Mustafizur Rahman is a highly visible researcher in the areas of micro/nano machining and covering both conventional (turning, milling, etc.) and non-conventional EDM, ECM, wire-EDM, etc.) processes. He is the first researchers in the world to propose compound machining processes using both conventional and non-conventional simultaneously and/or sequentially, especially in the areas of micro and nano machining.
He is the first person in the world to develop a first of its kind machine to carry out this compound machining to perform multiple machining processes in one setup thus removing the error due to setup. This new-concept machine has made a paradigm shift in the domain of micro and machining. His group has the credit of establishing “simultaneous EDM and ECM process” first time in the world.
He has successfully established a new machining zone termed “extrusion-like mechanism zone” in addition to the usually known “ploughing and shearing zones”. This new concept proposed through analytical solution has been substantiated through experimental investigations. This concept has clearly explains the “ductile mode machining” of even brittle material and enables mirror finish surfaces without the application of any further processing, like grinding and/or polishing. This mode of machining is very useful for optics industries.
His most significant contribution in the areas of micro and nano machining is reflected through the book “Advanced Machining Processes” (Volume 11 of Comprehensive Materials Processing)which has been compiled by him and published by Elsevier. It is most likely the first book on fundamentals of micro/nano machining. It is composed of his significant breakthrough innovations in manufacturing mostly through his PhD supervision projects. He has also added few chapters from other renowned professors working in related areas.