Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions.

Khan, Muhammad Ali; Jaffery, Syed Husain Imran; Khan, Mushtaq; Younas, Muhammad; Butt, Shahid Ikramullah; Ahmad, Riaz; Warsi, Salman Sagheer

doi:10.5194/ms-10-561-2019

Blue hydrogen in the United Kingdom: a policy and environmental case study. (2025)
Journal Article
OBUROH, A., OKE, A., NJUGUNA, J. and YOUNAS, M. [2025]. Blue hydrogen in the United Kingdom: a policy and environmental case study. Energy reviews [online], In Press. Available from: https://doi.org/10.1016/j.enrev.2025.100131

Blue hydrogen is one of the energy carriers to be adopted by the United Kingdom to reduce emissions to net Zero by 2050 and its use is majorly influenced by policy and technological innovations. With more than 10 blue hydrogen facilities planning pro... Read More about Blue hydrogen in the United Kingdom: a policy and environmental case study..

Numerical analysis and life cycle assessment of type V hydrogen pressure vessels. (2025)
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SAHARUDIN, M.S., HASBI, S., SAHU, S.K., MA, Q. and YOUNAS, M. 2025. Numerical analysis and life cycle assessment of type V hydrogen pressure vessels. Journal of composites science [online], 9(2), article number 75. Available from: https://doi.org/10.3390/jcs9020075

The growing concern about greenhouse gas emissions and global warming has heightened the focus on sustainability across industrial sectors. As a result, hydrogen energy has emerged as a versatile and promising solution for various engineering applica... Read More about Numerical analysis and life cycle assessment of type V hydrogen pressure vessels..

Innovative and sustainable advances in polymer composites for additive manufacturing: processing, microstructure, and mechanical properties. (2025)
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SAHARUDIN, M.S., ULLAH, A. and YOUNAS, M. 2025. Innovative and sustainable advances in polymer composites for additive manufacturing: processing, microstructure, and mechanical properties. Journal of manufacturing and materials processing [online], 9(2), article number 51. Available from: https://doi.org/10.3390/jmmp9020051

Additive manufacturing (AM) has revolutionised the production of customised components across industries such as the aerospace, automotive, healthcare, electronics, and renewable energy industries. Offering unmatched design freedom, reduced time-to-m... Read More about Innovative and sustainable advances in polymer composites for additive manufacturing: processing, microstructure, and mechanical properties..

Investigating wire electric-discharge machining (WEDM) parameters for improved machining of D2 steel: a multi-objective optimization study. (2025)
Journal Article
AFRIDI, S.A., YOUNAS, M., KHAN, Z. and KHAN, A.M. [2025]. Investigating wire electric-discharge machining (WEDM) parameters for improved machining of D2 steel: a multi-objective optimization study. International journal of precision engineering and manufacturing [online], Latest articles. Available from: https://doi.org/10.1007/s12541-024-01203-4

Wire Electric-Discharge Machining (WEDM) represents a non-traditional approach to metal cutting, providing the advantage of precision manufacturing over conventional methods. In recent years, the metal machining industry has witnessed numerous benefi... Read More about Investigating wire electric-discharge machining (WEDM) parameters for improved machining of D2 steel: a multi-objective optimization study..

Digital twin framework using real-time asset tracking for smart flexible manufacturing system. (2025)
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ULLAH, A., YOUNAS, M. and SAHARUDIN, M.S. 2025. Digital twin framework using real-time asset tracking for smart flexible manufacturing system. Machines [online], 13(1), article 37. Available from: https://doi.org/10.3390/machines13010037

This research article proposes a new method for an enhanced Flexible Manufacturing System (FMS) using a combination of smart methods. These methods use a set of three technologies of Industry 4.0, namely Artificial Intelligence (AI), Digital Twin (DT... Read More about Digital twin framework using real-time asset tracking for smart flexible manufacturing system..

Insights into machining techniques for additively manufactured Ti6Al4V alloy: a comprehensive review. (2024)
Journal Article
SAMBO, A.M., YOUNAS, M. and NJUGUNA, J. 2024. Insights into machining techniques for additively manufactured Ti6Al4V alloy: a comprehensive review. Applied sciences [online], 14(22), article number 10340. Available from: https://doi.org/10.3390/app142210340

Investigation into the post-processing machinability of Ti6Al4V alloy is increasingly crucial in the manufacturing industry, particularly in the machining of additively manufactured (AM) Ti6Al4V alloy to ensure effective machining parameters. This re... Read More about Insights into machining techniques for additively manufactured Ti6Al4V alloy: a comprehensive review..

Machinability performance of single coated and multicoated carbide tools during turning Ti6Al4V alloy. (2024)
Journal Article
ALI, A., YOUNAS, M., KHAN, M., JAFFERY, S.H.I. and KHAN, Z. [2024]. Machinability performance of single coated and multicoated carbide tools during turning Ti6Al4V alloy. International journal of precision engineering and manufacturing [online], Latest Articles. Available from: https://doi.org/10.1007/s12541-024-01147-9

This paper presents the machinability performance of uncoated, single-coated, and multicoated carbide tools during turning of Grade 5 (Ti6Al4V) Titanium alloy, which is challenging to machine due to its distinctive material properties. Coated tools w... Read More about Machinability performance of single coated and multicoated carbide tools during turning Ti6Al4V alloy..

Development and application of digital twin control in flexible manufacturing systems. (2024)
Journal Article
ULLAH, A. and YOUNAS, M. 2024. Development and application of digital twin control in flexible manufacturing systems. Journal of manufacturing and materials processing [online], 8(5), article number 214. Available from: https://doi.org/10.3390/jmmp8050214

Flexible manufacturing systems (FMS) are highly adaptable production systems capable of producing a wide range of products in varying quantities. While this flexibility caters to evolving market demands, it also introduces complex scheduling and cont... Read More about Development and application of digital twin control in flexible manufacturing systems..

Optimizing DMF utilization for improved MXene dispersions in epoxy nanocomposites. (2024)
Journal Article
JANJUA, A.A., YOUNAS, M., ILYAS, R.A., SHYHA, I., FAISAL, N.H., INAM, F. and SAHARUDIN, M.S. 2024. Optimizing DMF utilization for improved MXene dispersions in epoxy nanocomposites. Journal of composites science [online], 8(9), article 340. Available from: https://doi.org/10.3390/jcs8090340

Dimethylformamide (DMF), a polar solvent, is commonly used for preparing graphene/epoxy nanocomposites. While previous research has commonly predominantly highlighted the improvement in physio-mechanical properties of these nanocomposites, the effect... Read More about Optimizing DMF utilization for improved MXene dispersions in epoxy nanocomposites..

Impact of dry and cryogenic cutting medium on shear angle and chip morphology in high-speed machining of titanium alloy (Ti-6Al-4V). (2024)
Journal Article
HASSAN, A., KHAN, M.A., YOUNAS, M., JAFFERY, S.H.I., KHAN, M., AHMED, N. and AWANG, M. 2024. Impact of dry and cryogenic cutting medium on shear angle and chip morphology in high-speed machining of titanium alloy (Ti-6Al-4V). International journal of automotive and mechanical engineering [online], 21(2), pages 11316-11331. Available from: https://doi.org/10.15282/ijame.21.2.2024.11.0874

Ti-6Al-4V, a titanium alloy, is widely employed in various engineering sectors due to its attractive combination of strong corrosion resistance and specific strength. However, titanium alloys frequently result in serrated chips, which present conside... Read More about Impact of dry and cryogenic cutting medium on shear angle and chip morphology in high-speed machining of titanium alloy (Ti-6Al-4V)..

Investigation of tool wear and energy consumption in machining Ti6Al4V alloy with uncoated tools. (2024)
Journal Article
YOUNAS, M., KHAN, M., JAFFERY, S.H.I., KHAN, Z. and KHAN, N. 2024. Investigation of tool wear and energy consumption in machining Ti6Al4V alloy with uncoated tools. International journal of advanced manufacturing technology [online], 132(7-8), pages 3785-3799. Available from: https://doi.org/10.1007/s00170-024-13548-1

This research studies the energy consumption and wear mechanism of carbide cutting tools in dry machining of Ti6Al4V alloy. In the first phase of experiments, full factorial design experiments were employed to study the tool wear rate (R) and specifi... Read More about Investigation of tool wear and energy consumption in machining Ti6Al4V alloy with uncoated tools..

Hydrodynamic characterisation of fire sprinkler system of a passenger railroad car. (2023)
Journal Article
CRAIG, M., YOUNAS, M. and ASIM, T. 2023. Hydrodynamic characterisation of fire sprinkler system of a passenger railroad car. International journal of condition monitoring and diagnostic engineering management (COMADEM) [online], 26(3), pages 15-23. Available from: https://apscience.org/comadem/index.php/comadem/article/view/403

Fire safety is one of the major concerns in the public transport and thus passenger trains in the UK seek continuous improvement in passenger safety and comfort. In order to combat fire, there is a legal requirement in most countries across the globa... Read More about Hydrodynamic characterisation of fire sprinkler system of a passenger railroad car..

Multi-objective parametric optimization of driver-based electromagnetic sheet metal forming of SS304 using AA6061-T6 driver. (2023)
Journal Article
KHAN, Z., KHAN, M., YOUNAS, M., DANISH, A.S., KHAN, A. and DJAVANROODI, F. 2024. Multi-objective parametric optimization of driver-based electromagnetic sheet metal forming of SS304 using AA6061-T6 driver. Mechanics of advanced materials and structures [online], 31(5), pages 6593-6606. Available from: https://doi.org/10.1080/15376494.2023.2235344

This study uses statistical techniques to optimize the electromagnetic forming process for driver-based sheet metal forming with a flat coil. AA6061T6 sheet was used as a driver to form SS304 sheets. The optimization of maximum elongation, die fittin... Read More about Multi-objective parametric optimization of driver-based electromagnetic sheet metal forming of SS304 using AA6061-T6 driver..

Dynamic analysis of closed die electromagnetic sheet metal forming to predict deformation and failure of AA6061-T6 alloy using a fully coupled finite element model. (2022)
Journal Article
KHAN, Z., KHAN, M., YOOK, S.-J., KHAN, A., YOUNAS, M., ZAHIR, M.Z. and ASAD, M. 2022. Dynamic analysis of closed die electromagnetic sheet metal forming to predict deformation and failure of AA6061-T6 alloy using a fully coupled finite element model. Materials [online], 15(22), article 7997. Available from: https://doi.org/10.3390/ma15227997

This research presents a fully coupled 3D numerical model to analyse the dynamics of high-speed electromagnetic forming process for aluminium alloy AA6061-T6. The effect of Lorentz force distribution, velocity and kinetic energy on deformation, the b... Read More about Dynamic analysis of closed die electromagnetic sheet metal forming to predict deformation and failure of AA6061-T6 alloy using a fully coupled finite element model..

Mechanical properties and weld characteristics of friction stir welding of thermoplastics using heat-assisted tool. (2022)
Journal Article
SHAH, F., YOUNAS, M., KHAN, M., KHAN, A., KHAN, Z. and KHAN, N. 2023. Mechanical properties and weld characteristics of friction stir welding of thermoplastics using heat-assisted tool. Welding in the world [online], 67(2), pages 309-323. Available from: https://doi.org/10.1007/s40194-022-01385-3

Friction stir welding (FSW) is a welding technique in which a non-consumable rotating tool with a profiled pin is pressed on the adjoining surfaces and transverse along the welding direction to produce a weld trail. The technique was first applied to... Read More about Mechanical properties and weld characteristics of friction stir welding of thermoplastics using heat-assisted tool..

Development and analysis of tool wear and energy consumption maps for turning of titanium alloy (Ti6Al4V). (2021)
Journal Article
YOUNAS, M., JAFFERY, S.H.I., KHAN, A. and KHAN, M. 2021. Development and analysis of tool wear and energy consumption maps for turning of titanium alloy (Ti6Al4V). Journal of manufacturing processes [online], 62, pages 613-622. Available from: https://doi.org/10.1016/j.jmapro.2020.12.060

Machine tools are the main source of electric power consumption in industrial operations. Thus, in manufacturing, energy-efficient and cleaner production methods are preferred to mitigate production costs. Titanium alloys are known for their poor mac... Read More about Development and analysis of tool wear and energy consumption maps for turning of titanium alloy (Ti6Al4V)..

Numerical and experimental investigation of the effect of process parameters on sheet deformation during the electromagnetic forming of AA6061-T6 alloy. (2020)
Journal Article
KHAN, Z., KHAN, M., JAFFERY, S.H.I., YOUNAS, M., AFAQ, K.S. and KHAN, M.A. 2020. Numerical and experimental investigation of the effect of process parameters on sheet deformation during the electromagnetic forming of AA6061-T6 alloy. Mechanical sciences [online], 11(2), pages 329-347. Available from: https://doi.org/10.5194/ms-11-329-2020

Electromagnetic forming is a high-speed sheet metal forming technique to form metallic sheets by applying magnetic forces. In comparison to the conventional sheet metal forming process, electromagnetic forming is a process with an extremely high velo... Read More about Numerical and experimental investigation of the effect of process parameters on sheet deformation during the electromagnetic forming of AA6061-T6 alloy..

Synthesis and characterization of CoFe2O4/MWCNTs nanocomposites and high-frequency analysis of their dielectric properties. (2020)
Journal Article
KHAN, L.U., YOUNAS, M., KHAN, S.U. and REHMAN, M.Z.U. 2020. Synthesis and characterization of CoFe2O4/MWCNTs nanocomposites and high-frequency analysis of their dielectric properties. Journal of material engineering and performance [online], 29(1), pages 251-258. Available from: https://doi.org/10.1007/s11665-020-04572-9

Nanoparticles of CoFe2O4 were synthesized by chemical co-precipitation method. The CoFe2O4/MWCNT nanocomposites were synthesized with increasing contents of MWCNTs, i.e., 0.0, 2.0, 3.0, and 5.0% by weight via ultrasonication method in a dispersive me... Read More about Synthesis and characterization of CoFe2O4/MWCNTs nanocomposites and high-frequency analysis of their dielectric properties..

Multi-objective optimization of turning titanium-based alloy Ti-6Al-4V under dry, wet, and cryogenic conditions using gray relational analysis (GRA). (2020)
Journal Article
KHAN, M.A., JAFFERY, S.H.I., KHAN, M., YOUNAS, M., BUTT, S.I., AHMAD, R. and WARSI, S.S. 2020. Multi-objective optimization of turning titanium-based alloy Ti-6Al-4V under dry, wet, and cryogenic conditions using gray relational analysis (GRA). International journal of advanced manufacturing technology [online], 106(9-10), pages 3897-3911. Available from: https://doi.org/10.1007/s00170-019-04913-6

In modern manufacturing industries, the importance of multi-objective optimization cannot be overemphasized particularly when the desired responses are differing in nature towards each other. With the emergence of new technologies, the need to achiev... Read More about Multi-objective optimization of turning titanium-based alloy Ti-6Al-4V under dry, wet, and cryogenic conditions using gray relational analysis (GRA)..

Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions. (2019)
Journal Article
KHAN, M.A., JAFFERY, S.H.I., KHAN, M., YOUNAS, M., BUTT, S.I., AHMAD, R. and WARSI, S.S. 2019. Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions. Mechanical sciences [online], 10(2), pages 561-573. Available from: https://doi.org/10.5194/ms-10-561-2019

Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of h... Read More about Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions..

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