Papers by shahrul kamaruddin
Metals, Jan 18, 2023
This article is an open access article distributed under the terms and conditions of the Creative... more This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY
IOP Conference Series: Materials Science and Engineering, 2018
Image processing for computer vision function plays an essential aspect in the manufacturing indu... more Image processing for computer vision function plays an essential aspect in the manufacturing industries for the tool condition monitoring. This study proposes a dependable direct measurement method to measure the tool wear using image-based analysis. Segmentation and thresholding technique were used as the means to filter and convert the colour image to binary datasets. Then, the edge detection method was applied to characterize the edge of the drill bit. By using cross-correlation method, the edges of original and worn drill bits were correlated to each other. Cross-correlation graphs were able to detect the difference of the worn edge despite small difference between the graphs. Future development will focus on quantifying the worn profile as well as enhancing the sensitivity of the technique.
ISO 9001:2008 Implementation In a SME: A Case Study
ISO 9001:2008 Quality Management Systems (QMS) standard was published as a standard that contains... more ISO 9001:2008 Quality Management Systems (QMS) standard was published as a standard that contains the requirements which an organization needs to fulfil to achieve customer satisfaction through consistent products and services that meet the customers ’ requirements. The standard accreditation allows the companies regardless of its size, type and product or service to compete in the business. However, most of the standard’s implementation models developed focused on large organizations structure. Thus, there is a need for a suitable model to guide small and medium enterprises (SMEs) in implementing ISO 9001:2008. By referring to available published models and framework, eliminating some unnecessary steps and simplifying available implementation processes; this paper provides a simple yet practical model for SMEs to start their quest towards accreditation. The model covers all eight QMS principle in ISO 9001:2008. The model was then implemented as a case study research in one SMEs ’ c...
Growing demands of plastics deriving environmental and social concern on the plastics contained i... more Growing demands of plastics deriving environmental and social concern on the plastics contained in municipal waste. Comprehending to this fact, this study emphasizes on minimization of plastic wastes during extrusion blow molding process by controlling the processing parameters including parison thickness, chiller temperature, melting temperature and extruder speed. L8 Taguchi orthogonal array (OA), signal to noise (S/N) ratio and analysis of variance (ANOVA) were conducted to investigate the influence of numerous blow moulding processing parameters on the plastic wastes.
Optimization of wear behavior on unreinforced/glass fiber reinforced plastic injection moulded gear via integration of Taguchi method and principal component analysis
PROCEEDINGS OF 8TH INTERNATIONAL CONFERENCE ON ADVANCED MATERIALS ENGINEERING & TECHNOLOGY (ICAMET 2020), 2021
To date, plastic gears are continuing to displace metal gears in a widening arena of applications... more To date, plastic gears are continuing to displace metal gears in a widening arena of applications. Plastic gears are presently not just being used for light-stacked applications but also in automotive starter gears, turbo actuators, and electronic throttle control. Despite of the benefits of plastic gears including noiseless operation, low weight, and working without lubrication, the occurrence of wear in plastic gears limit its application particularly in higher contact force during the operation. Therefore, in this study an attempt has been made to study the applicability and practical ability of using glass fiber in plastic gear in order to reduce the wear failure in plastic gear. The integration of Taguchi Method and Principal Component Analysis (PCA) optimization were implemented to investigate the effects of controlled parameters (gear combinations, speed, running time and load) on the wear behavior, tooth thickness and addendum circles measurement of glass fiber reinforced pl...
Nowadays, polycrystalline diamond compact (PDC) cutters performance dropped and affects the perfo... more Nowadays, polycrystalline diamond compact (PDC) cutters performance dropped and affects the performance of drilling efficiency. The objective of this project is to investigate the effect of PDC cutters geometry and optimize their geometry features. An intensive study in PDC cutters geometry would help complete the section with high penetration and low wear rate. Relatively deepened analysis was carried out and come out with four important geometries features that can help in improving the penetration and reduce wear rate. They are chamfer angle, back rake angle, side rake angle and diameter. An appropriate optimization method that effectively controls all influential geometries factors during PDC cutters manufacturing is therefore critical. By adopting L9 Taguchi OA, the simulation experiment is conducted by using explicit dynamics finite element analysis (FEA). A1B1C3D1 are identified as the optimal geometry. The set of optimum geometries is identified as the following: chamfer ang...
Evaluation on the feasibility of using bamboo fillers in plastic gear manufacturing via the Taguchi optimization method
Journal of Physics: Conference Series, 2017
Journal of Physics: Conference Series, 2017
At times, the polycrystalline diamond compact (PDC) bit's performance dropped and affects the rat... more At times, the polycrystalline diamond compact (PDC) bit's performance dropped and affects the rate of penetration (ROP). The objective of this project is to investigate the effect of PDC cutter geometry and optimize them. An intensive study in cutter geometry would further enhance the ROP performance. The relatively extended analysis was carried out and four significant geometry factors have been identified that directly improved the ROP. Cutter size, back rake angle, side rake angle and chamfer angle are the stated geometry factors. An appropriate optimization technique that effectively controls all influential geometry factors during cutters manufacturing is introduced and adopted in this project. By adopting L 9 Taguchi OA, simulation experiment is conducted by using explicit dynamics finite element analysis. Through a structure Taguchi analysis, ANOVA confirms that the most significant geometry to improve ROP is cutter size (99.16% percentage contribution). The optimized cutter is expected to drill with high ROP that can reduce the rig time, which in its turn, may reduce the total drilling cost.
PDC cutter optimization using response surface methodology with orthogonal arrays
AIP Conference Proceedings, 2018
IOP Conference Series: Materials Science and Engineering, 2018
The polymer gears are widely used as basic motion transfer elements in many industries. Continuou... more The polymer gears are widely used as basic motion transfer elements in many industries. Continuous improvement on the quality performance of polymer gears is very important for their ability to meet present demand. So that, controlling the parameters setting in polymers gears are very importance in order to get the best gears quality. In this study, the influences of injection moulding processing parameters on shrinkage of polypropylene gears was investigated by using Taguchi approach. It was found that the optimal processing parameters for addendum circle shrinkage, dedendum circle shrinkage and tooth thickness shrinkage are A1B1C3D3E1F2G3, A3B1C3D3E3F1G3, and A1B3C3D2E3F2G1 respectively. This results showed that pattern of fluctuation showed either an improvement or reduction in quality characteristics upon the change of process parameters setting.
A study on the capability of carbon dioxide continuous laser to cut E-glass
ISRN Industrial Engineering, 2013
The performance of plastic gears in wide variety of power and motion transmission applications is... more The performance of plastic gears in wide variety of power and motion transmission applications is rather limited due to weak mechanical properties and divergent mechanism of failures. A methodical simulation is carried out to analyze the gear performance with various gating system types, gate locations, and processing parameters via grey-based Taguchi optimization method. With the obtained optimum results in simulation stage, the flow patterns of polymer melt inside the mould during filling, packing, and cooling processes are studied and the plastic gear failures mechanism related to processing parameters are predicted. The output results in the future can be used as guidance in selecting the appropriate materials, improving part and mould design, and predicting the performance of the plastic gear before the real process of the part manufacturing takes place.
A Study of Hybrid Optimization of Injection Moulding Process Parameters for Plastic Gear
Advanced Materials Research, 2012
This paper presents a hybrid optimization method for optimizing the injection moulding process pa... more This paper presents a hybrid optimization method for optimizing the injection moulding process parameters for plastic gear. This proposed method combines the Taguchi robust design, grey relational analysis (GRA) and principal component analysis (PCA) in designing the experiments and analyzing the behaviour of shrinkage in addendum circles (AC), dedendum circles (DC) and tooth thickness (TT) of the moulded gear. The proposed hybrid optimization method appears to be a necessity to overcome the shortcomings in multiple quality characteristics optimization as well as provides a statistical solution in defining a weight for each quality characteristic.
International Journal of Manufacturing Engineering, 2014
Shrinkage behavior is a crucial problem in manufacturing plastic molded gear. This is because it ... more Shrinkage behavior is a crucial problem in manufacturing plastic molded gear. This is because it negatively affects the dimensional stability and accuracy of the involute profile, as well as the concentricity, roundness, tooth spacing uniformity, and size of the gear. By integrating the Taguchi robust design, Grey relational analysis, and principal component analysis, we investigated the dimensional stability related to the shrinkage of tooth thickness, addendum circle, and dedendum circle of molded gear via the optimization of processing parameters and glass fiber reinforcement. The results revealed that the optimal combination of the processing parameters of the molded gear to achieve minimum shrinkage is melt temperature of 260°C, packing pressure of 60%, packing time of 5 s, and cooling time of 30 s. The melt temperature showed the highest comparability sequence among the four key process parameters examined, followed by packing pressure, cooling time, and packing time. Meanwhil...
Quality control and design optimisation of plastic product using Taguchi method: a comprehensive review
International Journal of Plastics Technology, 2012
ABSTRACT The Taguchi method is a powerful approach for solving quality problems in various aspect... more ABSTRACT The Taguchi method is a powerful approach for solving quality problems in various aspects of the engineering field. Due to the increase of plastic parts consumption in each day, continuing customer satisfaction and economic viability in a competitive plastic industry environment are gaining tremendous attention. Thus, Taguchi method offers a simple yet systematic approach to optimize design for performance, enhancing the product quality and reduce the cost as well. A lot of studies have been conducted on the efficiency of this method. However a total comprehensive review of the implementation of the Taguchi method particularly in the plastic industry is limited. This paper presents an extensive review of past literature on the application of the Taguchi method in plastic industries focusing on product quality enhancing and obtaining the desired properties for new materials. From the review, it can be concluded that the Taguchi method has made extensive contribution to the plastic industry by bringing focused and awareness to robustness to improving quality.
Investigating the Effects of Injection Moulding Process Parameters on Multiple Tensile Characteristics of Plastic Spur Gear via Experimental Approach
Advanced Materials Research, 2013
This paper presents the original development of an experimental approach in studying the multiple... more This paper presents the original development of an experimental approach in studying the multiple tensile characterizations as key quality characteristics for several different plastic gear materials related to various parameters in injection moulding process. In this study, emphases are given on a new low-cost mechanism for the testing of the injection moulded plastic spur gear specimens with various teeth module. The testing fixture are developed and validated to provide uniform state of tension with series of plastic gear specimens produced in accordance with the systematically designed of experiment. The effects of changes in the process parameters including melt temperature, packing pressure, packing time and cooling time at three different levels on the elongation at break and ultimate strength of plastic gear is evaluated and studied through the proposed experimental approach.
2013 International Conference on Robotics, Biomimetics, Intelligent Computational Systems, 2013
In manufacturing industries, inspection process is the most vital process in production line in o... more In manufacturing industries, inspection process is the most vital process in production line in order to certify the quality of the product. At the end of every production line, there would be one quality assurance section to do the inspection. Sometimes quality inspection is not just needed at the end of the production line, it is also needed at specific area or at the process where usually problem occurs that denotes to bad quality product. This phenomenon frequently occurs in joining thermoplastic materials which used ultrasonic welding. Ultrasonic welding had increasing popularity as it offers a continued safe operation, faster and also low cost as it able to join weld part less than one second. Despite of its advantages in joining parts, ultrasonic welding is one of process that needs a special care and its own inspection process since it leads to major reject products because of its bad quality welding. Conventional inspection for ultrasonic welding joining usually used a destructive testing method, for an example pull/ push test. This testing will brings to waste in time and material cost. In order to encounter this matter, non destructive testing using ultrasonic testing is used in this research. It is been done by detecting the signal of ultrasonic welding vibration during the ultrasonic welding process of thermoplastic materials joining. This obtained signal will then be analyzed to acquire the abnormalities within the signal which represents the defects between the joint, thus concludes the quality of the product.
Investigating the Effects of Blending Ratio and Injection Parameters on the Tensile Properties of Glass Fiber-Filled Nylon 66 Composite Gear
Applied Mechanics and Materials, 2014
The recycling of plastic products is gaining widespread attention because of its significance in ... more The recycling of plastic products is gaining widespread attention because of its significance in the reduction of petroleum consumption and in the conservation of limited resources. It is also an effective method of handling plastic waste, as opposed to traditional landfill and incineration waste disposal methods. This study attempts to find a method by which to manage the increasing amount of PA66-GF waste generated by the gear industry through the recycling method. By adopting the L27 Taguchi orthogonal array, S/N ratio and ANOVA are conducted to evaluate the impact of recycled materials on various compositions. The different settings of injection parameters on the gears’ Young’s modulus and elongation at break are also identified and examined.
Investigating the Effects of Injection Molding Parameters on the Mechanical Properties of Recycled Plastic Parts Using the Taguchi Method
Materials and Manufacturing Processes, 2011
ABSTRACT The growing amount of plastic parts produced nowadays makes the search for alternatives ... more ABSTRACT The growing amount of plastic parts produced nowadays makes the search for alternatives in recycling and the further use of these nonbiodegradable materials imperative. The degradation of the mechanical properties of recycled plastic products poses the primary limitation for the usage of recycled plastic. One of the foremost causes of mechanical property degradation is variation in processing parameters. An appropriate optimization method that effectively controls all influential processing parameters during manufacturing is therefore critical. This study investigates the effects of injection molding parameters on the mechanical properties of recycled plastic parts. The preliminary experiment is conducted by using Moldflow Plastic Insight (MPI) integrated with the L18 Taguchi orthogonal array (OA). The significant processing parameters obtained from the preliminary experiment were used to conduct the principal experiment. By adopting L9 Taguchi OA, the parts made from recycled plastic were produced by injection molding. ANOVA confirms that the most significant factor for flexural modulus of a recycled toolbox tray is injection time (∼40.49% percentage contribution). For stress at yield, the most significant factor is melt temperature with percentage contribution of about 43.34%.
Jurnal Teknologi, 2016
Facility layout design has an important function in manufacturing systems because it affects manu... more Facility layout design has an important function in manufacturing systems because it affects manufacturing costs, work in progress, lead times, and production output. This study presents facility layout designs for multi-product and small-lot-sized production lines. This research focuses on the development and analysis of layout alternatives on the basis of performance measures and aims to improve production efficiency. Thus, the tools and techniques available for the layout designed were investigated. Related data were collected, and alternative layouts were developed using the WITNESS simulation software. Finally, the alternative layouts were ana1yzed and evaluated using the analytic hierarchy process to identify the best possible layout. Two important parameters observed in the alternative layouts: the ability to produce a desired output and the flexibility of each layout coherent with the fluctuation of product demands in the industry. Results from analysis shows that suggested ...
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Papers by shahrul kamaruddin