less attention than last-mile delivery. Nevertheless, MMD is typically more predictable, presenting greater opportunities for enhancements. An optimised middle-mile distribution network can reduce transportation costs and delivery times. The main challenges of MMD include route distance, the locations of distribution centres, and delivery duration. Routing is an essential element of logistics, significantly contributing to economic growth. Inefficient routing may result in elevated expenses, especially for courier and logistics companies. Nodes, also known as distribution centres, are critical components in the distribution system. The initiation or termination of these nodes is frequently restricted by corporate constraints, rendering such modifications challenging. Consequently, optimisation initiatives must prioritise the selection of nodes according to their relevance to the company's comprehensive delivery process. This study presents a hybrid approach for the Close-Open Mixed Vehicle Routing Problem (COMVRP), which addresses both open and closed routes while integrating Multi-Criteria Decision Making (MCDM). The objective is to reduce the overall delivery distance. We propose a refined Genetic Algorithm (GA) that integrates with the Analytical Hierarchical Process (AHP) and the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). In managerial decision-making, the AHP-TOPSIS method is used to improve an initial COMVRP generated by the nearest neighbour algorithm. The AHP technique focuses on criteria weights, whereas TOPSIS emphasises delivery centres’ performance as the priority node. This solution set achieves ideal GA performance, displaying minimal route distances with external vehicle deployment. The calculation results also showed that the proposed model reduced the total route distance by 4.86%, which exceeded the standard COMVRP model with 28.03% less than the current postal delivery system.

REAL-TIME ALERT NOTIFICATION SYSTEM FOR OPTIMIZING MANUFACTURING PRODUCTION LINE VIA MOBILE APPLICATION

N.A. Emran — 2024-12-23

The existing system employed by Konica Minolta for handling emergency text alerts is ineffective and lacks reliability. The company, which specializes in business and industrial imaging solutions, relies on email notifications for daily emergencies. This approach has several drawbacks, as notifications are sent to all employees simultaneously, leading to irrelevant alerts for those not involved in the specific projects. Additionally, the visibility of these notifications raises concerns about confidentiality and privacy, potentially compromising sensitive information. As the volume of notifications increases, tracking and analyzing content becomes increasingly challenging. The objective of the Mobile Alert Notification System for Manufacturing Production Lines (MANSMPL) is to provide targeted alerts tailored by incorporating the role-based access control (RBAC) method specifically for manufacturing environments. To validate the identified problems, unstructured interviews and surveys with domain experts were conducted. The findings from the interviews and surveys were instrumental in designing MANSMPL. The developed application effectively streamlines the notification process, ensuring that alerts are relevant to the intended recipients. MANSMPL offers a novel solution that is tailored to a manufacturing environment that restricts alerts to intended recipients while maintaining the confidentiality and privacy of sensitive information.

EXPERIMENTAL COMPARISON ON MECHANICAL PROPERTIES, MICROSTRUCTURAL CHANGES AND HEAT-AFFECTED-ZONE (HAZ) SIZE OF TIG- AND LASER WELDED EN AW 6082-T6

A.M. Najib — 2024-12-23

The heat-affected zone (HAZ) reduces 30%-50% of mechanical strength in a welded 6000 series of aluminium components. The softening phenomenon of welded aluminium is not adequately addressed in current design standards such as Eurocode 9 and the British Standard Institution (BSI) Standard. In the present study, comprehensive experimental work is conducted to investigate the influence of welding methods and parameters on the occurrence of HAZ. Through experimental analysis of tungsten inert gas (TIG) and laser welding coupons, the severity and extension of HAZ were compared using tensile strength, hardness values and microstructure distribution. It is evident that tensile strength and hardness values of welded components significantly depended on heat input, welding speed, and welding method. The strength reduction in laser-welded components was inconsistent with that of TIG-welded components. However, the extent of HAZ was much narrower in laser-welded components than in TIG welding. The grain size significantly increased after the welding process due to the fusion process. The orientation of the grain was found to be different for each welding method and was greatly influenced by the welding speed and temperature gradient of the weld pool. A comparitive analysis of mechanical and microstructural properties in TIG and laser-welded components can provide a basis to further improve the current design standards, particularly on the softening factor of welded joining. The results will significantly contribute to the enhancement of welding quality in the industrial joining practice.