spin-while-burn: the new approach for tiny medical device fabrication

This book explains the challenges and advancements in cutting precise cylindrical shapes on difficult materials through spark erosion. Titled ＂Spin while Burn,＂ it addresses the drawbacks associated with this process, including unsatisfactory surface finish and limited productivity. Despite utilizing advanced computing and statistical optimization methods, achieving the ideal balance between material removal rate (MRR) and surface quality remains elusive. In response, the book introduces a hybrid ultrasonic-assisted approach in the wire electrical discharge turning (WEDT) process. By integrating a rotating workpiece with ultrasonic vibration, the authors evaluate its impact on MRR and surface finish. Through meticulous design experiments and statistical analysis, they explore various cutting parameters and machining paths. The book highlights the characterization of machined surfaces through elemental analysis and surface morphology evaluations. The results demonstrate the positiveeffects of integrating ultrasonic vibration into WEDT, even without optimized ultrasonic parameters. By reducing electrode wire debris and employing multi-objective parameter optimization using the genetic algorithm, significant improvements are achieved in MRR and surface roughness compared to conventional WEDT. ＂Spin while Burn＂ consists of five chapters, delving into the challenges, history, principles, performance, and future perspectives of the Spin-while-Burn process in manufacturing. This comprehensive book offers valuable insights into enhancing surface quality and productivity in the cutting of precise cylindrical shapes on challenging materials through spark erosion.

MOHD SHAHIR KASIM, is a Professor in the Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin. He received his BEng from Coventry University, United Kingdom, MSc. from Universiti Putra Malaysia in manufacturing system engineering and PhD in mechanical and material engineering from National University of Malaysia. He has six years of industrial experience in sugar refinery, petrol chemical and aircraft manufacturing and as visiting professor at Tokushima University, Japan. His research interest includes high speed machining on Inconel 718 and process optimization.

MUHAMMAD AKMAL MOHD ZAKARIA, received his Master of Science and Bachelor of Engineering (Hons) in Manufacturing Engineering majoring in Process and Precision Engineering from Universiti Teknikal Malaysia Melaka. He is a PhD Student at Advanced Manufacturing Centre, Universiti Teknikal Malaysia Melaka. He started his professional career as Project Engineer specialized in factory digitalization, internet of things (IoT) and real-time optimization at Nitto Denko Materials Malaysia. His area of interest includes statistical-artificial intelligence modelling, advanced machining and computational mechanics.

SAIFUL BAHRI MOHAMED, is a professor at the Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin (UniSZA), Terengganu, Malaysia. Presently, he is the Dean of the Faculty of Design and Innovative Technology, UniSZA. He completed his studies at Sultan Zainal Abidin Religious College in 1989, and earned an Industrial Technology diploma. Two years later, Dr. Saiful Bahri graduated with a Bachelor of Manufacturing Systems Engineering (Hons) from Newcastle Upon Tyne Polytechnic, UK. He then was employed for two years as an Engineer in Product Support Development in ASTEC Pekan Sdn. Bhd. Utilizing his bachelor’s degree. He graduated in 1995 and completed his studies at Loughborough University of Technology, UK and was awarded an MSc in Science (Computer integrated manufacturing). Then, he became a member of KUSZA as a junior lecturer program and pursued his studies at Salford University, UK and was awarded the title of a PhD in Manufacturing in the year 2000