Muhammad Jamil

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Verified

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• Doctor of Engineering
• Associate Profesor at Nanjing University of Aeronautics and Astronautics

Although AM attracts manufacturers for its layered production, reducing waste and supporting sustainability, persistent defects remain, requiring optimized parameters or post-processing. Preemptively avoiding defects with well-centered process parameters is crucial for improving the performance and reliability of additive manufacturing (AM) parts....

Cutting-edge developments in metal additive manufacturing (AM) technologies have redefined engineering boundaries by enabling the production of intricate components at unprecedented levels of customization. Despite these developments, metal AM products typically contain numerous microstructural and surface defects—underscoring the necessity for rig...

This study addresses the effect of the trace Nb addition in 357 cast alloy and its subsequent role in driving the aging and precipitation kinetics. The variations in microstructure and mechanical properties are analyzed with a primary focus on restoring the ductility in over age state without compromising the strength characteristics. The prepared...

To address the challenges of poor machinability and short tool life in titanium alloy machining, in this paper, swallowtail-shaped bionic micro-textures were proposed to improve lubrication conditions in tool-workpiece contact area. A three-dimensional milling model was developed to optimize the geometric parameters of the swallowtail-shaped micro-...

The move toward environmentally friendly methods in the global manufacturing sector has led to the use of minimum quantity lubrication (MQL) as an eco-friendly alternative to traditional flood cooling. However, the natural limits of MQL in high-performance settings have led to the use of nanotechnology, which has resulted in the creation of nanoflu...

Light-weight alloys have proven to be of paramount importance in automotive, aeronautical, and biomedical applications due to their inherent attractive properties. In literature, the machinability assessment of magnesium alloys is limited in comparison to other alloys. The machinability assessment of AZ61 magnesium alloy seems untapped as per the a...

Nickel-based superalloys are classified as difficult-to-cut materials due to their high strength, toughness, cold work hardening, and low thermal conductivity, leading to chip adhesion, accelerated tool wear, and high cutting forces. In the meantime, high cutting forces and built-up edges increase the power consumption and corresponding carbon emis...

The metal processing industry faces significant environmental and energy consumption challenges, which are increasingly important in global sustainability initiatives. Traditional metal-cutting methods, which involve substantial quantities of cutting fluids and generate considerable waste and emissions, are now considered unsustainable. The sustain...

Numerical simulations of the cutting process play a key role in manufacturing and cost optimization. Inherent in finite element analysis (FEA) simulations is the correct description of material behavior during machining. For this purpose, various material models are used to describe the behavior of the material in the range of high deformation, hig...

Metal matrix composites (MMC) are used in a variety of industries, their applications including the major sectors such as automotive, medical, electrical, sports, electronics, and aerospace, due to their lightweight and exceptional mechanical and physical abilities. The key advantages of these materials are higher wear-resistance, stiffness, streng...

Purpose This paper is supposed to provide a critical review of current research progress on thermal management in grinding of superalloys, and future directions and challenges. By understanding the current progress and identifying the developing directions, thermal management can be achieved in the grinding of superalloys to significantly improve t...

Accurate prediction of cutting force is essential not only for estimating power and torque but also for precise chatter prediction, where even the derivative of the cutting force function is crucial. The traditional cutting force model does not consider the runout, and the enhanced models that consider it are often difficult to be established due t...

Sustainable manufacturing has become a global and societal goal. Although its execution is much slower, the manufacturing sector is also slowing down the unsustainable practices. One of the difficulties in the implementation of sustainability is to re-engineer its evaluation for specific fields. This study brings sustainable manufacturing underpinn...

The development of cutting-edge monitoring technologies such as embedded devices and sensors has become necessary to ensure an industrial intelligence in modern manufacturing by recording machine, process, tool, and energy consumption conditions. Similarly, machine learning based real time systems are popular in the context of Industry 4.0 and are...

The accelerated growth of 3D printing technologies has revolutionized the potential of ceramic materials, offering unprecedented control over microstructures, saving labor cost, material, and process time. Stereolithography-based 3D printing has grown to fabricate advanced ceramics materials with the flexibility of mass production. 3D printing gene...

The pursuit of enhanced cooling and lubrication methods for machining processes that are energy-efficient, environmentally friendly, and cost-effective is receiving significant attention from both academia and industry. The reduction of CO2 emissions is closely tied to electrical and embodied energy consumption. This study introduces a novel LN2 oi...

A new approach of measurement and analysis of PVD-TiAlN coated carbide tools in machining of Monel 400 alloy under hybrid cooling conditions, Measurement (2023), doi: https:// Abstract: This research work focuses on the efficacy of minimum quantity lubrication (MQL) and cryogenic carbon dioxide (CO 2) cooling in high-speed machining of nickel-based...

SiC particle-based aluminum matrix (SiCp/Al 20%) is characterized by poor surface quality, high cutting forces, and accelerated tool wear during machining. Environmentally friendly cooling/lubrication (CO2 snow, MQL) can advance the machinability of such composites even at high material removal rates. In this experimental study, milling of SiCp/Al...

Nowadays, the transportation industry is curious about fabricating lightweight vehicles under a sustainable manufacturing process to minimize fuel consumption costs and environmental footprints. Assessing the sustainability performance metrics of the friction stir welding (FSW) process reduces the sawing costs and environmental impacts. However, th...

Under different working conditions, the tribological characteristics of materials show a complicated and non-linear relation. As a result, it is crucial to advance tribology by prioritising a data-driven strategy to estimate service capability in order to expedite the material design and preparation. With this aim, the present work firstly deals wi...

Carbon fiber reinforced silicon carbide (C f /SiC) composite materials possess high strength， wear resistance， and anisotropy， thus their machining is very difficult and demands extra precautions. In this research， finite element analysis (FEA) simulations and experiments of the slot milling process have been carried out to analyze the cutting perf...

Metal matrix composites (MMCs) are lightweight, hard materials applied in heavy-duty applications such as automobile, aerospace, and electronics, as well as sports equipment. MMCs reveal exceptional physical and mechanical properties, including high strength, corrosion, wear resistance, higher stiffness, and toughness. However, owing to poor surfac...

Ti-6Al-4V alloy has widespread uses in a variety of engineering applications such as in the manufacturing of aerospace, automotive, and prosthetics body-parts owing to its unique characteristics. However, the machining of Ti-6Al-4V generates high cutting temperature due to poor thermal conductivity. This high cutting temperature triggers chemical r...

Among several kinds of metal matrix composite materials (MMCs), such as silicon-based reinforced aluminum matrix (SiCp/Al) composites have become the most valuable composite material due to their various applications in industries, sports equipment, electrons, and automotive. Due to the presence of hard ceramic reinforcements, the SiCp/Al composite...

In this innovative work, Inconel 718 alloy turning simulation models under dry and cryogenic machining (Cryo) conditions are developed. The machinability characteristics of the aforementioned alloy were assessed with relation to cutting temperature (Tct) and cutting force (Fcf). The comparison of the Tct and Fcf results from simulation with those o...

In this paper, the face milling experiments were performed to investigate the cutting process of SiCp/Al (SiCp 65%) volume percentage and their effect on tool life and tool wear mechanism. The study was performed based on different cutting parameters (cutting speed vc, feed per tooth fz, and axial depth of cut ap, 1mm, and width of cut ae 8mm,) and...

Response measurement of various functionality states of machines is an inevitable part of smooth production. An effectively efficient measurement and control system of the machinery helps the inspection engineers to detect failures. In the recent age, the concept of industry 5.0, which focuses on the interaction between humans and machines, has inc...

The application of cutting fluid in the field of engineering manufacturing has a history of hundreds of years, and it plays a vital role in the processing efficiency and surface quality of parts. Among them, water-based cutting fluid accounts for more than 90% of the consumption of cutting fluid. However, long-term recycling of water-based cutting...

This study investigates the corrosion behaviour of magnesium (Mg-AZ91D) alloy reinforced with nano metal oxides (ZnO, MnO, and TiO2) using the tribocorrosion methodology. The mechanical characteristics of the materials were investigated using ASTM standards for AZ91D alloy, AZ91D/ZnO, AZ91D/MnO, and AZ91D/TiO2 composites. The AZ91D/TiO2 nanocomposi...

Carbon fiber-reinforced plastics (CFRP) are widely used in the aerospace and automobile industries because of their ultralight weight, high strength, excellent corrosion resistance, and anti-fatigue properties. However, the machining of CFRP is still challenging due to its super hardness and sensitivity to heat. Cryogenic milling is a kind of susta...

Hybrid minimum quantity lubrication and compressed carbon dioxide (MQL + CO2) lubri-coolant can play a crucial role in advancing machinability as well as sustainability. However, it is also the fact that the high-pressure throttling of CO2 produces fog and hinders the low-pressure MQL mist to touch the cutting zone adequately. Therefore, a low-pres...

In aviation engineering, ensuring the safety and reliability of aviation parts has strict requirements. Compressive residual stresses can improve the corresponding performance by effectively resisting crack initiation and extending the fatigue lives of aviation parts. Shot peening is considered as a suitable processing technology for the introducti...

Hybrid lubri-cooling is a latest technology that provides synergistic cooling and lubrication effect in the machining area especially in the cutting of titanium and its alloys. In this current study, cryogenic-LN 2 , minimum quantity lubrication (MQL), and hybrid cryogenic LN 2-MQL are applied and compared against dry medium in perspective of in-de...

Cryogenic cooling has excellent cooling and poor lubrication, while minimum quantity lubrication (MQL) has vice versa. Therefore, eco-friendly hybrid lubri-coolants are getting attention nowadays to achieve sufficient cooling and lubrication for high-speed machining hard-to-cut materials. In this research, ethanol, Blaser oil, and hybrid ethanol-Bl...

Extreme pressure (EP) and antiwear (AW) additives are necessary for boundary lubrication. However, their mechanisms and physical and chemical properties remain unclear. EP and AW additives were reviewed to fill gaps in theoretical and industrial applications. Compounds containing chlorine, sulfur, and phosphorus elements were first used in boundary...

Haynes-25 is a cobalt-based alloy resistant to oxidation and possesses high-temperature properties. Despite the excellent properties, the machinability of Haynes-25 is extremely difficult. Sustainable machining of this alloy is inevitable for producing earth-friendly products. Thus, researchers and scientists have been seeking alternative sustainab...

Modern industries are seeking innovative and clean cooling techniques in the machining domain to reduce the cost and environmental impact of manufacturing. To diminish the environmental impact of machining, cryogenic and minimum quantity lubrication (MQL) are recent known cooling/lubrication techniques to determine a perfect alternative to mineral-...

Realizing the integrated manufacturing of components with high specific strength and stiffness is easy using carbon fiber reinforced polymer (CFRP), which has become the preferred material for weight reduction and efficiency enhancement in the aerospace field. Massive connection holes are machined in assembly. However, CFRP is a multiphase material...

Regenerative chatter is a major limitation in the milling of Ti-6Al-4V, resulting in undesirable surface and reducing cutting efficiency. It is well-acknowledged that variable pitch cutter and the process damping effect are effective methods to suppress chatter, and that these two methods are compatible. In this paper, a novel anti-vibration millin...

In this work, the drilling performance of carbon fibre reinforced plastic (CFRP) composites is analysed in terms of thrust force (Fn), torque (Mz), specific cutting energy (SEC), delamination factor (Fd), and hole quality under dry and cryogenic cooling conditions. An in-house developed multi-jet liquid nitrogen (LN2) delivery setup is used for exp...

Cutting fluid plays a cooling-lubrication role in the cutting of metal materials. However, the substantial usage of cutting fluid in traditional flood machining seriously pollutes the environment and threatens the health of workers. Environmental machining technologies, such as dry cutting, minimum quantity lubrication (MQL), and cryogenic cooling...

Recent burgeoning development in nanotechnology unfolded an avenue in the manufacturing industry. Owing to the superior heat transfer potential of nano-additives, it could be interesting to improve the heat transfer and tribological capability of metal cutting fluids by mixing nanofluids in emulsions properly. To attain high heat transfer performan...

It is a well-known fact that the consumption of conventional cutting fluids in metalworking industries leads to severe health and environmental issues. Owing to the EPA (Environmental Protection Agency) increasing regulations regarding pollution and contamination, there is a dire need for a greener fluid with excellent cooling and lubrication chara...

Although AISI52100 tool steel is commonly utilized under high temperature and fatigue applications owing to superior tensile strength, corrosion resistance, and stiffness, however, it is called difficult-to-cut material. In this work, a novel application of dry ice blasting as a cooling technology in milling AISI52100 tool steel is proposed to meas...

Water-based cutting fluid has a broad application area and a hundred year history, but its poor corrosion inhibition and anti-rust ability limit its further promotion. Adding corrosion inhibitors can effectively solve the above problems. However, no review papers are available on cutting fluid corrosion inhibitors, and their mechanism, suitability,...

To eliminate the negative effect of traditional metal-working fluids and achieve sustainable manufacturing, the usage of nano-enhanced biolubricant (NEBL) is widely researched in minimum quantify lubrication (MQL) machining. It’s improved tool wear and surface integrity have been preliminarily verified by experimental studies. The previous review p...

Burgeoning demand for machinability, health, and ecology, Environmental Protection Agency (EPA) regulations are pushing the modern manufacturing sector to apply dry or biodegradable cutting fluids, which are insufficient in the machining of difficult-to-cut materials. Therefore, this study is devoted to proposing a newly developed hybrid ethanol-es...

Aluminum alloy is the main structural material of aircraft, launch vehicle, spaceship, and space station and is processed by milling. However, tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy. The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters, material...

Dear Colleagues, The COVID-19 pandemic has pushed the modern manufacturing sector to seek advancements in machining processes with exceptional product quality, precise tolerances, and eco-friendly manufacturing. As mineral-based emulsion cooling is common practice in the industry to machine difficult-to-cut materials, design and machining using a...

It is an inevitable trend of sustainable manufacturing to replace flood and dry machining with minimum quantity lubrication (MQL) technology. Nevertheless, for aeronautical difficult-to-machine materials, MQL couldn’t meet the high demand of cooling and lubrication due to high heat generation during machining. Nano-biolubricants, especially non-tox...

Cutting fluid has cooling and lubricating properties and is an important part of the field of metal machining. Owing to harmful additives, base oils with poor biodegradability, defects in processing methods, and unreasonable emissions of waste cutting fluids, cutting fluids have serious pollution problems, which pose challenges to global carbon emi...

Grinding is one of the important machining processes that are widely applied in precision manufacturing. In the beginning, studies mostly focused on dry machining. In time, emerging technologies have led to change in the development of the machining process. New techniques and tools have been developed over the last decade that has brought the proc...

Advance cooling/lubrication (lubricooling) approaches are getting fame in industry and academia due to their excellent performance. A significant amount of work has been conducted to investigate the effect of various lubricooling approaches on the machinability of the hardened steel. However, sustainability-based performance evaluation of lubricool...

Carbon fiber–reinforced polymers (CFRPs) are vulnerable to damage locally through machining operations due to an applied cutting force and high-temperature generation. Though traditional lubri-cooling medium will reduce the heat-generated damage of CFRPs, the use of synthetic fluids, however, significantly affects the environment and public health...

Recent burgeoning development in nanotechnology unfold an avenue in the manufacturing industry. Owing to the superior heat transfer potential of nanoadditives mentioned recently, it could be interesting to improve the heat transfer and tribological capability of metal cutting fluids by mixing nanofluids in emulsions properly. In order to attain hig...

Titanium, being a structural material, undergoes drilling process frequently for its engineering applications. The superior mechanical properties of titanium alloys make hole-making a highly unsustainable process. The process is marred by high cutting forces, intense tool damage, high energy consumption, poor hole quality, and high process cost. Th...

In this work, a novel hybrid lubri-cooling (ethanol, ester oil, dry ice) is proposed as metal cutting fluid. To validate the effectiveness of the proposed hybrid lubri-cooling, thermo-physical, and tribological performance is tested initially with pin-on-disc (WC–6Co, Ti–6Al–4V) tribology. The effectiveness of ethanol-ester oil with/without mixing...

The manufacturing industries consume one-third of global energy. Intensive use of electrical energy in industries provides the researchers and experts strong reasons to develop and propose strategies to minimize energy consumption. Evidently, the advanced technologies such as nanofluid minimum quantity lubrication in machining and process optimizat...

Owing to limited rigidity and wall thickness, the machining of thin-walled components leads to chatter, poor surface quality, and low productivity. It is well-acknowledged that end-mill geometry and cutting conditions have a significant influence on the process stability of thin-walled parts. In order to reduce the milling chatter, an anti-vibratio...

Machining of titanium is considered as a challenging process due to its ability to interact with various tool materials when critical cutting temperature is exceeded, resulting in excessive tool wear and poor surface finish, etc. To exhibit an efficient machining process, this research study has experimentally investigated the key quality indicator...

The present study shows the optimization of process parameters of additive manufacturing, joining, and subtractive manufacturing processes: (i) fused deposition modeling (ii) submerged arc welding (iii) turning. The adopted evolutionary methods are particle swarm optimization (PSO), classical bacterial foraging optimization (C‐BFO), self‐adaptive b...

Hole-making in CFRP plates has been unsustainable due to poor hole quality, high specific energy consumption, a trade-off between shortened drill life and low productivity, and high processing cost. This experimental study investigates the effects of using throttle and evaporative cryogenic fluids, actualized by applying compressed carbon dioxide a...

Air-leakage detection is among the most important processes at the assembly stage of unclosed components, especially for large aircraft. A series of air-leakage detecting methods are generally applied during the final assembly, nevertheless, many of them are less effective to detect the leakage at the assembly stage. The present study aims to discu...

Lightweight materials are finding plentiful applications in various engineering sectors due to their high strength-to-weight ratios. Hole-making is an inevitable requirement for their structural applications, which is often marred by thermal damages of the drill causing unacceptable shortening of tool life. Efficient cooling of the tool is a prime...

A well-acknowledged role of cutting fluids in any cutting operation has made them inevitable to utilize regarding the provision of adequate cooling and lubrication. Mineral-based cutting fluids are common practice in the industry; however, they are not suitable for our ecology and health. Therefore, there is a need to implement sustainable cooling/...

This study focuses on the development and property enhancement of novel Muntingia Calabura bark micro-fiber reinforced bio-epoxy composite through surface modification techniques using NaOH and silane. The proposed novel plant fiber was extracted from an agro-waste after the tree’s lifespan which was causing landfill. The performance characteristic...

The urgent need for an innocuous and sustainable machining system is essential in this modern manufacturing era. Therefore, a study is devoted to fulfilling a missing bridge between sustainability measures (process time, specific cutting energy, energy efficiency, carbon emissions) and machining characteristics (tool wear, surface roughness, cuttin...

China’s manufacturing sector accounts for more than half of the country’s total energy demand, and specifically, metal processing is one of the manufacturing sectors that consume significant energy. However, reducing the electrical energy consumption of the machine tool, improving productivity, and ultimately increasing profit is a challenge while...