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Mahmood Al Bashir

Bio: Mahmood Al Bashir is an academic researcher from Wichita State University. The author has contributed to research in topics: Surface roughness & Machining. The author has an hindex of 5, co-authored 9 publications receiving 167 citations. Previous affiliations of Mahmood Al Bashir include Ahsanullah University of Science and Technology.

Papers
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Journal ArticleDOI
TL;DR: In this article, the performance modeling of hard milling to attain an optimum parameter setting for the minimum cutting force and surface roughness was performed by adopting Grey-based Taguchi method and composite desirability function.
Abstract: The present work focuses on the performance modeling of hard milling to attain an optimum parameter setting for the minimum cutting force and surface roughness. Furthermore, it was attempted to compute the minimum quantity lubricant flow rate precisely, besides the cutting speed and table feed rate, by adopting Grey-based Taguchi method and composite desirability function. The experimental data was collected by end milling of hardened AISI 4140 steel using carbide cutter under dry and minimum quantity lubrication conditions according to Taguchi L 16 orthogonal array. The predictive model of the responses was formulated by using response surface methodology. The analysis of variance revealed that the table feed has the maximum influence on cutting force, and the flow rate of lubricant has the highest effect on surface roughness. The parameter setting at lower table feed, higher cutting speed, and 150-ml/h lubricant flow yield the minimum value of the responses. Finally, the results of confirmation test verified the adequacy and supremacy of the optimization models; however, Grey-based Taguchi method induced a better optimization.

110 citations

Journal ArticleDOI
TL;DR: In this paper, an experimental investigation was performed in milling hardened AISI 4140 steel of hardness 40 HRC in both dry and minimal quantity lubricant (MQL) conditions, as part of neat machining, to make a strong comparison of the undertaken machining environments.
Abstract: In this article, an experimental investigation was performed in milling hardened AISI 4140 steel of hardness 40 HRC. The machining was performed in both dry and minimal quantity lubricant (MQL) conditions, as part of neat machining, to make a strong comparison of the undertaken machining environments. The MQL was impinged int the form of pulse jet, by using the specially developed pulse-jet-attachment, to ensure that the cutting fluid can be applied in different timed pulses and quantities at critical zones. The tool wear, cutting force and surface roughness were taken as the quality responses while cutting speed, table feed rate and flow rate of the pulse were considered as influential factors. The depth of cut was kept constant at 1.50 mm because of its less significant effects and the straight oil was adopted as cutting fluid in pulse-jet-MQL. The effects of different factors, on the quality responses, are analyzed using ANOVA. It is observed that MQL applicator system exhibits overall better performance when compared to dry milling by reducing surface roughness, cutting force and prolonging tool life but a flow rate of 150 ml/h has tremendous effects on the responses. This investigation and afterward results are expected to aid the industrial practitioner and researcher to adopt the pulse-MQL in high speed milling to prolong tool life, reduce tool wear, diminish cutting force generation and promote better surface finish.

51 citations

Journal ArticleDOI
TL;DR: In this article, an innovative design for the application of minimum quantity lubricant (MQL) in the form of pulse jet was created, following the development of that applicator, and the surface milling of AISI 4140 steel, heat treated to 40 HRC was investigated with pulse jet minimum quantity applicator using VG-68 grade straight cut cutting oil as the cutting fluid in respect of cutting force, surface roughness and tool flank wear with machining time.
Abstract: Minimum quantity lubricant (MQL) machining is an emerging cooling technology that ensures green machining. In this research work, an innovative design for the application of MQL in the form of pulse jet was created, following the development of that applicator. The surface milling of AISI 4140 steel, heat treated to 40 HRC, was investigated with pulse jet minimum quantity lubricant applicator using VG-68 grade straight cut cutting oil as the cutting fluid in respect of cutting force, surface roughness and tool flank wear with machining time. Four flute carbide end mill cutter was used to investigate the change in tool wear, and compared with that of the dry condition. The result and analysis indicate that this pulse jet MQL applicator can be utilized in hard milling operation to ensure better surface finish and minimal tool wear and cutting force.

21 citations

Journal ArticleDOI
TL;DR: An empirical model of principal flank wear was developed for the different hardness of workpiece (HRC40, HRC48 and HRC56) while turning by coated carbide insert with different configurations (SNMM and SNMG) under both dry and high pressure coolant conditions as mentioned in this paper.
Abstract: Hard turning is increasingly employed in machining, lately, to replace time-consuming conventional turning followed by grinding process. An excessive amount of tool wear in hard turning is one of the main hurdles to be overcome. Many researchers have developed tool wear model, but most of them developed it for a particular work-tool-environment combination. No aggregate model is developed that can be used to predict the amount of principal flank wear for specific machining time. An empirical model of principal flank wear (VB) has been developed for the different hardness of workpiece (HRC40, HRC48 and HRC56) while turning by coated carbide insert with different configurations (SNMM and SNMG) under both dry and high pressure coolant conditions. Unlike other developed model, this model includes the use of dummy variables along with the base empirical equation to entail the effect of any changes in the input conditions on the response. The base empirical equation for principal flank wear is formulated adopting the Exponential Associate Function using the experimental results. The coefficient of dummy variable reflects the shifting of the response from one set of machining condition to another set of machining condition which is determined by simple linear regression. The independent cutting parameters (speed, rate, depth of cut) are kept constant while formulating and analyzing this model. The developed model is validated with different sets of machining responses in turning hardened medium carbon steel by coated carbide inserts. For any particular set, the model can be used to predict the amount of principal flank wear for specific machining time. Since the predicted results exhibit good resemblance with experimental data and the average percentage error is <10 %, this model can be used to predict the principal flank wear for stated conditions.

19 citations

Proceedings ArticleDOI
12 Jul 2016
TL;DR: In this paper, the variation of the surface roughness of the produced surfaces with the changes in tool insert configuration, use of coolant and different cutting parameters (cutting speed, feed rate) has been investigated.
Abstract: Hard turning is gradually replacing the time consuming conventional turning process, which is typically followed by grinding, by producing surface quality compatible to grinding. The hard turned surface roughness depends on the cutting parameters, machining environments and tool insert configurations. In this article the variation of the surface roughness of the produced surfaces with the changes in tool insert configuration, use of coolant and different cutting parameters (cutting speed, feed rate) has been investigated. This investigation was performed in machining AISI 1060 steel, hardened to 56 HRC by heat treatment, using coated carbide inserts under two different machining environments. The depth of cut, fluid pressure and material hardness were kept constant. The Design of Experiment (DOE) was performed to determine the number and combination sets of different cutting parameters. A full factorial analysis has been performed to examine the effect of main factors as well as interaction effect of factors on surface roughness. A statistical analysis of variance (ANOVA) was employed to determine the combined effect of cutting parameters, environment and tool configuration. The result of this analysis reveals that environment has the most significant impact on surface roughness followed by feed rate and tool configuration respectively.

12 citations


Cited by
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Journal ArticleDOI
TL;DR: In this paper, a comprehensive analysis of literature pertaining to ecological trends in machining processes of difficult-to-cut materials (e.g. hard steels, Ti-based alloys, Ni based alloys) has been performed.

260 citations

Journal ArticleDOI
TL;DR: In this article, an attempt has been made to evaluate the effectiveness of two cooling and lubrication techniques namely cryogenic cooling and hybrid nanoadditive-based minimum quantity lubrication (MQL).
Abstract: Owing to superior physio-chemical characteristics, titanium alloys are widely adopted in numerous fields such as medical, aerospace, and military applications. However, titanium alloys have poor machinability due to its low thermal conductivity which results in high temperature during machining. Numerous lubrication and cooling techniques have already been employed to reduce the harmful environmental footprints and temperature elevation and to improve the machining of titanium alloys. In this current work, an attempt has been made to evaluate the effectiveness of two cooling and lubrication techniques namely cryogenic cooling and hybrid nanoadditive–based minimum quantity lubrication (MQL). The key objective of this experimental research is to compare the influence of cryogenic CO2 and hybrid nanofluid–based MQL techniques for turning Ti–6Al–4V. The used hybrid nanofluid is alumina (Al2O3) with multi-walled carbon nanotubes (MWCNTs) dispersed in vegetable oil. Taguchi-based L9 orthogonal-array was used for the design of the experiment. The design variables were cutting speed, feed rate, and cooling technique. Results showed that the hybrid nanoadditives reduced the average surface roughness by 8.72%, cutting force by 11.8%, and increased the tool life by 23% in comparison with the cryogenic cooling. Nevertheless, the cryogenic technique showed a reduction of 11.2% in cutting temperature compared to the MQL-hybrid nanofluids at low and high levels of cutting speed and feed rate. In this regard, a milestone has been achieved by implementing two different sustainable cooling/lubrication techniques.

170 citations

Journal ArticleDOI
TL;DR: In this paper, the authors presented the study of roughness parameters (Ra, Rq, Rz), tool wear parameters (VB, VS) and material removal rate (MRR) in MQL-assisted hard turning by using coated cemented carbide tool.

142 citations

Journal ArticleDOI
TL;DR: In this paper, the synergistic effect of multiangle 2D ultrasonic and minimum quantity lubrication (NMQL) was investigated in zirconia ceramic grinding. And the results reveal that the adhesion and material peeling phenomenon on the workpiece surface is reduced compared with dry grinding without ultrasonic vibration.
Abstract: Nanofluid minimum quantity lubrication (NMQL) technique has many technological and economic advantages in grinding operation. NMQL can improve grinding performance in terms of cooling and lubrication and is ecofriendly because it consumes a small amount of grinding fluid. Ultrasonic machining can improve grinding performance owing to its reciprocating vibration mechanism and furrow widening. Consequently, the simultaneous utilization of these techniques is anticipated to improve the surface quality, especially for hard brittle materials. In this research, multiangle two-dimensional (2D) ultrasonic vibration is utilized in zirconia ceramic grinding. Results reveal that the adhesion and material peeling phenomenon on the workpiece surface is obviously reduced compared with dry grinding without ultrasonic vibration. The synergistic effect of multiangle 2D ultrasonic and NMQL is also studied. With increased angle, the roughness value is found to initially increase (from 45° to 90°) and then decreases (from 90° to 135°). Moreover, the lubricating effect under 90° is the poorest, with the highest Ra and RSm values of 0.703 μm and 0.106 mm, respectively; conversely, the minimum Ra value (0.585 μm) is obtained under 45°, and the lowest RSm value (0.076 mm) is obtained under 135°.

106 citations

Journal ArticleDOI
TL;DR: In this article, the influence of pure cooling-lubrication (C/L) agents to reduce friction at faying surfaces can ameliorate overall machinability.
Abstract: In machining of soft alloys, the sticky nature of localized material instigated by tool-work interaction exacerbates the tribological attitude and ultimately demeans it machinability. Moreover, the endured severe plastic deformation and originated thermal state alter the metallurgical structure of machined surface and chips. Also, the used tool edges are worn/damaged. Implementation of cooling-lubrication (C/L) agents to reduce friction at faying surfaces can ameliorate overall machinability. That is why, this paper deliberately discussed the influence of pure C/L methods, i.e., such as dry cutting (DC) and nitrogen cooling (N2), as well as hybrid C/L strategies, i.e., nitrogen minimum quantity lubrication (N2MQL) and Ranque–Hilsch vortex tube (RHVT) N2MQL conditions in turning of Al 7075-T6 alloy, respectively. With respect to the variation of cutting speed and feed rate, at different C/Ls, the surface roughness, tool wear, and chips are studied by using SEM and 3D topographic analysis. The mechanism of heat transfer by the cooling methods has been discussed too. Furthermore, the new chip management model (CMM) was developed under all C/L conditions by considering the waste management aspects. It was found that the R-N2MQL has the potential to reduce the surface roughness up to 77% and the tool wear up to 118%. This significant improvement promotes sustainability in machining industry by saving resources. Moreover, the CMM showed that R-N2MQL is more attractive for cleaner manufacturing system due to a higher recyclability, remanufacturing, and lower disposal of chips.

106 citations