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Engineering, Industrial & Manufacturing Engineering; Additive manufacturing; fused deposition modeling; FDM; dimensional accuracy; manufacturing process repeatability; polymer testing
Online: 12 December 2018 (12:58:13 CET)
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This report describes the collection of a large dataset (6930 measurement) on dimensional error in the fused deposition modeling (FDM) additive manufacturing process for full-density parts. Three different print orientations were studied, as well as seven raster angles (0°, 15°, 30°, 45°, 60°, 75°, and 90°) for the rectilinear infill pattern. All measurements were replicated ten times on ten different samples to ensure a comprehensive dataset. Eleven polymer materials were considered: acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), high-temperature PLA, wood-composite PLA, carbon-fiber-composite PLA, copper-composite PLA, aluminum-composite PLA, high-impact polystyrene (HIPS), polyethylene terephthalate glycol-enhanced (PETG), polycarbonate, and synthetic polyamide (nylon). The samples were ASTM-standard impact testing samples, since this geometry allows the measurement of error on three different scales; the nominal dimensions were 3.25mm thick, 63.5mm long, and 12.7mm wide. This dataset is intended to give engineers and product designers a benchmark for judging the accuracy and repeatability of the FDM process for use in manufacturing of end-user products.
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Engineering, Industrial & Manufacturing Engineering; Stainless Steel ASTM A312 Grade 304L, Under Salt Vapor; Corrosion Rate, Welding Procedure
Specification, CFD Modeling
Online: 12 December 2018 (12:17:36 CET)
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This work studied the corrosion of welded pipes and how welding destroyed surface film of pipes. Surface reaction of a welded pipe is key to understanding phenomena and important factors during the corrosion. This paper presents experiment and CFD modeling approaches of a welded pipe corrosion under salt vapor condition. The pipes were welded at currents of 60 A,70 A and 80 A to observe the effect of welding current on corrosion. A welded pipe is a stainless-steel ASTM A312 grade 304L and period of experiment about 0-600 hours that they are tested in vertical and horizontal alignments. In CFD software, there is not direct model of corrosion but it can use surface reaction and create add-on species and chemical reaction technique for imitating the corrosion mechanism. The modeling approaches of corrosion have presented in 3-dimensional transient times in CFD simulation. Surface reactions were performed by Species Model which involve site species. Site species in Species Model took place at gas-solid interfaces and in this case are salt vapor and surface pipe. Chemical reaction rate on the surface controls lost weight of a welded pipe and the model can be validated with experiment. In conclusion, in period 0-600 hours error between CFD modeling and experiment have error trend decreased. The error at 600 hours is 6% both of vertical pipe and horizontal pipe test. The modeling approaches closely with the performed experiment and can be accepted. Moreover,
the model is able to predict corrosion of a welded pipe of different sizes and their lost weight after 600 hours without experiment. Also the model can predict lifetime of pipe.
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Engineering, Industrial & Manufacturing Engineering; Face milling; Cost saving; Power consumption; Surface quality; Tool wear
Online: 6 December 2018 (14:09:34 CET)
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Face milling is a well known commercial process highly used in heavy industries that consumes high amount of power. Besides power issue, modern manufacturing industries are aiming for per part cost reduction keeping the product quality unimpaired. Unexpectedly if the part is rejected in any stage of manufacturing, the cost of manufacturing dramatically increases. Major cause of part rejection is excessive tool wear that imparts poor surface profile or catastrophic tool failure that causes adherence of broken tool debris onto machined surface. Furthermore, the tool wear is associated with sliding distance (frictional distance) and the tool life quantifies the cost of tools. As such, from the perspective of manufacturing industries it is imperative to optimize the surface quality parameter, cost of part, power consumption, and material removal – this is exactly what is accomplished here. By this work, it is possible to conserve power consumption, produce parts with lower cost, manufacture with uncompromising surface quality and enhanced material removal rate. Moreover, as intermediate factors of interest, the influences of sliding distance, tool life and tool flank wear on the overall machining performance are evaluated. The multi-objective optimization by Grey Relational Analysis (GRA) revealed that for improved product performance and fast manufacturing (case 1) optimum results are: feed per tooth fz = 0.25 mm/tooth, cutting speed vc = 392.6 m/min and cutting length l = 0.5 mm; for resource conservation (case 2) the optimum results are: feed per tooth fz = 0.125 mm/tooth, cutting speed vc = 392.6 m/min, cutting length l = 0.5 mm.
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Engineering, Industrial & Manufacturing Engineering; mold flux; low fluorine; internal crack; surface roughness; slag film
Online: 6 December 2018 (08:40:10 CET)
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As an essential synthetic material used in continuous casting of steels, mold fluxes improve the surface quality of steel slabs. In this study, a CaO-SiO2-Na2O based low-fluorine mold flux was solidified by an improved water-cooled copper probe with different temperatures of molten flux and different probe immersion times. The heat flux through solid films and the film structures were calculated and inspected, respectively. The results indicate: large internal cracks (formed in the glassy layer of films during solidification) were observed, the formation and evolution of those cracks contributed to the the unstable heat flux density. The roughness of the surface in contacted with the water-cooled copper probe formed as films were still glassy and the roughness have no causal relationship with crystallization or devitrification. Combeite with columnar and faceted dendritic shapes is the main crystal in the film.
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Engineering, Industrial & Manufacturing Engineering; inkjet; printer; topology; tolerance; machine
Online: 5 December 2018 (07:35:06 CET)
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Machines for direct digital inkjet printing on cylindrical containers are a new technology out on the market. Their commercialization in the industrial sector has been affected by their high precision. This leads to the use of mechanisms with narrow manufacturing tolerances and to the search for topologies that have the least accumulated error without affecting quality. Machines with topologies to work on flat substrates have printing and productivity problems working on cylindrical substrates. This research paper presents the qualitative design of a direct digital inkjet printer working over cylindrical substrates comparing five mechanical topologies; three topologies with radial distribution and two topologies with parallel distribution. The aim of these topologies is to find the precision, quality and efficiency of the printer taking into account the restrictions present in its construction. Each topology has separate constitutive mechanisms, it is analyzed the tolerance ranges between the print head and the substrate whose cumulative error maximizes the inkjet print resolution to determine precision. From five Topologies, number 1, 2 and 5 meet the requirements. the topology 2 meets the requirements but it is not able to be developed due to current technological limitations.
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Engineering, Industrial & Manufacturing Engineering; personal cooling system; heat and mass transfer; environmental temperature; relative humidity; phase change materials; thermal management
Online: 3 December 2018 (16:11:11 CET)
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The hybrid personal cooling system (HPCS) consisted of ventilation fans and phase change materials (PCMs) covered with insulation pads is a promising wearable cooling system to mitigate heat strain and heat-related illnesses of occupational workers with heavy labor in hot environments. Effects of clothing characteristics (e.g., thermal resistance of insulation pads, latent heat and melting temperature of PCMs) on the thermal performance of the HPCS have been investigated in detail in our previous study. Apart from the aforementioned factors, environmental conditions, i.e., environmental temperature and relative humidity, also significantly affect the thermal performance of the HPCS. In this paper, a numerical parametric study was performed to investigate the effects of the environmental temperature and relative humidity (RH) on the thermal management of the HPCS. Five levels of air temperature under environmental RH=50% were chosen (i.e., 32, 34, 36, 38 and 40 ºC) to study the impact of environmental temperature on the HPCS’s cooling performance. In addition, four levels of environmental RH at ambient temperatures of 36 and 40 ºC were selected (i.e., 30, 50, 70 and 90%) to examine the effect of RH on cooling performance of the HPCS. Results show that high environmental temperatures could accelerate the PCM melting process and thereby weaken the cooling performance of HPCS. In the moderately hot environment (36 °C), the HPCS presented good cooling performance with the maximum core temperature at around 37.5 °C during excise when the ambient RH≤70%, whereas good cooling performance could be only seen under RH≤50% in the extremely hot environment (40 °C). Thus, it may be concluded that the maximum environmental RH for the HPCS exhibiting good cooling performance decreases with the increase in the environmental temperature.
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Engineering, Industrial & Manufacturing Engineering; flexible abrasive tools; finishing; rounding edge; superalloys
Online: 3 December 2018 (08:57:22 CET)
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Many manufacturing sectors require high surface finishing. After machining operations such as milling or drilling, undesirable burrs or insufficient edge finishing may be generated. For decades, many finishing processes have been handmade-basis; this fact is accentuated when dealing with complex geometries especially for high value-added parts. In recent years, it’s a tendency of trying to automate as far as possible this kind of processes, repeatability and time/money savings are main purposes. Based on that idea, the aim of this work is to check new tools and strategies for finishing aeronautical parts, especially critical engine parts made on Inconel 718, a very ductile nickel alloy. Automating edge finishing of chamfered holes is a complicated but really important goal. In this paper, flexible abrasive tools were used for this purpose. A complete study of different abrasive possibilities was carried out, mainly focusing on roughness analysis and final edge results obtained.
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Engineering, Industrial & Manufacturing Engineering; AWJM; stack; CFRP; aluminium UNS A97050; SOM/SEM; kerf taper; surface quality; macrogeometric deviations
Online: 3 December 2018 (05:01:01 CET)
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The incorporation of plastic matrix composite materials into structural elements of the aeronautical industry requires contour machining and drilling processes along with metallic materials prior to final assembly operations. These operations are usually performed using conventional techniques, but they present problems derived from the nature of each material that avoid implementing One Shot Drilling strategies that work separately. In this work, the study focuses on the evaluation of the feasibility of Abrasive Waterjet Machining (AWJM) as a substitute for conventional drilling for stacks formed of Carbon Fiber Reinforced Plastic (CFRP) and aluminum alloy UNS A97050 through the study of the influence of abrasive mass flow rate, traverse feed rate and water pressure in straight cuts and drills. For the evaluation of the straight cuts, Stereoscopic Optical Microscopy (SOM) and Scanning Electron Microscopy (SEM) techniques are used inspection techniques have been used. In addition, the kerf taper through the proposal of a new method and the surface quality in different cutting regions have been evaluated. For the study of holes, the macrogeometric deviations of roundness, cylindricity and straightness have been evaluated. Thus, this experimental procedure reveals the conditions that minimize deviations, defects, and damage in straight cuts and holes obtained by AWJM.
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Engineering, Industrial & Manufacturing Engineering; multi-objective optimization; resource efficiency; metal mines; production process; NSGA-II
Online: 29 November 2018 (10:59:56 CET)
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The optimization of the production process of metal mines has been traditionally driven only by economic benefits while ignoring resource efficiency. However, it has become increasingly aware of the importance of resource efficiency since mineral resource reserves continue to decrease while the demand continues to grow. To better utilize the mineral resources for sustainable development, this paper proposes a multi-objective optimization model of the production process of metal mines considering both economic benefits and resource efficiency. Specifically, the goals of the proposed model are to maximize the profit and resource utilization rate. Then, the fast and elitist Non-Dominated Sorting Genetic Algorithm (NSGA-II) is used to optimize the multi-objective optimization model. The proposed model has been applied to the optimization of the production process of a stage in the Huogeqi Copper Mine. The optimization results provide a set of Pareto-optimal solutions that can meet varying needs of decision makers. Moreover, compared with those of the current production indicators, the profit and resource utilization rate of some points in the optimization results can increase respectively by 2.99% and 2.64%. Additionally, the effects of the decision variables (geological cut-off grade, minimum industrial grade and loss ratio) on objective functions (profit and resource utilization rate) were discussed using variance analysis. The sensitivities of the Pareto-optimal solutions to the unit copper concentrate price were studied. The results show that the Pareto-optimal solutions at higher profits (with lower resource utilization rates) are more sensitive to the unit copper concentrate prices than those obtained in regions with lower profits.
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Engineering, Industrial & Manufacturing Engineering; energy flexibility; retail stores; influential factors; employee engagement; customer engagement; utility collaboration
Online: 19 November 2018 (08:37:27 CET)
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Retail buildings can provide energy flexibility to the grid with the possibility of load shifting and building automation systems. Demand response is a collective innovation in the smart grid domain. Various stakeholders should be involved in the demand response activities to ensure the success. The owners or senior management of retail buildings need to consider the stakeholders who are directly influenced by the demand response participation, e.g. customers and employees. Meanwhile, demand response activities are influenced by various factors, such as energy market structure, policy, etc. Therefore, this paper investigates the demand response readiness for retail buildings with three aspects: energy control preferences, stakeholder engagement, and cross-national differences. A questionnaire is designed and collected with store managers in Denmark (N=51) and the Philippines (N=36). The result shows that: 1) retail stores are much readier to participate in the implicit demand response by manual energy control compared to the utility control or building automation. Meanwhile, store managers have significant concerns about business activities and indoor lighting compared to other aspects; 2) the statistically significant influential factors for retail stores to participate in the demand response are related to whether the DR participation matches the company goals, influences business operation, and whether retail stores are lack of related knowledge; 3) retail stores believe that stakeholders should be informed about the DR activities but not involved in; 4) there are significant differences regarding the energy control preferences and concerns between retail stores in Denmark and the Philippines, but no significant difference regarding the stakeholder engagement.
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Engineering, Industrial & Manufacturing Engineering; hybrid machines; hybrid manufacturing; additive manufacturing; subtractive manufacturing; Directed Energy Deposition; Powder Bed Fusion
Online: 15 November 2018 (08:21:29 CET)
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Hybrid machine tools combining additive and subtractive processes have arisen as a solution to the increasing manufacture requirements, boosting the potentials of both technologies, while compensating and minimizing their limitations. Nevertheless, the idea of hybrid machines is relatively new and there is a notable lack of knowledge in the field. Therefore, in the present paper, an insight into the advancements of hybrid machines is given, identifying their real capabilities, together with the latest developments from an industrial context. In addition, the current situation and future perspectives of hybrid machines from the point of view of process planning, monitoring and inspection are discussed. Finally, the challenges that must be overcome and the opportunities that the hybrid machines will provide in the forthcoming years are presented.
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Engineering, Industrial & Manufacturing Engineering; parts design, additive manufacturing, fused filament fabrication, fatigue, taguchi, ABS
Online: 8 November 2018 (15:19:44 CET)
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In this paper, the fatigue response of Fused Filament Fabrication (FFF) Acrylonitrile butadiene styrene (ABS) parts is studied. Different building parameters (layer height, nozzle diameter, infill density, and printing speed) were chosen to study their influence on the lifespan of cylindrical specimens according to a design of experiments (DOE) using the Taguchi methodology. The same DOE was applied on two different specimen sets using two different infill patterns: rectilinear and honeycomb. The results show that infill density is the most important parameter for both studied patterns. The specimens manufactured with the honeycomb pattern show longer lifespans. The best parameter set associated to that infill was chosen for a second experimental phase, in which the specimens were tested under different maximum bending stresses to construct the Wöhler curve associated to this 3D printing configuration. The results of this study are useful to design and manufacture ABS end-use parts that are expected to work under oscillating periodic loads.
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Engineering, Industrial & Manufacturing Engineering; Lean-logistics; optimization; simulation, Response Surface Methodology
Online: 8 November 2018 (10:38:04 CET)
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The present work aims at the comprehensive application of stochastic and optimization tools with the support of Information and Communication Technologies (ICT) through a case study in a logistics process for electronic goods; simulation and Response Surface Methodology (RSM) are applied for this purpose. The problem to be evaluated is to define an optimal distribution cost for products shipped to wholesale customers located in different cities in Mexico from a manufacturing plant in Tijuana, Mexico. The factors under study are the product allocation for each distribution center, finished good inventory level and on time deliveries, which are supposed to be significant to get the objective. The methodology applied for this problem considers the design of a discrete event simulation model to represent virtually the real life of logistics process, which is considered a complex system due to different activities are interrelated to carry it out. This model is used to execute the different experiments proposed by the RSM. The results obtained from simulation model were analyzed with the RSM to define the mathematical model that allows identifying the parameters of the factors in order to optimize the process. The findings prove how the ICT facilitate the application of stochastic tools with the purpose of process optimization.
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Engineering, Industrial & Manufacturing Engineering; multi-objective approach, sustainable purchasing, lot sizing, Cap and Trade, Economic Order Quantity, Carbon Price
Online: 5 November 2018 (15:12:06 CET)
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Sustainability in material purchasing is a growing area of research. Goods purchasing decisions strongly affect transportation path flows, vehicle consolidation, inventory levels and related obsolescence costs. Within a global sourcing context, companies experience the need of new decision making approaches capable to consider a large variety of factors, also linked with society and environment. Environmental impact assessment has become a key requirement for materials purchasing and transportation decisions since global warming is a rising concern both in academic and industrial researches. In fact, it is well known that the freight transport industry is responsible for large amounts of carbon emissions contributing to global warming. In this paper, we initially analyse and compare the environmental economic policies established by the International Governments in relation to the carbon trading systems adopted. Then, we develop a multi-objective lot sizing approach useful in practice to define the sustainable quantity to purchase when a Cap and Trade mitigation policy is present. We further analyse the model behaviour according to different carbon price values by demonstrating that carbon prices are still far too low to motivate managers towards sustainable purchasing choices.
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Engineering, Industrial & Manufacturing Engineering; 3-D printing; additive manufacturing; distributed manufacturing; open-source; polymers; recycling; waste plastic; extruder; upcycle; circular economy
Online: 5 November 2018 (07:45:36 CET)
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Although distributed additive manufacturing can provide high returns on investment the current markup on commercial filament over base polymers limits deployment. These cost barriers can be surmounted by eliminating the entire process of fusing filament by 3-D printing products directly from polymer granules. Fused granular fabrication (FGF) (or fused particle fabrication (FPF)) is being held back in part by the accessibility of low-cost pelletizers and choppers. An open-source 3-D printable invention disclosed here provides for precise controlled pelletizing of both single thermopolymers as well as composites for 3-D printing. The system is designed, built and tested for its ability to provide high tolerance thermopolymer pellets from a number of sizes capable of being used in a FGF printer. In addition, the chopping pelletizer is tested for its ability to chop multi-materials simultaneously for color mixing and composite fabrication as well as precise fractional measuring back to filament. The US$185 open-source 3-D printable pelletizer chopper system was successfully fabricated and has a 0.5 kg/hr throughput with one motor, and 1.0 kg/hr throughput with two motors using only 0.24 kWh/kg during the chopping process. Pellets were successfully printed directly via FGF and indirectly after being converted into high-tolerance filament in a recyclebot.
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Engineering, Industrial & Manufacturing Engineering; additive manufacturing; powder-bed fusion; laser sintering; polypropylene; process parameter optimization; mechanical properties; computer tomography
Online: 5 November 2018 (03:50:51 CET)
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The use of commodity polymers such as polypropylene (PP) is key to open new market segments and applications for the additive manufacturing industry. Technologies such as powder-bed fusion (PBF) can process PP powder; however, much is still to learn concerning process parameters for reliable manufacturing. This study focusses in the process-property relationships of PP using laser-based PBF. The research presents an overview of the intrinsic and the extrinsic characteristic of a commercial PP powder as well as fabrication of tensile specimens with varying process parameters to characterize tensile, elongation at break, and porosity properties. The impact of key process parameters, such as power and scanning speed are systematically modified in a controlled design of experiment. The results were compared to the existing body of knowledge; the outcome is to present a process window and optimal process parameters for industrial use of PP. The computer tomography data revealed a highly porous structure inside specimens ranging between 8.46% and 10.08%, with porosity concentrated in the interlayer planes in the build direction. The results of the design of experiment for this commercial material show a narrow window of 0.122 ≥ Ev ≥ 0.138 J/mm3 led to increased mechanical properties while maintaining geometrical stability.
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Engineering, Industrial & Manufacturing Engineering; additive manufacturing; topology optimization; lattice; Ti6Al4V; automotive; light-weighting
Online: 2 November 2018 (09:38:06 CET)
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This paper provides an overview of the new CPAM Project on Additive Manufacturing (AM) in design and simulation, focusing on topology & lattice structure optimization for a light-weighting advantage. This industry/academia collaboration project aims to utilize existing hardware and software tools, and investigate the practical limits of the technologies, providing eventual guidelines for general use. This will provide a solid foundation for the practical use of metal AM optimized solid and latticed structures especially for Ti6Al4V parts. Two case studies are demonstrated here, one a purely topology optimized design, and one also incorporating lattice optimized design, both from Ti6Al4V and load-bearing components, to be utilized in the Nelson Mandela University (NMU) Eco-Car Project in competition, late in 2018. This paper presents the Design for Additive Manufacturing (DfAM) process, the challenges met iro applying a DfAM design mindset, and a unique final voxel-based smoothing step finishing off the design process. Detailed structural integrity assessment of these parts are included - the question remains: can Additive Manufacturing help win the race?
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Engineering, Industrial & Manufacturing Engineering; student relationship management; critical success factors; knowledge management; employees’ involvement; student orientation; SRM technology; confirmatory factor analysis
Online: 2 November 2018 (04:04:24 CET)
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Due to the upward trend in the globalization of sustainability issues and the intense competitive environment, it is evident that higher education institutions need new strategic approaches to succeed. To this end, the inquiry for this paper has been made into the debate about student relationship management. Going through the literature indicates that institutions have mainly perceived the concept as a technological initiative for solving the problems in individual domains, accompanied by uncoordinated efforts. Thus, the aims of this study are to theoretically present critical success factors of this strategic approach and to empirically examine the recognized factors. To do so, confirmatory factor analysis that is a quantitative analytic method was performed. The results and analyses revealed that there has been a significant correlation between the four critical success factors including knowledge management, student relationship management technology, student orientation, and employees’ involvement. It was also found that these factors are significantly correlated with the construct of student relationship management success. The findings have consequently highlighted that in addition to the technological tool, the role of knowledge management, employees’ involvement, and student orientation appeared to be particularly important for the implementation of the application.
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Engineering, Industrial & Manufacturing Engineering; biomimicry; biomimetic engineering; energy absorption; lattice structure; additive manufacturing; powder bed fusion; X-ray tomography; microCT; non-destructive testing; 3D image analysis
Online: 23 October 2018 (10:10:15 CEST)
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Biomimicry in additive manufacturing often refers to topology optimization and the use of lattice structures, due to the organic shape of the topology-optimized designs, and the lattices often looking similar to many light-weight structures found in nature such as trabecular bone, wood, sponges, coral, to name a few. Real biomimetic design however involves the use of design principles taken in some way from natural systems. In this work we use a methodology whereby high resolution 3D analysis of a natural material with desirable properties is “reverse-engineered” and the design tested for the purpose. This allows more accurate replication of the desired properties, and adaption of the design parameters to the material used for production (which usually differs from the biological material). One such example is the impact-protective natural design of the glyptodont body armour. In this paper we report on the production of body armour models in metal (Ti4Al4V) and analyze the resulting mechanical properties, assessing their potential for impact protective applications. This is the first biomimetic study using metal additive manufacturing to date.
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Engineering, Industrial & Manufacturing Engineering; non-destructive testing; process optimization; porosity; pore hotspots; image-based simulations; 3D image analysis
Online: 23 October 2018 (09:58:18 CEST)
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This paper presents the latest developments in microCT, both globally and locally, for supporting the additive manufacturing industry. There are a number of recently developed capabilities which are especially relevant to the non-destructive quality inspection of additive manufactured parts; and also for advanced process optimization. These new capabilities are all locally available but not yet utilized to their full potential, most likely due to a lack of knowledge of these capabilities. The aim of this paper is therefore to fill this gap and provide an overview of these latest capabilities, showcasing numerous local examples.
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Engineering, Industrial & Manufacturing Engineering; continuum rolling contact; geometry relationship; pressure distribution; stress behavior; rolling die and slab
Online: 23 October 2018 (05:51:12 CEST)
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In the world industry plant, solid and solid metals are always in contact even their motions not independent. Modeling of rolling die contact with slab primarily needs to describe the Tribology of contact phenomena. Consideration of continuum theory of rolling contact how a contact region is formed between rolling die and slab, and how the tangential force is distributed over the contact area with coefficient of friction is important. The central concern of numerical model is used in this work to indicate a set of equations, derived from the contact principle, that transfer the physical event into the mathematical equations including the laws of nature, such as newton’s laws, boundary conditions, state of stresses and their derivatives at particular time and locations. In this paper the elasticity stress behavior of rolling die contact with slab for number of cyclic loads is modeled. The model is including new proposed constitutive equations for discontinuity of the velocity, pressure distribution in rolling contact from the enter side to exit side of the neutral point. To verify the model, finite element simulation and experimental data from the literature are considered. The results show good agreement with finite element simulation and experimental data.
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Engineering, Industrial & Manufacturing Engineering; production system; simulation manufacturing process; simulation model; work in process
Online: 22 October 2018 (04:56:28 CEST)
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During the last decades, the production systems have developed different strategies to increase their competitiveness in the global market. In a manufacturing and services systems, Lean Manufacturing has been consolidated through the correct implementation of its tools. The present paper presents a case study developed in a Food Packer company where a Simulation Model was considered as an alternative to reduce the waste time generated by the poor distribution of operations and transportation areas for a product within the factory. As a matter of fact, the company has detected problems on the layout distribution that prevents to fulfill the market demand. In addition, the principal aim was to create a simulation model to test different hypothetical scenarios and alternative designs for the layout distribution without modifying its facilities. Moreover, the implemented methodology was based on classical models of simulation projects and a compendium of the manufacturing systems optimization by simulation process used during the last ten years. Also, a mathematic model supported by the Promodel ® simulation software was developed considering the company characteristics; along with the model development, it was possible to compare the production system performance from the percentage of used locations, the percentage of resources utilization, the number of finished products, and the level of Work in Process (WIP). Finally, the verification and validation stages were performed before running the scenarios in the real production area. The results generated by the implementation of the project represent an increase of 68% in the production capacity and a reduction of 5% in the WIP. In addition, both outcomes are associated with the resources management, which were reassigned to other production areas.
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Engineering, Industrial & Manufacturing Engineering; fuzzy inference system; fuzzy logics; linear motion blur; fuzzy debluring; electron beam calibration; signal & image processing
Online: 19 October 2018 (04:53:27 CEST)
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This paper presents a novel method of restoring the electron beam (EB) measurements that are degraded by linear motion blur. This is based on a Fuzzy Inference System (FIS) and Wiener inverse filter, together providing autonomy, reliability, flexibility and real-time execution. This system is capable of restoring highly degraded signals without requiring the exact knowledge of EB probe size. The FIS is formed of three inputs, eight fuzzy rules and one output. The FIS is responsible to monitor the restoration results, grade their validity and choose the one that yields to a better grade. These grades are produced autonomously by analyzing results of Wiener inverse filter. To benchmark the performance of the system, ground truth signals obtained using an 18 um wire probe are compared with the restorations. Main aims are therefore a) Provide unsupervised deblurring for device independent EB measurement; b) Improve the reliability of the process; c) Apply deblurring without knowing the probe size. These, further facilitates the deployment and manufacturing of EB probes and probe independent and accurate EB characterization. It also makes restoration of previously collected EB measurements easier, where the probe sizes are not known or recorded.
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Engineering, Industrial & Manufacturing Engineering; lean manufacturing; PDCA; defects; Pareto chart; flowchart
Online: 16 October 2018 (09:09:54 CEST)
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Defects are considered one of the wastes in manufacturing systems that negatively affect the delivery times, cost and quality of products leading to manufacturing companies facing a critical situation with the customers and to not comply with the IPC-A-610E standard for the acceptability of electronic components. This is the case is a manufacturing company located in Tijuana, Mexico. Due to an increasing demand on the products manufactured by this company, several defects have been detected in the welding process of electronic boards, as well as in the components named Thru-Holes. It is for this reason that this paper presents a lean manufacturing application case study. The objective of this research is to reduce at least 20% the defects generated during the welding process. In addition, it is intended to increase 20% the capacity of 3 double production lines where electronic boards are processed. As method, the PDCA cycle, is applied. The Pareto charts and the flowchart are used as support tools. As results, defects decreased 65%, 79% and 77% in three analyzed product models. As conclusion, the PDCA cycle, the Pareto charts, and the flowchart are excellent quality tools that help decrease the number of defective components.
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Engineering, Industrial & Manufacturing Engineering; large coaxial probe; thin planar materials; low-loss materials; relative permittivity; reflection coefficient; calibration
Online: 12 October 2018 (08:19:52 CEST)
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This paper focuses on the non-destructive dielectric measurement for low-loss planar materials with a thickness of less than 3 mm using a large coaxial probe with an outer diameter of 48 mm. The aperture probe calibration procedure required only to make a measurement of the half-space air and three offset shorts. The reflection coefficient for the thin material is measured using a Keysight E5071C network analyzer from 0.3 MHz to 650 MHz and then converted to a relative dielectric constant and tangent loss via closed form capacitance model and lift-off calibration process. Measurement error of dielectric constant, Δεr is less than 2.5 % from 1 MHz to 400 MHz and the resolution of loss tangent, tan δ measurement is capable of achieving 3×10-3.
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Engineering, Industrial & Manufacturing Engineering; pulsed electrochemical micromachining; current confinement; material removal rate; efficiency
Online: 12 October 2018 (05:31:35 CEST)
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In this work a research on pulsed electrochemical micromachining of Stainless Steel is presented. A suitable equipment to study the process is described as well as a fitting procedure to machine and measure the variables involved. A tool of Tungsten with a tip of about 5 mm diameter sunk in an electrolyte of NaNO3 is used for the process. The pulse on-time must be maintained in the order of ns to achieve a good current confinement, since the tool is active. Some experiments were made to assess the most important variables of the process, as current confinement, surface roughness, material removal rate and efficiency. It is observed that the current confinement get worse when the pulse on-time increases, as well as surface roughness. The material removal rate and the efficiency increase with the voltage amplitude and the pulse on-time. The voltage amplitude must be higher than 12 V so that the phenomenon of passivation disappears. There is a compromise in the choice of the variables, so a suitable combination of parameters is determined so that a good material removal rate with an acceptable result is achieved.
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Engineering, Industrial & Manufacturing Engineering; queuing problem; TRIZ; Arena software; average waiting time
Online: 8 October 2018 (11:28:17 CEST)
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A university canteen is a queueing system characterised by non-stationary time of arrival with limited resources where the arrival rate is time dependent and has different pattern of arrival for different time interval. This means at certain time of the day, the arrival rate is much higher than other time and for a university canteen, the arrival rate of customer during the lunchtime is much higher and the food (resources) is limited. Non-stationary time dependent queueing system is not easily modelled mathematically hence such queueing systems are modelled using simulation tools such as ARENA. In order to model a non-stationary time dependent queueing system with limited resources and solve queueing problems using ARENA, researchers have to depend on their knowledge and experience in identifying the appropriate and relevant parameters for the system and make modifications to these parameters of the system to solve queueing problems by means of trial and error. Hence, this research work explores the potentials of applying a systematic problem solving tool, TRIZ to help users to make better decisions in deriving solutions to improve a non-stationary time dependent queueing system with limited resources. A case study was carried out to minimize the waiting time of the customers at the cafeteria of the Faculty of Engineering, Universiti Putra Malaysia (UPM), which has queueing problems for years during lunchtime. TRIZ was applied in this case study and the results showed that TRIZ can assist researchers to derive a solution model that lead to shorter waiting time without incurring additional cost and resources.
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Engineering, Industrial & Manufacturing Engineering; solid state recycling; metallic scrap/sludge; powder metallurgy; in-situ reduction
Online: 27 September 2018 (15:07:43 CEST)
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The issues of metallic scrap management and its utilization in manufacturing plants are nowadays intensely considered to address essential sustainability guidelines. Efficient recycling procedure for shop floor metallic scrap is not yet available because of abundance and contamination of nonmetallic constituents. Other ferrous metallic scrap are melted and purified during secondary steelmaking to get products in the form of blooms and billets are obtained. This study illustrates the potential of powder technology (powder metallurgy (PM) and metal injection molding (MIM)) based process for solid-state recycling and attainment of usable products. Industrially downgraded grinding sludge is pulverized and used as a raw material. Results showed properties of sintered parts are significantly improved due to in-situ reduction and densification during sintering. Recyclability Index (RI) was created to compare the effect of process variables on obtained products. Based on RI, recycled ferrous parts have about 70% comparable properties with equivalent pure iron parts. Complex reduction and sintering behavior in MIM, particularly, diffusion and pore volume kinetics limits applicability of MIM with this recycling approach. However, few industrial parts were developed and manufactured by PM based approach to validate the applicability of this novel recycling-cum-manufacturing process for the production of porous parts.
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Engineering, Industrial & Manufacturing Engineering; reliability centered maintenance (RCM); individual sectioned forming machine; FMEA; risk analysis
Online: 26 September 2018 (04:04:27 CEST)
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This study investigated the breakdown trend in an automated production with an aim to recommend the application of Reliability-centered maintenance (RCM) for an improved productivity via a new preventive maintenance (PM) program. Individual Section-forming machine (ISM): a glass blowing machine for making glass bottles was used as the case study of an automated production system. The machine parts and the working mechanisms were analysed with a special focus on methods of processes and procedures that will enable the ISM maintenance department run more effective and achieve its essential goal of ensuring effective machine operation and reducing machine downtime. In this work, information is provided on the steps and procedures to identify critical components of the ISM using Failure Modes and Effect Analysis (FMEA) as a tool to develop an optimal maintenance program based on the reliability data of the equipment’s functional components. A relationship was established between the failure rate of the machine components and the maintenance costs such that using the recommended PM program, an evidence of improvement in the machine’s availability, safety and cost-effectiveness will result into an increase in the company’s profit margin.
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Engineering, Industrial & Manufacturing Engineering; Protrusion, illumination, height, effective pixel, gray level, teaching
Online: 24 September 2018 (15:02:56 CEST)
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Protrusive defects on the color filter of thin-film transistor (TFT) liquid crystal displays (LCDs) frequently damage the valuable photomask. An fast method using side-view illuminations associated with digital charge-couple devices (CCDs) to detect the protrusive defect in the four substrates, which are the black matrix (BM), red, green, and blue. Between the photomask and substrate, the depth of field (DOF) is normally 300 μm for the proximity-type aligner; we select the four substrates to evaluate the detectability in the task. The experiment is capable of detecting measurements of 300 μm and even lower than 100 μm can be assessed successfully. The maximum error of the measurement is within 6% among the four samples. Furthermore, the uncertainty analysis of three standard deviations is conducted. Thus, the method is cost-effective to prevent damage for valuable photomasks in the flat panel display industry.
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Engineering, Industrial & Manufacturing Engineering; Additive manufacturing; modular design; design-for-manufacturability; sustainable design; design optimization; product re-design
Online: 21 September 2018 (15:23:15 CEST)
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This work explores an additive-manufacturing-enabled combination-of-function approach for design of modular products. AM technologies allow the design and manufacturing of nearly free-form geometry, which can be used to create more complex, multi-function or multi-feature parts. The approach presented here replaces sub-assemblies within a modular product or system with more complex single parts that are designed and manufactured using AM technologies. This approach can increase the reliability of systems and products by reducing the number of interfaces, as well as allowing the optimization of the more complex parts during the design. The smaller part count and the ability of users to replace or upgrade the system or product parts on-demand should reduce user risk, life-cycle costs, and prevent obsolescence for the user of many systems. This study presents a detailed review on the current state-of-the-art in modular product design in order to demonstrate the place, need and usefulness of this AM-enabled method for systems and products that could benefit from it. A detailed case study is developed and presented to demonstrate the concepts.
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Engineering, Industrial & Manufacturing Engineering; Fatigue; Delamination; Acoustic Emission; Failure Mechanisms; Composite Materials; Nanofibers, Marine Applications.
Online: 21 September 2018 (10:47:43 CEST)
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The use of high strength to weight ratio laminated composites is emerging in marine industry and applications as a very efficient solution for improving productivity. Nevertheless, delamination between the layers is a limiting factor for the wider application of laminated composites, as it reduces the stiffness and strengths of the structure. Interleaving nanofibrous mats between layers of composite laminates has been proved to be an effective method for improving composites delamination resistance. This paper aims to characterize the effect of interleaved nanofiber on mode I interlaminar properties and failure mechanisms when subjected to static and fatigue loadings. For this purpose, virgin and nanomodified woven laminates were subjected to Double Cantilever Beam (DCB) specimens. Static and fatigue tests were performed and the tests were monitored by acoustic emission technique. The mechanical results showed a 130% increase of delamination toughness for nanomodified specimens in the static loadings and more crack growth resistance in the fatigue loading. The AE results revealed that different type of failure mechanisms was the cause of these improvements for the modified specimens compared with the virgin ones.
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Engineering, Industrial & Manufacturing Engineering; machining; titanium; temperature; strain; grain refinement; ultrafine; nanocrystalline
Online: 11 September 2018 (09:03:57 CEST)
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New metastable β titanium alloys are receiving increasing attention due to their excellent biomechanical properties and machinability is critical to their uptake. In this study machining chip microstructure have been investigated to gain an understanding of strain and temperature fields during cutting. For higher cutting speeds, ≥60 m/min, the chips have segmented morphologies characterised by a serrated appearance. High levels of strain in the primary shear zone promote formation of expanded shear band regions between segments which exhibit intensive refinement of the β phase down to grain sizes below 100 nm. The presence of both α and β phases across the expanded shear band suggests that temperatures during cutting are in the range of 400–600 °C. For the secondary shear zone, very large strains at the cutting interface result in heavily refined and approximately equiaxed nanocrystalline β grains with sizes around 20–50 nm, while further from the interface the β grains become highly elongated in the shear direction. An absence of the α phase in the region immediately adjacent to the cutting interface indicates recrystallization during cutting and temperatures in excess of the 720 °C β transus temperature.
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Engineering, Industrial & Manufacturing Engineering; supply chains; simulation model; contamination
Online: 3 September 2018 (08:36:12 CEST)
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This article aims to serve as a guide for the construction of supply chain simulation models designed with a lean approach, using Promodel software. To achieve this, a supply chain was designed for a fictitious company located in the City of Celaya, Guanajuato and a set of suppliers located in different cities within the same State. It was used as a google tool to define the distances between each of the companies. As a final result, a representative model of a supply chain was obtained, as well as a methodology that allows the construction of lean supply chains regardless of the number of companies that comprise it. The effect of the variability in the delivery times between suppliers was incorporated into the simulation model, as well as an equation that calculates the pollution emissions of the vehicles that integrate the network that moves the products between the companies. With this work it is possible to represent networks of supply chains of real world companies, where the variability and contamination factor is included, to facilitate the decision making regarding the number of vehicles, inventory levels, quantities to be shipped, frequency in the shipments, etc. with the purpose of contaminating as little as possible and at the same time preventing interruptions in the supply chain using the least amount of resources possible.
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Engineering, Industrial & Manufacturing Engineering; circular economy; remanufacturing; fuel cells; data-driven; systems dynamics
Online: 31 August 2018 (05:31:03 CEST)
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Remanufacturing is a viable option to extend the useful life of an end-of-use product or its parts, ensuring sustainable competitive advantages under the current global economic climate. Challenges typical to remanufacturing still persist, despite its many benefits. According to the European Remanufacturing Network a key challenge is lack of accurate, timely and consistent product knowledge as highlighted in a 2015 survey of 188 European remanufacturers. With more data being produced by electric and hybrid vehicles, this adds to the information complexity challenge already experienced in remanufacturing. Therefore, it is difficult to implement real-time and accurate remanufacturing for the shop floor; there are no papers that focus on this within an electric and hybrid vehicle environment. To address this problem this paper attempts to (1) identify the required parameters/ variables needed for fuel cell remanufacturing by means of interviews (2) rank the variables by Pareto analysis (3) develop a casual loop diagram for the identified parameters/ variables to visualise its impact on remanufacturing (4) model a simple stock and flow diagram to simulate and understand data and information-driven schemes in remanufacturing.
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Engineering, Industrial & Manufacturing Engineering; laser powder bed fusion; additive manufacturing; X-ray tomography; in-situ imaging; Ti6Al4V; lattice structures
Online: 30 August 2018 (06:12:34 CEST)
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This paper reports on the production and mechanical properties of Ti6Al4V micro-lattice structures, with strut thickness nearing the single-track width of the laser-based powder bed fusion (LPBF) system used. Besides providing new information on the mechanical properties and manufacturability of such thin-strut lattices, this paper also reports on the in-situ deformation imaging of micro-lattice structures with 6 unit cells in every direction. LPBF lattices are of interest for medical implants, due to the possibility of creating structures with an elastic modulus close to that of the bones and small pore sizes which allow effective osseointegration. In this work four different cubes were produced by laser powder bed fusion and subsequently analyzed using microCT, compression testing and one selected lattice was subjected to in-situ microCT imaging during compression. The in-situ imaging was performed at 4 steps during yielding. The results indicate that mechanical performance (elastic modulus and strength) correlate well with actual density and that this performance is remarkably good, despite the high roughness and irregularity of the struts at this scale. In-situ yielding is visually illustrated.
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Engineering, Industrial & Manufacturing Engineering; inverse problem; industrial tomography; machine learning, sensors, cyber-physical system, Industry 4.0
Online: 29 August 2018 (05:56:49 CEST)
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The article presents a cyber-physical system for acquiring, processing and reconstructing images from measurement data. The technology was based on process tomography, intelligent measurement sensors, machine learning, Big Data, Cloud Computing, Internet of Things as a solution for Industry 4.0. Industrial tomography enables observation of physical and chemical phenomena without the need of internal penetration and allows real-time monitoring of production processes. The application includes specialized intelligent devices for tomographic measurements and dedicated algorithms for solving the inverse problem. The work focuses mainly on electrical tomography and image reconstruction using deterministic methods and machine learning, the reconstruction results were compared, different measurement models were used. The researches were carried out for synthetic data and laboratory measurements. The main advantage of the proposed system is the possibility of spatial data analysis and their high processing speed. The presented research results show that the process tomography gives the possibility to analyse the processes taking place inside the facility without disturbing the production, analysis and detection of obstacles, defects and various anomalies. Knowing the characteristics of a given solution, the application allows you to choose the appropriate method to reconstruct the image.
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Engineering, Industrial & Manufacturing Engineering; technology transfer; anthropotechnology; offset policy
Online: 24 August 2018 (05:45:03 CEST)
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This research aimed, within the scope of the anthropotechnological approach, analyze the technology transfer, performed via the offset policy in the field of public health, called the Radiotherapy Expansion Plan, from the Health Ministry. The objective of this policy is to create and improve accredited organizations, concerning the oncological treatment, specifically in the insertion of radiotherapeutic equipment. This process is divided into two stages: the insertion of the radiotherapy equipment, and the compensations provided for in the commercial agreement. To meet this purpose, the research started from understanding the theoretical and methodological approaches of the fields of study of anthropotechnology, technology transfer and offset policy. In this sense, there was used the methodological strategy of the case study, supported by applied research, with a qualitative and exploratory approach. External and internal environments of a specific situation were analyzed, located in the State of Paraná, which received the radiotherapy equipment. It was verified that the initiatives of insertion of radiotherapeutic equipment in the context of the Expansion Plan have undergone numerous confrontations, inserted in the contextual and organizational particularities that affect its development and effectiveness. There are challenges that require responses from a set of organizations involved, in order to implement the trade agreement established by the offset policy, highlighting the first stage as a process of technology transfer. Thus, the situation located in the State of Paraná consistently consolidated the insertion of the radiotherapy equipment. It allowed its disclosure as a reference situation, and based on the dimensions and indicators analysis provided by anthropotechnology, made possible the comprehensionof the technology transfer involved in the process.
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Engineering, Industrial & Manufacturing Engineering; TLP bonding; eutectic; aluminum alloys; duplex stainless steel
Online: 17 August 2018 (11:48:39 CEST)
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Transient liquid phase (TLP) bonding of Al-6063 and UNS S32304 was performed using copper foil as an interlayer between the base metals. A compression load was applied normal to the specimens. Metallurgical examination of the produced joints showed three distinct regions including a reaction zone, diffusion affected zone and the base metals. The diffusion of copper into aluminum resulted in an Al-Cu eutectic structure. However, the oxide layer on the aluminum surface controlled the dissolution behavior of copper and the extent of its wettability with the base metals. Although voids and intermetallic compounds were detected at the interfaces of the processed joints, a defect free joint was produced at 570°C. In addition, the results from corrosion tests showed that the use of copper as an interlayer decreased the corrosion resistance of the joints. However, increase in thickness of the joining reaction zone with increasing bonding temperature was observed to increase corrosion resistance.
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Engineering, Industrial & Manufacturing Engineering; count data; Bayesian regression; technological sustainability; Poisson probability distribution; patent analysis
Online: 13 August 2018 (07:53:13 CEST)
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Technology development changes society and society demands new and innovative technology development. We analyze technology to understand society and technology itself. Many researches have been introduced in various fields. Most of them were about patent analysis. This is because detailed and accurate results of research and development are patented. In this paper, we study on new patent analysis method based on count data model and Bayesian regression analysis. Using count data model, we analyze the technological keywords extracted from the collected patent documents. We use the posterior distribution of Bayesian statistics to reflect the experience and knowledge of the relevant technological experts in the analysis model. Moreover, we apply the proposed model to finding sustainable technologies. Finding and developing sustainable technologies is an important activity for companies and research institutes to maintain their technological competitiveness. To illustrate how our modeling could be applied to real domain, we carry out a case study using the patent documents related to artificial intelligence.
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Engineering, Industrial & Manufacturing Engineering; circular economy; industry 4.0; data; 9R’s; digital technologies; digital intelligence
Online: 8 August 2018 (05:31:47 CEST)
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The Circular Economy has been of growing significance within academic, policymaking and industry groups. Latest developments in the field of Circular Economy has led to an expansion of CE studies focused on interrogating CE as a paradigm, its relationship with sustainability and concepts and definitions of the Circular Economy. Research has also identified the significant potential of applying circular approaches to areas of the economy, including manufacturing and Industry 4.0, which, with data, is enabling latest the advances in digital technologies. This is the first review paper to integrate the fields of CE and digital technologies resulting in a framework which provides directions for policymakers and guidance for future research. To achieve this, we conduct a systematic literature review of the empirical literature related to digital technologies, industry 4.0 and circular approaches, from the point of the 9 Rs. The systematic literature review (SLR) is based on peer-reviewed articles published between 2000-2018. The findings reveal that while research on the circular economy has been on an annual rise, research on digital technologies enabled circular economy is still relatively an untouched area of research across all nine (9) circular approaches. As such this is an area rife for further research. This paper also presents illustrative charts and graphs to summarize the current trends in circular economy research in manufacturing. From this, a framework for future circular economy research for manufacturing for digital technologies is proposed.
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Engineering, Industrial & Manufacturing Engineering; Grid-connected wind turbine; Differential speed regulation; Power control; Simulation
Online: 6 August 2018 (09:45:04 CEST)
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The differential gear train and speed regulating motor constitute the variable ratio transmission for grid-connected wind turbine with differential speed regulation. The synchronous generator in the system can accessing the power grid without frequency converter. The transmission can realize the mode of variable speed constant frequency that the wind rotor speed is varying and the generator rotor speed is constant. The power control method is studied under the different wind speed which is lower or higher than rated wind speed with using the relational expression of utilization rate of wind energy Cp, pitch angle β and the tip speed ratio λ. The SIMULINK software is used to build the 1500 kW wind turbine model with differential speed regulation. Some different wind speed is made as input. The feasibility of power control method for grid-connected wind turbine with differential speed regulation is verified by the comparison between the simulation results and the theoretical value of the key parameters.
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Engineering, Industrial & Manufacturing Engineering; Robust Design, Taguchi Method, Product Design, Manufacturing Systems, Quality Engineering, Quality Loss Function.
Online: 26 July 2018 (15:20:02 CEST)
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One of the main technological and economic challenges for an engineer is designing high-quality products in manufacturing processes. Most of these processes involve a large number of variables included the setting of controllable (design) and uncontrollable (noise) variables. Robust Design (RD) method uses a collection of mathematical and statistical tools to study a large number of variables in the process with a minimum value of computational cost. Robust design method tries to make high-quality products according to customers’ viewpoints with an acceptable profit margin. This paper aims to provide a brief up-to-date review of the latest development of RD method particularly applied in manufacturing systems. The basic concepts of the quality loss function, orthogonal array, and crossed array design are explained. According to robust design approach, two classifications are presented, first for different types of factors, and second for different types of data. This classification plays an important role in determining the number of necessity replications for experiments and choose the best method for analyzing data. In addition, the combination of RD method with some other optimization methods applied in designing and optimizing of processes are discussed.
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Engineering, Industrial & Manufacturing Engineering; TCM; cutting force; flank wear; ANFIS; fuzzy; LabVIEW
Online: 24 July 2018 (06:29:35 CEST)
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In the manufacturing industry, cutting tool failure is a probable fault which causes damage to the cutting tools, workpiece quality and unscheduled downtime. It is very important to develop a reliable and inexpensive intelligent tool wear monitoring system for use in cutting processes. A successful monitoring system can effectively maintain machine tools, cutting tool and workpiece. In the present study, the tool condition monitoring system has been developed for Die steel (H13) milling process. Effective design of experiment and robust data acquisition system ensured the machining forces impact in the milling operation. Also, ANFIS based model has been developed based on cutting force-tool wear relationship in this research which has been implemented in the tool wear monitoring system. Prediction model shows that the developed system is accurate enough to perform an online tool wear monitoring system in the milling process.
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Engineering, Industrial & Manufacturing Engineering; porosity; multijetfusion; fluids; watertightness; 3Dprint; orientation; pressure; leakage;
Online: 17 July 2018 (11:10:14 CEST)
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The aim of this paper is to explore the watertightness behaviour for high pressure applications using Multijetfusion technology and polyamide 12 as a material. It reports an efficient solution for manufacturing functional prototypes and final parts for water pressure applications. It provides manufacturing rules to engineers in the pressurized product development process up to 10 MPa of nominal pressure. The research findings show manufacturers the possibility of using additive manufacturing as an alternative to traditional manufacturing. Water leakage was studied using different printing orientations and wall thickness for a range of pressure values. An industrial ball valve was printed and validated with the ISO 9393 standard also meeting tolerance requirements. This paper is a pioneering approach to the additive manufacturing of high performance fluid handling components. This approach solves the problem of leakage caused by porosity in additive manufacturing technologies
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Engineering, Industrial & Manufacturing Engineering; grinding, wheel wear, wear flat, precision, tribometry, pin on disk
Online: 10 July 2018 (13:24:06 CEST)
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Manufacturing of grinding wheels is continuously adapting to new industrial requirements. New abrasives and new wheel configurations, together with wheel wear control allow for grinding process optimization. However, the wear behavior of the new abrasive materials is not usually studied from a scientific point of view due to the difficulty to control and monitor all the variables affecting the tribochemical wear mechanisms. In this work an original design of pin on disk tribometer is developed in a CNC grinding machine. An Alumina grinding wheel with special characteristics is employed and two types of abrasive are compared: White Fused Alumina (WFA) and Sol-Gel Alumina (SG). The implemented tribometer reaches sliding speeds of between 20 and 30 m/s and real contact pressures up to 190 MPa. The results show that the wear behavior of the abrasive grains is strongly influenced by their crystallographic structure and the tribometer appears to be a very good tool for characterizing the wear mechanisms of grinding wheels, depending on the abrasive grains.
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Engineering, Industrial & Manufacturing Engineering; LMD; laser metal deposition; shielding gas; Argon; Helium; additive manufacturing; Inconel 718; melt pool temperature
Online: 29 June 2018 (15:44:04 CEST)
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The use of the LMD technology as a manufacturing and repairing technique in industrial sectors like the die and mold and aerospace is increasing within the last decades. Research carried out in the field of LMD process situates argon as the most usual inert gas, followed by nitrogen. Some leading companies have started to use helium and argon as carrier and shielding gas, respectively. There is therefore a pressing need to know how the use of different gases may affect the LMD process due to there is a lack of knowledge with regard to gas mixtures. The aim of the present work is to evaluate the influence of a mixture of argon and helium on the LMD process by analyzing single tracks of deposited material. For this purpose, special attention is paid to the melt pool temperature, as well as to the characterization of the deposited clads. The increment of helium concentration in the gases of the LMD processes based on argon will have three effects. The first one is a slightly reduction of the height of the clads. Second, an increase of the temperature of the melt pool. Last, smaller wet angles are obtained for higher helium concentrations.
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Engineering, Industrial & Manufacturing Engineering; alignments, dental pulp stem cells, nanofiber, neurogenesis, reduced graphene oxide
Online: 27 June 2018 (15:53:18 CEST)
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Stem cells derived from dental tissues—dental stem cells—are flavored due to their easy acquisition. Among them, dental pulp stem cells (DPSCs) extracted from the dental pulp have many advantages such as high proliferation and highly purified population. Although their ability for neurogenic differentiation has been highlighted and neurogenic differentiation using electrospun nanofibers (NFs) has been performed, graphene-incorporated NFs have never been applied for DPSC neurogenic differentiation. Here reduced graphene oxide (RGO)-polycaprolactone (PCL) hybrid electrospun NFs were developed and applied for enhanced neurogenesis of DPSCs. First, RGO-PCL NFs were fabricated by electrospinning with incorporation of RGO and alignments, and their chemical and morphological characteristics were evaluated. Furthermore, in vitro NF properties such as influence on the cellular alignments and cell viability of DPSCs were also analyzed. The influences of NFs on DPSCs neurogenesis was also analyzed. The results confirmed that an appropriate concentration of RGO promoted better DPSC neurogenesis. Furthermore, the use of random NFs facilitated contiguous junctions of differentiated cells, whereas the use of aligned NFs facilitated aligned junction of differentiated cells along the direction of NF alignments. Our findings showed that RGO-PCL NFs can be a useful tool for DPSC neurogenesis, which will help regeneration in neurodegenerative and neurodefective diseases.
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Engineering, Industrial & Manufacturing Engineering; laser; additive manufacturing; laser beam machining; laser polishing; waviness; roughness; Inconel 718
Online: 27 June 2018 (15:12:32 CEST)
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The present work proposes a novel manufacturing technique based on the combination of Laser Metal Deposition, Laser Beam Machining and Laser Polishing processes for the complete manufacturing of complex parts. Therefore, the complete process is based on the application of a laser heat source both for the building of the preform shape of the part by additive manufacturing and for the finishing operations. Their combination enables to manufacture near-net-shape parts and afterwards, remove the excess material via laser machining, which has resulted to be capable of eliminating the waviness resulting from the additive process. Besides, surface quality is improved via laser polishing to reduce the roughness of the final part. Therefore, conventional machining operations are eliminated, what results in a much cleaner process. In order to validate the capability of this new approach, the dimensional accuracy and surface quality of the resulting parts are evaluated. The process has been validated on an Inconel 718 test part, where a previously additively built up part has been finished by means of laser machining and laser polishing.
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Engineering, Industrial & Manufacturing Engineering; laser; welding; LBW; model; microstructure; bead seam; wobble strategy; Inconel 718
Online: 20 June 2018 (05:12:19 CEST)
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A numerical model was developed for predicting the bead geometry and microstructure in Laser Beam Welding of 2 mm thickness Inconel 718 sheets. The experiments were carried out with a 1 kW maximum power fiber laser coupled with a galvanometric scanner. Wobble strategy was employed for sweeping 1 mm wide circular areas for creating the weld seams and a specific tooling was manufactured for supplying protective Argon gas during the welding process. The numerical model takes into account both the laser beam absorption and the melt-pool fluid movement along the bead section, resulting in a weld geometry that depends on the process input parameters, such as feed rate and laser power. The microstructure of the beads was also estimated based on the cooling rate of the material. Features as bead upper and bottom final shapes, weld penetration and dendritic arm spacing were numerically and experimentally analyzed and discussed. The results given by the numerical analysis agree with the tests, making the model a robust predictive tool.
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Engineering, Industrial & Manufacturing Engineering; Lean, Just in Time, Pull System, Waste Management, Sustainable improvement, Waste flow Mapping.
Online: 13 June 2018 (14:33:00 CEST)
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Lean is one of the systematic approach to achieve higher value for organizations through eliminate non-value-added activities. It is an integrated set of tools, techniques, and principles designed to optimize cost, quality and delivery while improving safety. In Vietnam, industry waste management and treatment has become serious issue. The aim of this research is to present the effective of Lean application for industrial wastes collecting and delivery improvement. Through a case study, this paper showed the way of Lean tools and principles applied for wastes management and treatment such as Value Stream Mapping, Pull system, Visual Control, and Andon.... to get benefit on both economic and environment. In addition, the results introduced a good experience for Vietnamese enterprises in cost saving and sustainable development in waste management.
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Engineering, Industrial & Manufacturing Engineering; COS hydrolysis Reactor, numerical analysis, thermo-chemical transport phenomena, Monte Carlo simulation
Online: 12 June 2018 (14:19:00 CEST)
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During the recent decades, global warming by greenhouse gas evolution has attracted worldwide attention and evermore strict regulations thereon have become institutionalized as international policies. In the process, more environment-friendly power generation technologies have been developed utilizing fossil fuels with a view to timely commercialization. As one of such “clean coal” technology, Integrated Gasification Fuel Cell system is a promising power generation means and COS hydrolysis reactor is installed downstream of coal syngas to remove acidic gas constituents such as H2S and COS. The most significant design parameters affecting performance of the COS hydrolysis reactor were selected to be GHSV, (catalytic) reaction temperature, and length ratio and numerical modeling was performed considering heat and fluid flow transfer as well as chemical reaction kinetics. Effect of the selected design parameters on the variation of conversion rate and reactant gas mixture concentration were comprehensively investigated to predict performance of COS hydrolysis reactor. Stochastic modeling of reactor performance was finally performed using Monte Carlo simulation and linear regression fitting.
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Engineering, Industrial & Manufacturing Engineering; liquid metal sensors; liquid wire; wearables; athletic training; ankle complex; plantar flexion; resistance-based sensors; human ankle model; sensor substrate
Online: 7 June 2018 (11:15:27 CEST)
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Interviews from strength and conditioning coaches across all levels of athletic competition identified their two biggest concerns with the current state of wearable technology: (a) the lack of solutions that accurately capture data "from the ground up" and (b) the lack of trust due to inconsistent measurements. The purpose of this research is to investigate the use of liquid metal sensors, specifically Liquid Wire sensors, as a potential solution for accurately capturing ankle complex movements such as plantar flexion, dorsiflexion, inversion, and eversion. Sensor stretch linearity was validated using a Micro-Ohm Meter and a Wheatstone bridge circuit. Sensors made from different substrates were also tested and discovered to be linear at multiple temperatures. An ankle complex model and computing unit for measuring resistance values were developed to determine sensor output based on simulated plantar flexion movement. The sensors were found to have a significant relationship between the positional change and the resistance values for plantar flexion movement. The results of the study ultimately confirm the researchers' hypothesis that liquid metal sensors, and Liquid Wire sensors specifically, can serve as a mitigating substitute for inertial measurement unit (IMU) based solutions that attempt to capture specific joint angles and movements.
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Engineering, Industrial & Manufacturing Engineering; Indoor Positioning Technology; Bluetooth 4.0; Manufacturing Private Cloud; Internet of Things; Indoor Positioning Technology;
Online: 1 June 2018 (08:15:12 CEST)
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To enhance industrial competitiveness and increase productivity, every country has strived to create a smart factory by introducing technologies such as Internet of Things, big data and artificial intelligence into production line and build cyber-physical system for the purpose of promoting manufacturing efficiency. For mission assignment, production line management or manufacturing field analysis, the location information of employee, machine and material is very essential. To promote manufacturing efficiency, of course, the location information became more important. A Bluetooth low energy (BLE) positioning system for the manufacturing is developed in this research. A "Tag tracking" mechanism is addressed and adopted, which uses Beacon to catch the location information and a BLE receiver is also used to receive the broadcasting information from Beacon. The position information from the BLE receiver will be compared with the data in the database for calculating the location of the target. The status of the target may also be obtained by using the data from the BLE receiver. Comparing with the mobile device, this method can reduce energy consumption and make the maintenance simple and easy. In the real applications, the target may not be limited to human. The "Regional label positioning technology" is also investigated in this research. Defining a suitable zone location and arranging BLE receiver location, and positioning analysis theory are the key factors included in this developed technology. The developed system will be tested for real industry applications. The test results show that the feasibility of this technology.
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Engineering, Industrial & Manufacturing Engineering; plasma-TIG; coupled arc; arc profile; pressure distribution
Online: 30 May 2018 (09:39:07 CEST)
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In this article, a novel hybrid welding process called plasma-TIG coupled arc welding was proposed to improve the efficiency and quality of welding by utilizing the full advantage of plasma and TIG welding processes. The two arcs of plasma and TIG were pulled into each other into one coupled arc under the effect of Lorentz force and plasma flow force during welding experiments. The arc behavior of coupled arc was studied by means of it’s arc profile, arc pressure and arc force conditions. The coupled arc pressure distribution measurements were performed. The effects of welding conditions on coupled arc pressure were evaluated and the maximum coupled arc pressure was improved compared with single-plasma arc and single-TIG arc. It was found that the maximum arc pressure was mainly determined by plasma arc current and plasma gas flow. According to the results, the proposed coupled arc welding process have both advantages of plasma arc and TIG method, and it has a broad application prospect.
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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.