Suman Selvarajoo, Raja Ariffin Raja Ghazilla and Azuddin Mamat
The purpose of this paper is to understand the current practices of tool and die development, particularly in the Malaysian context with respect to collaborative manufacturing…
Abstract
Purpose
The purpose of this paper is to understand the current practices of tool and die development, particularly in the Malaysian context with respect to collaborative manufacturing (CM). It is important to gauge the presents of CM, which is one of the key elements of Industrial Revolution 4.0 (IR 4.0) so that significant initiatives could be taken. The findings are also expected to address the issues pertaining limited information related to collaborative tool and die development in Malaysia.
Design/methodology/approach
A survey was carried out among the key players in the local tool and die industry, covering issues such as operational structure in practice, internal collaboration, external collaboration and application of collaborative technology.
Findings
The results revealed that although practitioners realise that there are systems and available technological support, unfortunately, it has not been embraced due to poor communication, lack of commitment and cooperation from employees and business owners. In addition, industry players also need to be aware of the benefits concerning CM for a sustainable future.
Research limitations/implications
Many industry players are rather reluctant to participate in surveys and tend to reserve their opinions regarding their operational practices. Lack of awareness among the industry players contributed to the poor participation of the survey and based on the feedback, some of the industry players are not well-informed regarding the latest developments in the industry.
Originality/value
The data and feedback gained through the research offer the perspective for the current state of CM particularly the tool and die industry in Malaysia. This may be a preliminary study with limited data but the value of the information is significant for further in-depth study and policy alignment towards enhancing the tool and die industry which is rarely given attention to. Understanding the current state of CM particularly in the tool and die development would be critical for the expansion of IR 4.0 concerning this field in Malaysia.
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Mohd Nor Azam Mohd Dali, Jaharah A. Ghani, Che Hassan Che Haron and Sharudin Hassan
The purpose of this paper is to produce dimple structure on a cylindrical surface for Aluminium-Silicon (Al-Si) alloy piston (A390) using turning process. The process selection is…
Abstract
Purpose
The purpose of this paper is to produce dimple structure on a cylindrical surface for Aluminium-Silicon (Al-Si) alloy piston (A390) using turning process. The process selection is based on factors such as the capability of machining process, low cost process, minimum set up time and green working environment.
Design/methodology/approach
Three main machining parameters that greatly influenced the dimple structure fabrication were identified from previous researches (cutting parameters, vibration and cutting tool geometry). To facilitate dimple structure fabrication using turning process, a dynamic assisted tooling (DATT) was developed. Experiments were conducted on Al-Si A390 material for future application of automotive piston. A three-dimensional surface profiler (Alicona) was used for geometry measurement and analysis of dimple structure. The Taguchi method, with an L8 orthogonal array, was used to accommodate seven parameters used in the fabrication of dimpled structures using turning process. Signal-to-noise (S/N) ratio and observation on the shape of dimple structure array were used to determine the optimum machining condition.
Findings
Optimum parameters obtained using S/N ratio analysis were cutting speed of 9 m/min, depth of cut of 0.01 mm, amplitude displacement of 1 mm, nose radius of 0.4 mm and frequency of (25 Hertz). Whereas feed rate, rake and relief angles were not significant to the size, shape and dimple array; therefore, their selected values depend on requirement of the application. Based on the S/N ratio and uniformity of the array of dimple structure as the main reference, the sixth and eighth experiment conditions almost achieved the optimum condition which are able to produce the width of dimple structure of 396.82 and 560.43 μm, respectively, dimple length of 3,261.6 and 2,422.7 μm, respectively, dimple depth of 63.43 and 65.97 μm, respectively, area ratio of 10 and 10.39 per cent, respectively, and surface roughness of 3.0023 and 3.0054 μm, respectively. These results are within the range of dimple structure obtained by the previous researchers for sliding mechanical components application.
Originality/value
The optimum condition of machining parameters in producing uniform dimple structure led to the compilation of data base in dimple structure research via turning process. Dimple structure produced is similarly obtained with other processes like laser, burnishing, photochemical, etc. DATT developed has the ability to produce repeatable vibration frequency, stable and consistent amplitude displacement using a simple crank concept and structure that can be mounted on all types of lathe machine either conventional or computer numerical control.