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Engineering, Industrial & Manufacturing Engineering; nano-TiO2; water-based nanolubricant; hot rolling; grain refinement
Online: 22 May 2018 (12:27:13 CEST)
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Hot rolling tests of a low-alloy steel were conducted at a rolling temperature of 850 ℃ under different lubrication conditions, including benchmarks (dry condition and water) and water-based nanolubricants containing different concentrations of nano-TiO2 from 1.0 to 8.0 wt%. The effects of nanolubricants on rolling force, surface roughness, thickness of oxide scale and microstructure were systematically investigated through varying nano-TiO2 concentrations. The results show that the application of nanolubricants can decrease the rolling force, surface roughness and oxide scale thickness of rolled steels, and refine ferrite grains. In particular, the nanolubricant containing an optimal concentration (4.0 wt%) of nano-TiO2 demonstrates the best lubrication performance, owing to the synergistic effect of lubricating film, rolling, polishing and mending generated by nano-TiO2.
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Engineering, Industrial & Manufacturing Engineering; flare stack; non-destructive testing; inspection; guy wires; drones
Online: 17 May 2018 (08:00:41 CEST)
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Flare stacks are a key element in the safety of petrochemical and refinery industries; the correct operating conditions thereof must be ensured through a schedule for the periodic reviewing of all parts thereof. Advances in Non-Destructive Testing (NDT) in recent years and the application thereof to this field allow reliable, objective information to be obtained. This article describes and groups together the main applicable NDT techniques, analysing their advantages and disadvantages, updated with the new possibilities offered by unmanned aircraft or drones.
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Engineering, Industrial & Manufacturing Engineering; battery; commercialization; markov chain; new technology; techno-economic
Online: 4 May 2018 (10:16:46 CEST)
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LiFePO4 (LFP) or Lithium-ion battery with its advantages compared to common current motorcycle battery is an appropriate alternative in substituting wet and dry cell battery. Huge amount of demand of motorcycle along with the battery in Indonesia also make it an interesting product for business. In order to assess the commercial potential for such a new technology, market share needs to be estimated as well as the techno-economic feasibility. Hence, market share prediction using the residents of Surakarta Region and techno-economic analysis using NPV, IRR and PBP indicators have been conducted in this study. Calculation using markov chain method shows that LFP battery tends to dominate the market after certain period. Techno-economic analysis also figures out that the commercialization is feasible in three conditions - first mover, even with market leader and equilibrium point. Therefore, there is a great commercial potential for LFP battery especially in Indonesia.
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Engineering, Industrial & Manufacturing Engineering; magnesium alloy; accumulative roll bonding; thermal conductivity; texture
Online: 30 April 2018 (17:45:59 CEST)
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Accumulative roll bonding (ARB) is one of methods of severe plastic deformation which is relevant for industrial production of sheets. While mechanical properties of several magnesium alloys subjected to ARB process have been studied, the physical properties have been reported only for some magnesium alloys. These properties are influenced by the texture developed during the ARB process and the temperature load. In the presented contribution, we studied thermal diffusivity and thermal conductivity of an AZ31 magnesium alloy after 1 and 2 passes through the rolling mill. Thermal diffusivity was measured with the laser-flash method in the temperature range between 20 and 350 °C. Thermal conductivity depends on the number of rolling passes. The microstructure and texture of sheets are significant factors influencing the thermal properties.
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Engineering, Industrial & Manufacturing Engineering; laser hardening; geometrical approach; punctual approach; Taguchi method; artificial neural network
Online: 27 April 2018 (05:47:56 CEST)
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Maximum hardness and hardened depth are the responses of interest in relation to the laser hardening process. These values define heat treatment quality and have a direct impact on mechanical performance. This paper aims to develop models capable of predicting the shape of the hardness profile depending on laser process parameters for controlling laser hardening quality (LHQ), or rather the response values. An experimental study was conducted to highlight hardened profile sensitivity to process input parameters such as laser power (PL), beam scanning speed (VS) and initial hardness in the core (HC). LHQ modeling was conducted by modeling attributes extracted from the hardness profile curve using two effective techniques based on the punctual and geometrical approaches. The process parameters with the most influence on the responses were laser power, beam velocity and initial hardness in the core. The obtained results demonstrate that the geometrical approach is more accurate and credible than the punctual approach according to performance assessment criteria.
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Engineering, Industrial & Manufacturing Engineering; rapid prototyping; fused deposition; filament jams; extrusion failures; photogrammetry; manufacturing system
Online: 23 April 2018 (11:27:40 CEST)
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The main purpose of this paper is to present a system to detect extrusion failures in Fused Deposition Modelling (FDM) 3D printers by sensing that the filament is moving forward properly. After several years using these kind of machines, authors detected that there is not any system to detect the main problem in FDM machines. Authors thought in different sensors and used the Weighted Objectives Method, one of the most common evaluation methods, for comparing design concepts based on an overall value per design concept. Taking into account the obtained scores of each specification, the best choice for this work is the optical encoder. Once the sensor is chosen, it is necessary to design de part where it will be installed without interfering with the normal function of the machine. To do it, photogrammetry scanning methodology was employed. The developed device perfectly detects the advance of the filament without affecting the normal operation of the machine. Also, it is achieved the primary objective of the system, avoiding loss of material, energy and mechanical wear, keeping the premise of making a low-cost product that does not significantly increase the cost of the machine. This development has made it possible to use the printer with remains coil filament, which were not spent because they were not sufficient to complete an impression and also printing models in two colours with only one extruder.
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Engineering, Industrial & Manufacturing Engineering; bio-phosphate; ABC Animal-Bone-Char; 3R pyrolysis; phosphorus recovery; animal by-products; apatite
Online: 10 April 2018 (16:28:11 CEST)
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Disrupted nutrient recycling is a significant problem for Europe, while phosphorus and nitrogen are wasted instead of being used for plant nutrition. Mineral phosphate is critical raw material, which contains environmentally hazardous elements such as cadmium and uranium. Therefore, phosphorus recovery from agricultural by-product streams is critically important key priority. Phosphorus recovery from food grade animal bone by-products have been applied researched since 2002 with objective driven evolution progress towards specialized pyrolysis processing technology and animal bone char product (ABC) developments in economical industrial scale. Different animal bone by-products tested under different conditions at 400 kg/h throughput capacity in the continuously operated 3R zero emission autothermal carbonization system. The different material core treatment temperatures (between >300°C and <850°C) were combined with different residence times under industrial productive processing conditions. It has been industrial demonstrated that material core treatment temperature <850°C with 20 minutes residence time is necessary to achieve high quality ABC with useful agronomic value. The output ABC product having concentrated >30% phosphorus pentoxide (P2O5) and specific quality innovative fertilizer for agronomical efficient organic and low input farming applications as functional organic fertilizer, soil improver, growing medium and/or fertilizing product blend with high mineral phosphate fertiliser replacement value.
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Engineering, Industrial & Manufacturing Engineering; onion drying; exergy analysis; exergetic improvement potential rate; sustainability index
Online: 19 March 2018 (09:44:37 CET)
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This research work is concerned in the exergy analysis of the continuous-convection drying of onion. The influence of temperature and air flow rate was studied in terms of exergy parameters. The energy and exergy balances were carried out taking into account the onion drying chamber. Its behaviour was analysed based on exergy efficiency, exergy loss rate, exergetic improvement potential rate and sustainability index. The exergy loss rates increase with the temperature and air flow rate augmentation. Exergy loss rate is augmented at higher drying air temperatures and flow rates because the overall heat transfer coefficient increase. On the other hand, the exergy efficiency increases with the air flow rate augmentation. This behavior is due to the energy utilization was improved because the most amount of supplied energy was utilized for the moisture evaporation. However, the exergy efficiency decreases with the temperature augmentation due to the free moisture is less, then, the moisture begins diffusing from the internal structure to the surface. The exergetic improvement potential rate values show that the onion drying process presents a high potential to improve the exergy efficiency. The sustainability index of the drying chamber varied from 1.9 to 5.1. To reduce the environmental impact of the process, the parameters must be modified in order to ameliorate the exergy efficiency of the process.
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Engineering, Industrial & Manufacturing Engineering; open microcontrolled platform; data acquisition; remote measurement
Online: 8 March 2018 (15:21:13 CET)
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The commercial equipment that carries out the measurement of temperature has a high cost. Therefore, this article describes the development of a temperature measurement equipment, which uses a microcontrolled platform, responsible for managing the data of the collected temperature signals and making available the acquired information, so that they can be verified in real time at the measurement site, or remotely. The construction of the temperature measurement equipment was performed using open platform hardware / software, where performance tests were carried out with the objective of developing a temperature measurement equipment that has measurement quality and low cost.
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Engineering, Industrial & Manufacturing Engineering; Oxygen monitoring; LED; Photoluminescence; Wine production; Fermentation process; Process control.
Online: 1 March 2018 (16:16:37 CET)
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The importance of oxygen in the winemaking process is widely known, as it affects the chemical aspects and therefore the organoleptic characteristics of the final product. Hence, it is evident the usefulness of a continuous and real-time measurements of the levels of oxygen in the various stages of the winemaking process, both for monitoring and for control. The WOW project has focused on the design and the development an innovative device for monitoring the oxygen levels in wine. This system is based on the use of an optical fiber to measure the luminescent lifetime variation of a reference metal/porphyrin complex, which decays in presence of oxygen. The developed technology results in a high sensitivity and low cost sensor head that can be employed for measuring the dissolved oxygen levels at several points inside a wine fermentation or aging tank. This system can be complemented with dynamic modeling techniques to provide predictive behavior of the nutrient evolution in space and time given few sampled measuring points for both process monitoring and control purposes. The experimental validation of the technology has been first performed in a controlled laboratory setup to attain calibration and study sensitivity with respect to different photo-luminescent compounds and alcoholic or non-alcoholic solutions, and then in an actual case study during a measurement campaign at a renown Italian winery.
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Engineering, Industrial & Manufacturing Engineering; Product Service System (PSS); Servitization; Productization; Symbiosis; Enterprise Management; Conceptual Framework; Strategic Change
Online: 16 February 2018 (18:09:13 CET)
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To remain competitive in the current market, an enterprise must differentiate itself based on higher value propositions. For this purpose, since improving the product or service performance can reach some limits, one potential solution is to move towards new combinations of products and services. This evolution, called servitization, leads to the generation of Product-Service Systems (PSS). Servitization requires not only a clear understanding of enterprise core business but also a clear vision on the prevailing trends and challenges of PSS development from both business and technological points of view. In addition, the evolution path should be aligned with the enterprise strategy. This paper first highlights the notion of symbiotic PSS where Product Systems and Service Systems, and their stakeholders, interoperate seamlessly based on a win-win approach. Then it proposes a PSS Conceptual Framework (PSS-CF) which can be applied in the early stages of servitization to increase the understating of PSS dimensions and to facilitate the prioritization of the servitization investments. The framework dimensions were discussed in several iterations, from both academic and industrial points of view, in the frame of a European research project. Moreover, the applicability of the framework was studied in four different industrial Use-Cases.
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Engineering, Industrial & Manufacturing Engineering; product service system (pss); servitization; productization; conceptual model; conceptualization; enterprise management; strategic change
Online: 11 February 2018 (04:16:52 CET)
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Servitization or productization, indicating evolution from product to service economy or vice-versa, can be considered as a successful strategy to gain competitiveness based on novel combination of products and services. To decrease the risks of servitization and to support the sustainable development of its main outcome, being Product Service System (PSS), it is required not only to have a clear and common understanding of the core business and processes but also to share the same definitions on (PSS) concepts as the main outcome of servitization. For this purpose, managers could be supported by abstract models with a limited number and high ratio of known concepts in the early stages of PSS development. Through an extensive literature review on this subject, followed by a structured conceptualization approach and discussions with domain experts, this paper proposes a Conceptual Model (PSS-CM). To validate the results, PSS-CM and its elements were discussed in several iterations, from both academic and industrial points of view, in the frame of a European research project. In the frame of this project, a case study was also performed to illustrate the instantiation of PSS-CM.
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Engineering, Industrial & Manufacturing Engineering; surveying; close-range photogrammetry;internal coincidence precision estimation; external coincidence accuracy estimation; experimental work; testing
Online: 7 February 2018 (10:28:16 CET)
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Precision and accuracy estimation is an important index used to reflect the measurement performance and quality of a measurement system. To reveal the significance and connotations of the precision and accuracy estimation index of a close-range photogrammetry system, several common precision and accuracy estimation methods used in close-range photogrammetry are explained from a theoretical perspective, and the mechanism of the internal coincidence precision estimation and the external coincidence accuracy estimation are deduced, respectively. Through detailed experimental design and testing, the validity and reliability of the proposed precision and accuracy estimation methods are verified, which provides strong evidence for the quality control, optimisation, and evaluation of the measurement results from a close-range photogrammetry system. At the same time, it has significance for the further development of precision and accuracy estimation analysis of close-range photogrammetry systems.
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Engineering, Industrial & Manufacturing Engineering; additive manufacturing; laser metal deposition; hybrid machines; cutting fluid; coolant; lubricant; porosity; Inconel 718
Online: 25 January 2018 (05:19:37 CET)
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Hybrid manufacturing processes that combine additive and machining operations are gaining relevance in modern industry thanks to the capability of building complex parts with minimum material and, many times, with process time reduction. Besides, as the additive and subtractive operations are carried out in the same machine, without moving the part, dead times are reduced and higher accuracies are achieved. However, it is not clear whether the direct material deposition after the machining operation is possible or intermediate cleaning stages are required because of the possible presence of residual cutting fluids. Therefore, different LMD tests are performed on a part impregnated with cutting fluid, both directly and after the removal of the coolant by techniques such as laser vaporizing and air blasting. The present work studies the influence of the cutting fluid in the LMD process and the quality of the resulting part. Resulting porosity is evaluated and it is concluded that if the part surface is not properly clean after the machining operation, deficient clad quality can be obtained in the subsequent laser additive operation.
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Engineering, Industrial & Manufacturing Engineering; scandium; REEs; bauxite residue; selective leaching; process design aspects; thin film diffusion model; unyielding core; specific recovery
Online: 12 January 2018 (07:50:01 CET)
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Aiming at the industrial scale development of a Scandium (Sc)-selective leaching process of Bauxite Residue (BR), a sufficiently numerous set of process design aspects has been investigated, by appropriate exploitation of available experimental data. The interpretation of experimental data for Sc leaching yield, with sulfuric acid as the leaching solvent, has shown significant impact from acid feed concentration, mixing residence time, liquid to solids ratio, and times of leachate re-usage onto fresh BR. The thin film diffusion model, as the fundamental theory for leaching, either with constant particle size for selective leaching, or with shrinking particle size for less-, or non-, selective leaching, interprets sufficiently well the relevant experimental data. In both cases, a concept for an unyielding core supplements the basic model. Especially for the selective leaching mild conditions, the simplest model version keeps step with the experiments, since both prove 1st order kinetics, while especially for the extreme conditions including very low solvent excess, it is proposed a combined conversion rate model with diffusion and chemical reaction inside particles. The maximization of Sc recovery per unit of consumed solvent (i.e., specific recovery) emerged as highly critical for the process economics.
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Engineering, Industrial & Manufacturing Engineering; 3D printing; open source; RepRap; calibration; bed levelling
Online: 12 January 2018 (07:35:31 CET)
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Inexpensive piezoelectric diaphragms can be used as sensors to facilitate both nozzle height setting and build platform leveling in FFF (Fused Filament Fabrication) 3D printers. Tests simulating nozzle contact are conducted to establish the available output and an output of greater than 8 Volts found at 20 ºC, a value which is readily detectable by simple electronic circuits. Tests are also conducted at a temperature of 80 ºC and, despite a reduction of greater than 80% in output voltage, this is still detectable. The reliability of piezoelectric diaphragms is investigated by mechanically stressing samples over 100,000 cycles at both 20 ºC and 80 ºC and little loss of output over the test duration is found. The development of a nozzle contact sensor using a single piezoelectric diaphragm is described.
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Engineering, Industrial & Manufacturing Engineering; interconnection; multi-layer patterning; laser sintering; femtosecond laser ablation
Online: 8 January 2018 (09:04:08 CET)
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The development of printing technologies has enabled the realization of electric circuit fabrication on flexible substrate. However, the current technique remains restricted to single-layer patterning. In this paper, we demonstrate a fully solution-processable patterning approach for multi-layer circuits using a combined method of laser sintering and ablation. Selective laser sintering of silver (Ag) nanoparticle-based ink is applied to make conductive patterns on a heat-sensitive substrate and insulating layer. The laser beam path and irradiation fluence are controlled to create circuit patterns for flexible electronics. Microvia drilling using femtosecond laser through the polyvinylphenol-film insulating layer by laser ablation, as well as sequential coating of Ag ink and laser sintering, achieves an interlayer interconnection between multi-layer circuits. The dimension of microvia is determined by a sophisticated adjustment of laser focal position and intensity. Based on these methods, the flexible electronic circuit with chip-size-package light-emitting diodes was successfully fabricated and demonstrated with functional operations.
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Engineering, Industrial & Manufacturing Engineering; life cycle assessment; circular economy; material efficiency; recycling; reuse
Online: 18 December 2017 (06:36:56 CET)
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Material efficiency is a key element of new thinking to address the challenges of reducing impacts on the environment and of resource scarcity, whilst at the same time meeting service and functionality demands on materials. Directly related to material efficiency is the concept of the Circular Economy, which is based on the principle of optimising the utility embodied in materials and products through the life cycle. Whilst steel, as a result of high recycling rates, is one of the most ‘circular’ of all manufactured materials, significant opportunities for greater material efficiency exist, which are yet to be widely implemented. In the field of Life Cycle Management, Life Cycle Assessment (LCA) is commonly used to assess the environmental benefits of recovering and recycling materials through the manufacturing supply chain and at end-of-life. As well as containing information to calculate environmental impacts, LCA models also provide the flows of materials through the product life cycle and can also be used to quantify material efficiency and the circularity of a product system. Using an example taken from renewable energy generation, this paper explores the correlation between product circularity and the environmental case for strategies designed to improve material efficiency. An LCA-based methodology for accounting for the recovery and re-use of materials from the supply chain, and at end-of-life, is used as the basis for calculating the carbon footprint benefits of five material efficiency scenarios. Resulting carbon footprints were then compared with a number of proposed material circularity indicators. Two conclusions from this exercise were that i) LCA methodologies based around end-of-life approaches are well placed for quantifying the environmental benefits of material efficiency and circular economy strategies and ii) when applying indicators relating to the circularity of materials these should also be supported by LCA studies.
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Engineering, Industrial & Manufacturing Engineering; additive manufacturing; laser metal deposition; hot stamping; die and mold; conformal cooling; design optimization.
Online: 12 December 2017 (15:24:24 CET)
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Hot stamping dies include cooling channels to treat the formed sheet. The optimum cooling channels of dies & molds should adapt to the shape and surface of the dies, so that a homogeneous temperature distribution and cooling are guaranteed. Nevertheless, cooling ducts are conventionally manufactured by deep drilling, attaining straight channels unable to follow the geometry of the tool. Laser Metal Deposition (LMD) is an additive manufacturing technique capable to fabricate nearly free-form integrated cooling channels and therefore shape the so-called conformal cooling. The present work investigates the design and manufacturing of conformal cooling ducts, which are additively built up on hot work steel and then milled in order to attain the final part. Their mechanical performance and heat transfer capability has been evaluated, both experimentally and by means of thermal simulation. Finally, conformal cooling conduits are evaluated and compared to traditional straight channels. The results show that LMD is a proper technology for the generation of cooling ducts, opening the possibility to produce new geometries on dies & molds and, therefore, new products.
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Engineering, Industrial & Manufacturing Engineering; fiber-metal laminates (FMLs); multilayer sheet bulging; forming limits; numerical simulation; crack modes
Online: 4 December 2017 (06:54:03 CET)
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Fiber-metal laminates (FMLs) such as Kevlar reinforced aluminum laminate (ARALL), Carbon reinforced aluminum laminate (CARALL), and Glass reinforced aluminum laminate (GLARE) offer great potential for weight reduction applications in automobile and aerospace construction. In order to investigate the feasibility for utilizing such materials in the form of laminates, sheet hydro-bulging tests are studied under the condition of uniform blank holder force for three-layered aluminum and aluminum-composite laminates using orthogonal carbon and Kevlar as well as glass fiber in the middle. The experimental results validate the finite element results and they exhibited that the forming limit of glass fiber in the middle is the highest among the studied materials, while carbon fiber material performs the worst. Furthermore, the crack modes are different for the three kinds of fiber materials investigated in the research. This study provides fundamental guidance for the selection of multi-layer sheet materials in the future manufacturing field.
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Engineering, Industrial & Manufacturing Engineering; onboard cloud detecion; region of interest compression; themodynamic phase; spectral angle map; markov random field; dynamic stochastic resonance
Online: 16 November 2017 (04:29:19 CET)
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It is strongly desirable to accurately detect the clouds in hyperspectral images onboard before compression. However, conventional onboard cloud detection methods are not appropriate to all situation such as shadowed cloud or darken snow covered surfaces which are not identified properly in the NDSI test. In this paper, we propose a new spectral–spatial classification strategy to enhance the orbiting cloud screen performances obtained on hyperspectral images by integrating threshold exponential spectral angle map (TESAM), adaptive Markov random field (aMRF) and dynamic stochastic resonance (DSR). TESAM is performed to classify the cloud pixels coarsely based on spectral information. Then aMRF is performed to do optimal process by using spatial information, which improved the classification performance significantly. Some misclassification points still exist after aMRF processing because of the noisy data in the onboard environment. DSR is used to eliminate misclassification points in binary labeling image after aMRF. Taking level 0.5 data from hyperion as dataset, the average overall accuracy of the proposed algorithm is 96.28% after test. The method can provide cloud mask for the on-going EO-1 images and related satellites with the same spectral settings without manual intervention. The experiment indicate that the proposed method reveals better performance than the classical onboard cloud detection or current state-of-the-art hyperspectral classification methods.
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Engineering, Industrial & Manufacturing Engineering; integrated forward/reverse logistics network; accelerated benders’ decomposition; two-stage stochastic programming
Online: 20 October 2017 (03:07:28 CEST)
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In this paper, a two-stage stochastic programming modelling is proposed to design a multi-period, multistage, and single-commodity integrated forward/reverse logistics network design problem under uncertainty. The problem involves both strategic and tactical decision levels. The first stage deals with strategic decisions, which are the number, capacity, and location of forward and reverse facilities. At the second stage tactical decisions such as base stock level as an inventory policy is determined. The generic introduced model consists of suppliers, manufactures, and distribution centers in forward logistic and collection centers, remanufactures, redistribution, and disposal centers in reverse logistic. The strength of proposed model is its applicability to various industries. The problem is formulated as a mixed-integer linear programming model and is solved by using Benders’ Decomposition (BD) approach. In order to accelerate the Benders’ decomposition, a number of valid inequalities are added to the master problem. The proposed accelerated BD is evaluated through small-, medium-, and large-sized test problems. Numerical results reveal that proposed solution algorithm increases convergence of lower bound and upper bound of BD and is able to reach an acceptable optimality gap in a convenient CPU time.
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Engineering, Industrial & Manufacturing Engineering; state-space model; uncertainty; mixed-integer linear programming; model predictive control; bio-manufacturing
Online: 18 October 2017 (03:56:31 CEST)
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We present a generalized state-space model formulation particularly motivated by an online scheduling perspective. Through these proposed generalizations, we enable a natural way to handle routinely encountered disturbances and a rich set of corresponding counter-decisions. Thereby, greatly simplifying and extending the possible application of mathematical programming based online scheduling solutions to diverse application settings.
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Engineering, Industrial & Manufacturing Engineering; Alginate fiber; rhubarb natural dye; color strength &fastness; SEM; Eco-friendly
Online: 16 October 2017 (13:19:07 CEST)
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In this investigation dyeing of alginate fiber was carried out after cationic treatment of EPTAC (2, 3-Epoxypropyl Trimethyl Ammonium Chloride). Optimum dyeing process and parameter show good dyeing performance when alginate fiber dyed with rhubarb dye. In addition to cationic treatment is taken into account for alginate fiber to improve fastness, color strength, breaking strength. Later in dyeing for fixation ferrous sulfate, copper sulphate was considered as mordents. Moreover using pre-mordanting methods conveyed the dyeing of alginate fiber with the stave of metallic mordant and without metallic salt mordents. The evaluation of each color dyed material was done through following two terms for instance CIELAB (L*, a*, and b*) and K/S values. According to AATCC test methods color fastness to washing of the dyed fiber was determined whereas according to the ASTM D3822M standard the breaking strength of alginate fiber was estimated and tested. When dyeing was carried out on alginate fiber through considering optimum parameter like 80◦C for 90 min, M: L 1:40 and at pH 7 which showed optimum results. In addition to mostly very good wash fastness was obtained while there was no fading of the color, whereas the moderate level of color fastness to crocking was achieved. Later after dyeing the evaluations of SEM of the cationized alginate fiber and FTIR of powder from the rhubarb dye were observed. The results suggested that the surface of cationized alginate fiber was smoother than the raw alginate fiber.
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Engineering, Industrial & Manufacturing Engineering; Dynamic Scheduling; Semiconductor Manufacturing; Composite Rule Set; Support Vector Regression (SVR)
Online: 3 October 2017 (08:29:45 CEST)
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Various factors and constraints should be considered when developing a manufacturing production schedule, and such a schedule is often based on rules. This paper develops a composite dispatching rule based on heuristic rules that comprehensively consider various factors in a semiconductor production line. The composite rule is obtained by exploring various states of a semiconductor production line (machine status, queue size, etc.), where such indicators as makespan and equipment efficiency are used to judge performance. A model of the response surface, as a function of key variables, is then developed to find the optimized parameters of a composite rule for various production states. Further, dynamic scheduling of semiconductor manufacturing is studied based on support vector regression (SVR). This approach dynamically obtains a composite dispatching rule (i.e. parameters of the composite dispatching rule) that can be used to optimize production performance according to real-time production line state. Following optimization, the proposed dynamic scheduling approach is tested in a real semiconductor production line to validate the effectiveness of the proposed composite rule set.
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Engineering, Industrial & Manufacturing Engineering; sequential methods; change-point detection; online algorithms
Online: 1 September 2017 (05:24:10 CEST)
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Sequential hypothesis test and change-point detection when the distribution parameters are unknown is a fundamental problem in statistics and machine learning. We show that for such problems, detection procedures based on sequential likelihood ratios with simple one-sample update estimates such as online mirror descent are nearly second-order optimal. This means that the upper bound for the algorithm performance meets the lower bound asymptotically up to a log-log factor in the false-alarm rate when it tends to zero. This is a blessing, since although the generalized likelihood ratio (GLR) statistics are optimal theoretically, but they cannot be computed recursively, and their exact computation usually requires infinite memory of historical data. We prove the nearly second-order optimality by making a connection between sequential analysis and online convex optimization and leveraging the logarithmic regret bound property of online mirror descent algorithm. Numerical and real data examples validate our theory.
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Engineering, Industrial & Manufacturing Engineering; chemical plant environmental protection; stackelberg security games; source estimation methods; historical monitoring data; game theory
Online: 14 August 2017 (04:42:56 CEST)
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The chemical industry is an integral part of the world economy and a substantial income source for developing countries. However, existing regulations or the enforcement of these regulations, on controlling atmospheric pollutants sometimes may be insufficient, leading to the deterioration of surrounding ecosystems and to a quality decrease of the atmospheric environment. Previous works in this domain fail to generate executable solutions for inspection agencies due to practical challenges. In addressing these challenges, we introduce a so-called Chemical Plant Environment Protection Game (CPEP) to generate reasonable schedules of high-accuracy air quality monitoring stations for inspection agencies. First, Stackelberg Security Games (SSGs) are incorporated together with source estimation methods into this research. Second, high-accuracy air quality monitoring stations as well as gas sensors are modeled into the CPEP. Third, simplified data analysis on the regularly discharging of chemical plants is utilized to construct the CPEP. Finally, an illustrative case study is used to investigate the effectiveness of the CPEP Game, and a realistic case study is conducted to illustrate how the models and algorithms being proposed in this paper, work. Results show that playing a CPEP Game can reduce operational costs of high-accuracy air quality monitoring stations; moreover, playing the game leads to more compliance from the chemical plants towards the inspection agencies.
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Engineering, Industrial & Manufacturing Engineering; multi-attribute decision making; reinsurance; proportional reinsurance; non-proportional reinsurance; TOPSIS
Online: 10 July 2017 (15:42:50 CEST)
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This article addresses reinsurance decision making process, which involves the insurance company and the reinsurance company, and is negotiated through reinsurance intermediaries. The article proposes a decision flow to model the reinsurance design and selection process. In contrast to existing literature on pure proportional reinsurance or stop-loss reinsurance, this article focuses on the combination into Proportional-Stop-loss reinsurance design which better addresses interest of both parties. In terms of methodology, the significant contribution of the study is to incorporate Multiple Attribute Decision Making (MADM) into modelling the reinsurance selection. The Multi-Objective Decision Making (MODM) model is applied in designing reinsurance alternatives. Then MADM is applied to aid insurance companies in choosing the most appropriate reinsurance contract. To illustrate the feasibility of incorporating intelligent decision supporting system in reinsurance market, the study includes a numerical case study using simulation software @Risk in modeling insurance claims, and programming in MATLAB to realize MADM. Managerial implications could be drawn from the case study results. More specifically, when choosing the most appropriate reinsurance, insurance companies should base their decision on multiple measurements instead of single-criteria decision making models for their decisions to be more robust.
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Engineering, Industrial & Manufacturing Engineering; sustainability; value modeling; decision support; value driven design; review
Online: 12 June 2017 (13:51:25 CEST)
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Manufacturing organizations shall recognize sustainability as a business occasion to capitalize on, rather than an undesirable pressing situation. Still, empirical evidence shows that this opportunity is hard to capture and communicate in global strategic decisions, through planning by tactical management, to daily operational activities. This paper systematically reviews the modeling challenges at the crossroad of value and sustainability decisions making, spotlighting methods and tools proposed in literature to link sustainability to customer value creation at strategic, tactical and operational level. While statistical results show that the topic of sustainability and value modeling is trending in literature, findings from content analysis reveal that recent attempts to promote a value-based view in the sustainability discussion remain at a strategic level, with most of the proposed indicators being suited for managerial decision-making. The lack of support at operational level points to the opportunity of cross-pollinating sustainability research with value-centered methodologies originating from the aerospace sector. The Value Driven Design framework is proposed as main hub from which to derive models supporting engineers and technology developers in the identification of win-win-win situations, where sustainable improvements are aligned with business advantages.
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Engineering, Industrial & Manufacturing Engineering; machine tool metrology; temperature; uncertainty; traceability; error sources
Online: 2 May 2017 (04:35:18 CEST)
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Errors during manufacture of high value components are not acceptable nowadays in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power manufacture complex and accurate components that demand close measurements and fast feedback into manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They shall provide the possibility to measure the workpiece during or after the manufacturing process, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable for process control or product validation. Due to the similarity between a coordinate measuring machine and a machine tool, some of the methods applied for a correct assessment of uncertainty in coordinate measuring machines are adapted to the challenges of a machine tool. The scientific objective is to determine the uncertainty on a machine tool measurement and, in this way, convert it into a machine integrated traceable measuring process. This paper reviews the fundamentals of machine tool metrology.
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Engineering, Industrial & Manufacturing Engineering; intelligent robotics; flexibility; reusability; multisensor; state machine; software architecture; computer vision
Online: 20 April 2017 (04:14:33 CEST)
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This paper presents a state machine based architecture which enhances flexibility and reusability of industrial robots, more concretely dual-arm multisensor robots. The proposed architecture, in addition to allowing absolute control of the execution, eases the programming of new applications by increasing the reusability of the developed modules. Through an easy-to-use graphical user interface, operators are able to create, modify, reuse and maintain industrial processes increasing the flexibility of the cell. Moreover, the proposed approach is applied in a real use case in order to demonstrate its capabilities and feasibility in industrial environments. A comparative analysis is presented for evaluating presented approach versus traditional robot programming techniques.
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Engineering, Industrial & Manufacturing Engineering; TIG process; Composite Coating; St 304; Hardness; Wear Resistance
Online: 14 April 2017 (04:29:16 CEST)
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The aim of this paper is to develop a composite coating on St 304 steel employing TIG process. Ti wire cored with graphite powder is used as the means of coating material. The process parameters are varied in order to develop coating with optimum characteristics (i.e., hardness and wear resistance). The microstructure of the coating is analyzed with SEM and XRD. It is found that both of the hardness and wear resistance increase as the current increases while both of these properties decrease as the travelling speed increases. It is found that the coated samples with composite layers have more hardness than the substrate and it could range up to 1100 HV being almost 4.5 times higher than the hardness of St 304. Likewise, the wear resistance of coating is observed to be 4.5 times higher than that of substrate. The high performance of coating, as revealed by microstructural analysis, is due to formation of TiC and Cr23C6 .The optimum conditions to produce the coating are proposed to be 120 A current and 3.17 mm/s travel speed.
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Engineering, Industrial & Manufacturing Engineering; additive manufacturing; 3-D printing; metal additive manufacturing; selective laser melting; SLM; direct metal laser sintering; DMLS; metal powder processing
Online: 4 April 2017 (07:56:07 CEST)
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A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.
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Engineering, Industrial & Manufacturing Engineering; Laser triangulation displacement probe; Laser beam pointing; Prism
Online: 30 March 2017 (17:34:55 CEST)
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Directional dithering of a laser beam potentially limits the detection accuracy of a laser triangulation displacement probe. A theoretical analysis indicates that the measurement accuracy will linearly decrease as the laser dithering angle increases. To suppress laser dithering, a laser triangulation displacement probe with laser beam pointing control, which consists of a collimated red laser, a laser beam pointing control setup, a receiver lens, and a charge-coupled device, is proposed in this paper. The laser beam pointing control setup is inserted into the source laser beam and the measured object and can separate the source laser beam into two symmetrical laser beams. Hence, at the angle at which the source laser beam dithers, the positional averages of the two laser spots are equal and opposite. Moreover, a laser dithering compensation algorithm is used to maintain a stable average of the positions of the two spots on the imaging side. Experimental results indicate that with laser beam pointing control, the standard variance of the fitting error decreases from 0.3531 to 0.0100, the repeatability accuracy can be decreased from ±7mm to ±5 μm, and the nonlinear error can be reduced from ±6 %FS to ±0.16 %FS.
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Engineering, Industrial & Manufacturing Engineering; simulation software; manufacturing systems; process integration; machining optimization; Industry 4.0; knowledge-based manufacturing
Online: 27 March 2017 (10:28:34 CEST)
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The future of machine tools will be dominated by highly flexible and interconnected systems, in order to achieve the required productivity, accuracy and reliability. Nowadays, distortion and vibration problems are easily solved in labs for the most common machining operations by using models based on equations describing the physical laws of the machining processes; however additional efforts are needed to overcome the gap between scientific research and the real manufacturing problems. In fact, there is an increasing interest in developing simulation packages based on “deep-knowledge and models” that aid machine designers, production engineers or machinists to get the best of the machine-tools. This article proposes a methodology to reduce problems in machining by means of a simulation utility, which uses the main variables of the system&process as input data, and generates results that help in the proper decision-making and machining planification. Direct benefits can be found in a) the fixture/clamping optimal design, b) the machine tool configuration, c) the definition of chatter-free optimum cutting conditions and d) the right programming of cutting toolpaths at the Computer Aided Manufacturing (CAM) stage. The information and knowledge-based approach showed successful results in several local manufacturing companies and are explained in the paper.
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Engineering, Industrial & Manufacturing Engineering; arc sensing; P-GMAW; mathematical model
Online: 13 March 2017 (16:25:49 CET)
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Arc sensors have been used in seam tracking and widely studied since the 80s; commercial arc sensing products for T and V shaped grooves have been developed. However, it is difficult to use these arc sensors in narrow gap welding because arc stability and sensing accuracy are not satisfactory. Pulse gas melting arc welding (P-GMAW) has been successfully applied in narrow gap welding and all position welding processes, so it is worthwhile to research P-GMAW arc sensing technology. In this paper, we derived a linear mathematical P-GMAW model for arc sensing, and the assumptions for the model are verified through experiments and finite element methods. Finally, the linear characteristics of the mathematical model were investigated. In torch height changing experiments, uphill experiments, and groove angle changing experiments the P-GMAW arc signals all satisfied the linear rules. In addition, the faster the welding speed, the higher the arc signal sensitivities; the smaller the groove angle, the greater the arc sensitivities. The arc signal variation rate needs to be modified according to the welding power, groove angles, and swing or rotate speed.
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Engineering, Industrial & Manufacturing Engineering; simulation software; manufacturing systems; process integration; machining optimization; Industry 4.0; knowledge-based manufacturing
Online: 26 February 2017 (10:18:59 CET)
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The next future using machine tools will be dominated by highly flexible and interconnected systems, in order to achieve the required productivity, accuracy and reliability. Nowadays, distortion and vibration problems are easily solved for the most common cases by sing models based on equations describing the physical laws dominating the machining process; however additional efforts are needed to overcome the gap between scientific research and the real manufacturing problems. In fact, there is an increasing interest in developing simulation packages based on “deep knowledge and models” that aid the machine designer, the production engineer, or machinists to get the best of their machines. This article proposes a systematic methodology to reduce problems in machining by means of a simulation utility, which recognizes, collects and uses the main variables of the system/process as input data, and generates objective results that help in the proper decision-making. Direct benefits by such an application are found in a) the fixture/clamping optimal design, b) the machine tool configuration, c) the definition of chatter free optimum cutting conditions and the right programming of cutting tool path at the Computer Aided Manufacturing (CAM) stage. The information and knowledge-based approach showed successful results in several local manufacturing companies.
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Engineering, Industrial & Manufacturing Engineering; process improvement; ewe’s cheese; systemic design
Online: 30 December 2016 (07:34:54 CET)
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The research reported on this paper was aimed at improving the overall efficiency of a PDO certified artisanal cheese production process. Being a PDO certified foodstuff by the EU, it is considered to have properties and qualities determined by the geographical environment in which is made, with its production taking place in a specific and determined geographical location, in this case the Serra da Estrela region. In that sense, the authors conducted a mapping according to a systemic perspective of the processes involved in the context of manufacturing and distribution of certified Serra da Estrela cheese. Numerous methods were used throughout the process, such as a systemic design analysis, and techniques derived from ethnographic methods, which led to the collection of data in the field and consequently provided the immersion of the researcher in genuine work situations. Critical points were identified and emphasized in the systemic map with the purpose of encouraging initiatives to address and overcome the gaps and inefficiencies detected. The systemic design analysis triggered the development of design work. Observations following an ethnographic approach identified ergonomic risks in cheese making during the process of cutting excess chips, fostering the emergence of musculoskeletal disorders at the wrist. A tool that fits best to the task at hand was developed. A prototype of the new tool enabled collecting feedback from use in the work context, in order to inform product development. The domains of agricultural production and microbiology, considering the specific microorganisms developed trough the ripening process of the cheese, turned out to be aspects of high importance for the issue under focus, contributing to a broader understanding of the ripening process and its risks, simultaneously improving the efficiency and success of cheese production. If it were not for the systemic analysis, which served as a link between the boundaries of distinct domains such as the risk of microorganism contamination, ergonomics, energy efficiency, legislation and regulation policies, transportation challenges and economic viability, approached throughout the research. Simultaneously creating bridges between them, the various problems might not have been detected in the first place, as they are usually addressed in specialized disciplines, predetermined by the restrictions of each specific area of knowledge. As a consequence of the development of this research, which was based on an analysis that sought to establish possible connections between various disciplines and tried to constantly maintain a holistic perspective, making new connections and observing the issues from a new angle, apart from the already established methodologies. All this allowed to lay out the seeds for the development of a plan to tackle the critical points identified by the systemic analysis reported in this paper.
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Engineering, Industrial & Manufacturing Engineering; context sensitivity; cyber physical systems; flexible manufacturing system; process optimization; self-learning systems; SOA
Online: 28 December 2016 (11:13:22 CET)
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Highly flexible manufacturing systems require continuous run-time (self-) optimization of processes with respect to various parameters, e.g. efficiency, availability, energy consumption etc. A promising approach for achieving (self-) optimization in manufacturing systems is the usage of the context sensitivity approach. Thereby the Cyber-Physical Systems play an important role as sources of information to achieve context sensitivity. In this paper it is demonstrated how context sensitivity can be used to realize a holistic solution for (self-) optimization of discrete flexible manufacturing systems, by making use of Cyber-Physical System integrated in manufacturing systems/processes. A generic approach for context sensitivity, based on self-learning algorithms, is proposed aiming at a various manufacturing systems. The new solution is propos encompassing run-time context extractor and optimizer. Based on the self-learning module both context extraction and optimizer are continuously learning and improving their performance. The solution is following Service Oriented Architecture principles. The generic solution is developed and then applied to two very different manufacturing processes. This paper proposes a holistic solution to achieve context sensitivity for Flexible Manufacturing Systems, whereby the knowledge created by applying the context sensitivity approach can be used for (self-) optimization of manufacturing processes.
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Engineering, Industrial & Manufacturing Engineering; intermetallic; refractory metal; tribological property; toughening
Online: 2 December 2016 (11:04:19 CET)
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Intermetallic compounds are increasingly being expected to utilize in tribological environments, but to date the works are hindered by insufficient ductility at low and medium temperature. This paper presents a novel multiphase intermetallic alloy with the chemical composition of Mo-40Ni-13Si (at.%). Microstructure characterization reveals that a certain amount of ductile Mo phases formed during the solidification process of ternary Mo-Ni-Si alloy melt, which is undoubtedly beneficial to the ductility improvement of intermetallic alloy. Tribological properties of the designed alloy, including wear resistance, friction coefficient and metallic tribological compatibility, were evaluated under dry sliding wear test conditions at room temperature. Results suggested that the multiphase alloy possesses an excellent property for room-temperature wear applications, which is attributed to the unique microstructural features and thereby good combination in hardness and ductility. The corresponding wear mechanism is also reported by observing the worn surface, subsurface and wear debris of alloy, which to be found is soft abrasive wear.
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Engineering, Industrial & Manufacturing Engineering; energy saving; PAT; Urban Hydraulic Network; numerical modeling
Online: 19 October 2016 (10:17:33 CEST)
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Small and micro hydropower represents an attractive solution for electricity generation, with low cost and low environmental impact. The pump-as-turbine (PAT) approach has promise in this application owing to its low purchase and maintenance costs. In this paper, a new method to predict the inverse characteristic of industrial centrifugal pumps is presented. This method is based on results of simulations performed with commercial three-dimensional CFD software. Model results have been first validated in pumping mode using data supplied by pump manufacturers. Then, results have been compared to experimental data for a pump running in reverse condition. Experimentation has been performed on a dedicated test bench installed in the Department of Civil Construction and Environmental Engineering of the University of Naples Federico II. Three different pumps, with different specific speeds, have been analyzed. Using the model results, the inverse characteristic and the best efficiency point have been evaluated. Finally, results of this methodology have been compared to prediction methods available in the literature.
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Engineering, Industrial & Manufacturing Engineering; collection-distribution center; closed loop supply chain; fuzzy random variable; particle swarm optimization
Online: 11 October 2016 (11:02:47 CEST)
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Recycling waste products is an environmental-friendly activity that can bring benefits to accompany, saving manufacturing costs and improving economic efficiency. For the beer industry, recycling bottles can reduce manufacturing costs and reduce the industry's carbon footprint. This paper presents a model for a multi-objective collection-distribution center location and allocation problem in a closed loop supply chain for the beer industry, in which the objective is to minimize total costs and transportation pollution. Uncertainties in the form of randomness and fuzziness are jointly handled in this paper to ensure a more practical problem solution, for which returned bottle sand unusable bottles are considered fuzzy random variables. A heuristic algorithm based on priority-based global-local-neighbor particle swarm optimization (pb-glnPSO) is applied to ensure reliable solutions for this NP-hard problem. A case study on a beer operation company is conducted to illustrate the application of the proposed model and demonstrate the priority-based global-local-neighbor particle swarm optimization.
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Engineering, Industrial & Manufacturing Engineering; generalized thermodynamic optimization; iron and steel production processes; finite time thermodynamics; constructal theory; entransy theory; metallurgical process engineering
Online: 26 September 2016 (09:51:14 CEST)
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Combining modern thermodynamics theory branches, including finite time thermodynamics or entropy generation minimization, constructal theory and entransy theory, with metallurgical process engineering, this paper provides a new exploration on generalized thermodynamic optimization theory for iron and steel production processes. The theoretical core is to thermodynamically optimize performances of elemental packages, working procedure modules, functional subsystems, and whole process of iron and steel production processes with real finite-resource and/or finite-size constraints with various irreversibilities toward saving energy, decreasing consumption, reducing emission and increasing yield, and to achieve the comprehensive coordination among the material flow, energy flow and environment of the hierarchical process systems. A series of application cases of the theory are reviewed. It can provide a new angle of view for the iron and steel production processes from thermodynamics, and can also provide some guidelines for other process industries.
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Engineering, Industrial & Manufacturing Engineering; industrial automation; autonomous design; multi-agent systems; industry 4.0; biologically inspired techniques; AGV systems; energy efficiency
Online: 1 September 2016 (10:48:48 CEST)
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In this paper, modelling, simulation and verification of multi-agent manufacturing system with application of bio-inspired techniques are addressed. To this end, the new solution of abstract architecture for control and coordination decentralized systems - CODESA is suggested. Centralized architecture suffers from various problems, such as rigidity, scalability, low fault-tolerance or very limited flexibility, agility, energy efficiency and productivity. Prime is concrete application of CODESA in manufacturing domain. The undesirable characteristics of emergent behaviour are the problem to achieve optimization and impossibility to predict future states of the system. CODESA-Prime has been tested by simulations for automatic guided vehicle (AGV) systems guided by magnetic tape in Ella Software Platform.
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Engineering, Industrial & Manufacturing Engineering; real-time control; mechatronics; PZT actuators; vibration; hardware-in-the-loop
Online: 4 August 2016 (06:20:33 CEST)
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This paper proposes an innovative mechatronic piezo-actuated module to control vibrations in modern machine tools. Vibrations represent one of the main issues that compromise seriously the quality of the workpiece. The active vibration control (AVC) device is composed by a host part integrated with sensors and actuators synchronized by a regulator, able to make a self-assessment and adjust to the environmental alteration. This study presents the mechatronic model based on the kinematic and dynamic analysis of the AVC device. To ensure a real time performance, a H2-LQG controller has been developed and validated by simulations involving machine tool, PZT actuator and controller models. The Hardware-in-the-loop (HIL) architecture is adopted to control and attenuate the vibrations. A set of experimental tests has been performed to validate the AVC module on a commercial machine tool. The feasibility of the real time vibration damping is demonstrated and the simulation accuracy is evaluated.
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Engineering, Industrial & Manufacturing Engineering; CFD simulation; industrial furnace; heat flux; forging industry; thermal analysis
Online: 3 August 2016 (08:47:21 CEST)
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Industries, which are mainly responsible for high energy consumptions, need to invest in research projects in order to develop new managing systems for rational energy use and to tackle the devastating effects of climate change caused by human behavior. The study reported in this paper concerns the forging industry, where the production processes generally start with the heating of the steel in furnaces and continue with other processes, such as heat treatments and mechanical machining. One of the most critical operations, in terms of energy loss, is the opening of the furnace doors for the insertion and extraction operations. During this time, the temperature of the furnaces decreases by hundreds of degrees in a few minutes. Because the dispersed heat needs to be supplied again through the combustion of fuel, increasing the consumption of energy and the pollutant emissions, the evaluation of the amount of the lost energy is crucial for the development of operating or mechanical systems able to contain this dispersion. To perform this study, CFD simulation software was used. Results show that at the door opening, because of temperature and pressure differences between the furnace and the ambient, turbulences are generated. Results also show that the amount of energy lost for an opening of 10 minutes for radiation, convection and conduction is equal to 5606 MJ where convection is the main contributor with 5020 MJ. The model created, after being validated, has been applied to perform other simulations in order to improve the energy performance of the furnace. Results show that a reduction of the opening time of the door allows energy savings and limits pollutant emissions.