Journal articles: 'Machining, modelling, sustainable manufacturing'

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Celent, Luka, Dražen Bajić, Sonja Jozić, and Marko Mladineo. "Hard Milling Process Based on Compressed Cold Air-Cooling Using Vortex Tube for Sustainable and Smart Manufacturing." Machines 11, no. 2 (February 10, 2023): 264. http://dx.doi.org/10.3390/machines11020264.

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Improving machining performance and meeting the requirements of sustainable production at the same time represents a major challenge for the metalworking industry and scientific community. One approach to satisfying the above challenge is to apply different types of cutting fluids or to optimise their usage during the machining process. The fact that cutting fluids are well known as significant environmental pollutants in the metalworking industry has encouraged researchers to discover new environmentally friendly ways of cooling and lubricating in the machining process. Therefore, the main goal is to investigate the influence of different machining conditions on the efficiency of hard machining and find a sustainable solution towards smart manufacturing. In the experimental part of the work, the influence of various machining parameters and conditions on the efficiency of the process was investigated and measured through the surface roughness, tool wear and cutting force components. Statistical data processing was carried out, and predictive mathematical models were developed. An important achievement is the knowledge of the efficiency of compressed cold air cooling for hard milling with the resulting lowest average flank wear of 0.05 mm, average surface roughness of 0.28 µm, which corresponds to grinding procedure roughness classes of N4 and N5, and average tool durability increase of 26% compared to dry cutting and conventional use of cutting fluids. Becoming a smart machining system was assured via technological improvement achieved through the reliable prediction of tool wear obtained by radial basis neural networks modelling, with a relative prediction error of 3.97%.

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Niamat, Misbah, Shoaib Sarfraz, Wasim Ahmad, Essam Shehab, and Konstantinos Salonitis. "Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production." Energies 13, no. 1 (December 19, 2019): 38. http://dx.doi.org/10.3390/en13010038.

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Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The investigation, validation and deeper insights of developed models have been performed using ANOVA, validation experiments and microstructure analysis respectively. Pulse on time and current both appeared as the prominent process parameters having a significant influence on all three measured performance metrics. Multi-objective optimization has been performed in order to achieve sustainability by establishing a compromise between minimum quality, minimum cost and maximum productivity. Sustainability contour plots have been developed to select suitable desirability. The sustainability results indicated that a high level of 75.5% sustainable desirability can be achieved for AISI L3 tool steel. The developed models can be practiced on the shop floor practically to attain a certain desirability appropriate for particular machine limits.

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Mohd Zakaria, Muhammad Akmal, Raja Izamshah Raja Abdullah, Mohd Shahir Kasim, and Mohamad Halim Ibrahim. "Enhancing the Productivity of Wire Electrical Discharge Machining Toward Sustainable Production by using Artificial Neural Network Modelling." EMITTER International Journal of Engineering Technology 7, no. 1 (June 15, 2019): 261–74. http://dx.doi.org/10.24003/emitter.v7i1.365.

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Sustainability plays an important role in manufacturing industries through economically-sound processes that able to minimize negative environmental impacts while having the social benefits. In this present study, the modeling of wire electrical discharge machining (WEDM) cutting process using an artificial neural network (ANN) for prediction has been carried out with a focus on sustainable production. The objective was to develop an ANN model for prediction of two sustainable measures which were material removal rate (as an economic aspect) and surface roughness (as a social aspect) of titanium alloy with ten input parameters. By concerning environmental pollution due to its intrinsic characteristics such as liquid wastes, the water-based dielectric fluid has been used in this study which represents an environmental aspect in sustainability. For this purpose, a feed-forward backpropagation ANN was developed and trained using the minimal experimental data. The other empirical modelling techniques (statistics based) are less in flexibility and prediction accuracy. The minimal, vague data and nonlinear complex input-output relationship make this ANN model simple and perfects method in the manufacturing environment as well as in this study. The results showed good agreement with the experimental data confirming the effectiveness of the ANN approach in the modeling of material removal rate and surface roughness of this cutting process.

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Singh, Karmjit, and Ibrahim Sultan. "A Computer-Aided Sustainable Modelling and Optimization Analysis of CNC Milling and Turning Processes." Journal of Manufacturing and Materials Processing 2, no. 4 (September 27, 2018): 65. http://dx.doi.org/10.3390/jmmp2040065.

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The sustainability of a manufacturing process can be measured by three main factors which impact both ecological and financial constraints. These factors are the energy required to achieve a specific job, the material utilized for the job, and the time taken to complete that job. These factors have to be quantified and analysed so that a proper manufacturing system can be designed to optimize process sustainability. For this purpose, a computer package, which utilizes life cycle inventory models has been presented for CNC (Computer Numerical Control) milling and turning processes. Based on utilization of resources and production stages, the job completion time for the turning and milling processes can be divided into process (i.e., machining), idle and basic times. As parameters are different for evaluating the process times, i.e., depth and width of cut in case of milling, initial and final diameters for turning, two different case studies are presented, one for each process. The effect of material selection on the sustainability factors has been studied for different processes. Our simulations show that highly dense and hard materials take more time in finishing the job due to low cutting speed and feed rates as compared to soft materials. In addition, face milling takes longer and consumes more power as compared to peripheral milling due to more retraction time caused by over travel distance and lower vertical transverse speeds than the horizontal transverse speed used in a peripheral retraction process.

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Del Sol, Irene, Álvaro Domínguez Calvo, David Piñero, Jorge Salguero, and Moises Batista. "Study of the FDM Parameters of the ABS Parts in the Surface Quality after Machining Operations." Key Engineering Materials 813 (July 2019): 203–8. http://dx.doi.org/10.4028/www.scientific.net/kem.813.203.

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Additive Manufacturing (AM) is one of the Key Enabling Technologies (KET’s) in Industry 4.0. One of the most worldwide used technologies is Fussed Deposition Modelling (FDM), a technology commonly used for domestic purposes. However, it could become a profitable option for industrial applications such as protections parts, flexible clamping systems or large volume parts. One of the issues that keeps this technology away from the mainstream industry is the lack of dimensional accuracy and the appearance of layer deposition defects that are produced as a consequence of the nature of the process. Those defects are usually reduced using chemicals post treatments. However, this option considerably increases the cost of the part as well as it environmental impact for big size parts. This work studied machining procedures as sustainable post-operation in order to reduce FDM dimensional and superficial defects. For this purpose, Acrylonitrile-Butadiene-Styrene (ABS) parts produced by FDM were machined using different machining strategies. Parts were perimetral milled using up milling and down milling strategies and finally a face milling operation was performed. The relationship between the layer height and the directionality of the layers in machining results was analyzed, in terms of surface quality (Ra, Rz, Rsm) and dimensional accuracy. Rz and Rsm results had been analyzed to verify that the grooves produced in FDM process disappeared. Ra values were reduced by up to ten times after milling process. Dimensional accuracy is increased by up to 50% while the removed rate was kept in a maximum of 7%. Additionally, removed material can be reused by means of proper chip extraction system, favoring the performance of the resources.

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Liu, Guoliang, Tuğrul Özel, Jianming Li, Dexiang Wang, and Shufeng Sun. "Optimization and fabrication of curvilinear micro-grooved cutting tools for sustainable machining based on finite element modelling of the cutting process." International Journal of Advanced Manufacturing Technology 110, no. 5-6 (August 23, 2020): 1327–38. http://dx.doi.org/10.1007/s00170-020-05906-6.

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Rizzo, Antonella, Saurav Goel, Maria Luisa Grilli, Roberto Iglesias, Lucyna Jaworska, Vjaceslavs Lapkovskis, Pavel Novak, Bogdan O. Postolnyi, and Daniele Valerini. "The Critical Raw Materials in Cutting Tools for Machining Applications: A Review." Materials 13, no. 6 (March 18, 2020): 1377. http://dx.doi.org/10.3390/ma13061377.

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A variety of cutting tool materials are used for the contact mode mechanical machining of components under extreme conditions of stress, temperature and/or corrosion, including operations such as drilling, milling turning and so on. These demanding conditions impose a seriously high strain rate (an order of magnitude higher than forming), and this limits the useful life of cutting tools, especially single-point cutting tools. Tungsten carbide is the most popularly used cutting tool material, and unfortunately its main ingredients of W and Co are at high risk in terms of material supply and are listed among critical raw materials (CRMs) for EU, for which sustainable use should be addressed. This paper highlights the evolution and the trend of use of CRMs) in cutting tools for mechanical machining through a timely review. The focus of this review and its motivation was driven by the four following themes: (i) the discussion of newly emerging hybrid machining processes offering performance enhancements and longevity in terms of tool life (laser and cryogenic incorporation); (ii) the development and synthesis of new CRM substitutes to minimise the use of tungsten; (iii) the improvement of the recycling of worn tools; and (iv) the accelerated use of modelling and simulation to design long-lasting tools in the Industry-4.0 framework, circular economy and cyber secure manufacturing. It may be noted that the scope of this paper is not to represent a completely exhaustive document concerning cutting tools for mechanical processing, but to raise awareness and pave the way for innovative thinking on the use of critical materials in mechanical processing tools with the aim of developing smart, timely control strategies and mitigation measures to suppress the use of CRMs.

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SHARMA, RAJEEV, Binit Kumar Jha, and Vipin Pahuja. "ROLE OF SUSTAINABLE TECHNIQUES IN MANUFACTURING PROCESS: A REVIEW." International Journal of Engineering Technologies and Management Research 8, no. 2 (February 17, 2021): 41–45. http://dx.doi.org/10.29121/ijetmr.v8.i2.2021.869.

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Customary mineral based liquids are as a rule broadly utilized in cooling and greases in machining activities. Nonetheless, these cutting liquids are the suitable wellspring of numerous natural and organic issues. To kill the evil impacts related with cutting liquids, it is important to move towards practical machining methods. Such sustainable machining techniques utilize minimize the amount of cutting liquid, fluid nitrogen, vegetable oil or packed air as a cooling-oil medium. The liquids utilized in economical machining strategies are viewed as absolutely biodegradable and Eco-friendly. This paper is a careful survey of the relative multitude of current environmental friendly machining methods as of now rehearsed in the metal cutting cycle. It has been likewise discovered that these economical machining strategies more often than not give better outcomes as far as improved surface nature of the machined part, upgraded apparatus life, less cutting temperatures and slicing powers when contrasted with traditional wet machining techniques. The principle motivation behind this survey work is to recognize the diverse supportable strategies and empower the utilization of such procedures in metal machining, so that, the reducing interaction turns out to be more expense powerful and climate inviting.

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Liu, Pei Ling. "Towards Smart and Competitive Sustainable Machining." Key Engineering Materials 447-448 (September 2010): 301–5. http://dx.doi.org/10.4028/www.scientific.net/kem.447-448.301.

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Computer Numeric Control (CNC) revolutionized the machining technology and has been the cutting edge of digital manufacturing since 1950s. CNC machining model, simulation, verification, and optimization have been a vivid research topic of Smart Machining that automated the CNC programming (CAM) and cutting process, hence greatly increased machining productivity since 1990s. This paper traces back the history of CNC simulation, analysis the different CNC machining models, tested with application examples, and listed different CNC verification industry applications for the last 20 years. The new challenge comes from sustainable manufacturing. Towards smart and competitive sustainable machining, CNC model and simulation will be used to optimize the machining process, where the raw material could be saved through First Part Correct technology, the energy could be saved through cutting speed optimization, and used parts could be saved by remanufacturing.

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Farooqi, Awais, and Nukman bin Yusoff. "Green Manufacturing - Textured Novel Cutting Tool for Sustainable Machining: A Review." Applied Mechanics and Materials 899 (June 2020): 135–43. http://dx.doi.org/10.4028/www.scientific.net/amm.899.135.

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Green manufacturing concept has become a cutting edge in the field of sustainable machining. The prime objective of the philosophy is to find a technique in machining or material removal processes that are environmentally friendly, with minimal wastage, energy efficient and optimal condition for the machining processes. This review paper discusses the significance of textured novel cutting tools, is one of the promising technologies and process. It discusses the Dry Machining process to capture green sustainable manufacturing practices. The study may answer of how it stands among other methods including minimum quantity lubrication and nano fluid lubricant. This paper also presents the importance of advanced manufacturing tools to match the sustainable future needs with an idea of proposed methodology to conduct a research on textured novel cutting tools for sustainable machining.

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Filice, Luigino, Francesco Gagliardi, Fabrizio Quadrini, Erica Anna Squeo, and Vincenzo Tagliaferri. "Modelling manufacturing errors in machining of thermoplastics." International Journal of Computer Applications in Technology 33, no. 1 (2008): 72. http://dx.doi.org/10.1504/ijcat.2008.021887.

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Begović, Edin, Ibrahim Plančić, Sabahudin Ekinović, and Vedran Mizdrak. "ON ONE ASPECT OF SUSTAINABLE MANUFACTURING Power Consumption vs Productivity." Journal of Sustainable Technologies and Materials 2, no. 2 (June 30, 2022): 1–8. http://dx.doi.org/10.57131/jstm.2022.2.1.

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The paper presents one aspect of the analysis of energy consumption and productivity of the manufacturing operation. As an example of the operation, the operation of turning with a single-blade tool was taken. Sustainable development in its general concept implies sustainable materials, sustainable design, and sustainable manufacturing. This paper presents an analysis of one important part of sustainable manufacturing, and that is energy saving. The experimental study was conducted as follows. In laboratory conditions, an experimental-mathematical regression model of the relationship between cutting force and processing conditions was defined. Machining experiments were performed under ECO-friendly conditions with technology known as MQCL (Minimum Quantity Cooling Lubrication) machining. The obtained mathematical model was used to calculate the energy consumption and the workpiece material removal rate (MRR, productivity). The results of the analysis showed that there is a lot of space for optimization of machining conditions from the aspect of power consumption, with mandatory calculation and other machining costs, above all, the cost of tools and machine tools. In this regard, recommendations for analysis with the aim of power saving are given.

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Dambhare, S. G., S. J. Deshmukh, and A. B. Borade. "Machining parameter optimization in turning process for sustainable manufacturing." International Journal of Industrial Engineering Computations 6, no. 3 (2015): 327–38. http://dx.doi.org/10.5267/j.ijiec.2015.3.002.

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Varghese, Vinay, M. R. Ramesh, and D. Chakradhar. "Experimental investigation and optimization of machining parameters for sustainable machining." Materials and Manufacturing Processes 33, no. 16 (May 24, 2018): 1782–92. http://dx.doi.org/10.1080/10426914.2018.1476760.

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Zhang, Yanbin, Hao Nan Li, Changhe Li, Chuanzhen Huang, Hafiz Muhammad Ali, Xuefeng Xu, Cong Mao, et al. "Nano-enhanced biolubricant in sustainable manufacturing: From processability to mechanisms." Friction 10, no. 6 (January 14, 2022): 803–41. http://dx.doi.org/10.1007/s40544-021-0536-y.

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AbstractTo eliminate the negative effect of traditional metal-working fluids and achieve sustainable manufacturing, the usage of nano-enhanced biolubricant (NEBL) is widely researched in minimum quantify lubrication (MQL) machining. It’s improved tool wear and surface integrity have been preliminarily verified by experimental studies. The previous review papers also concluded the major influencing factors of processability including nano-enhancer and lubricant types, NEBL concentration, micro droplet size, and so on. Nevertheless, the complex action of NEBL, from preparation, atomization, infiltration to heat transfer and anti-friction, is indistinct which limits preparation of process specifications and popularity in factories. Especially in the complex machining process, in-depth understanding is difficult and meaningful. To fill this gap, this paper concentrates on the comprehensive quantitative assessment of processability based on tribological, thermal, and machined surface quality aspects for NEBL application in turning, milling, and grinding. Then it attempts to answer mechanisms systematically considering multi-factor influence of molecular structure, physicochemical properties, concentration, and dispersion. Firstly, this paper reveals advanced lubrication and heat transfer mechanisms of NEBL by quantitative comparison with biolubricant-based MQL machining. Secondly, the distinctive filmformation, atomization, and infiltration mechanisms of NEBL, as distinguished from metal-working fluid, are clarified combining with its unique molecular structure and physical properties. Furtherly, the process optimization strategy is concluded based on the synergistic relationship analysis among process variables, physicochemical properties, machining mechanisms, and performance of NEBL. Finally, the future development directions are put forward aiming at current performance limitations of NEBL, which requires improvement on preparation and jet methods respects. This paper will help scientists deeply understand effective mechanism, formulate process specifications, and find future development trend of this technology.

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Chirita, Bogdan, Catalin Tampu, Eugen Herghelegiu, and Cosmin Grigoras. "Modelling and optimization of magnesium alloy milling parameters." International Journal of Modern Manufacturing Technologies 13, no. 3 (December 25, 2021): 29–36. http://dx.doi.org/10.54684/ijmmt.2021.13.3.29.

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In the pursuit to lighter, less consuming products, manufacturers, especially in aviation and automotive industries, are turning more and more to using lightweight alloys such as the ones based on magnesium. Higher requirements for increased productivity have led to concepts like high-speed machining (HSM), high feed machining (HFM) or high-efficiency machining. Tighter regulations concerning requiring for more environmentally friendly industrial processes led to limitations in the use of cooling liquids and a search for cooling methods with less impact (dry cutting, cryogenic cooling, near dry machining and others). Better machining processes can only be achieved by modelling and optimization. This paper briefly presents the results obtained by our research team concerning the modelling and optimization attempts on face milling of magnesium alloys using different methods: design of experiments (e.g. factorial design, response surface method), fuzzy logic or neural networks.

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Ghandehariun, Amirmohammad, Yousef Nazzal, and Hossam Kishawy. "Sustainable manufacturing and its application in machining processes: a review." International Journal of Global Warming 9, no. 2 (2016): 198. http://dx.doi.org/10.1504/ijgw.2016.074955.

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Fittamami, Bening Maulina, Eko Pujiyanto, and Yusuf Priyandari. "Multi-Objective Optimization of Machining Parameters for Multi-Pass CNC Turning to Minimize Carbon Emissions, Energy, Noise and Cost." Jurnal Teknik Industri 23, no. 1 (May 31, 2021): 25–34. http://dx.doi.org/10.9744/jti.23.1.25-34.

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Global warming is a huge environmental issue today. This is due to the high level of world carbon emissions. The manufacturing process accounts for 30% of the world's carbon emissions production. Sustainable manufacturing is necessary to implement to reduce carbon emission levels caused by the manufacturing process. There are three aspects of sustainable manufacturing, namely environmental aspects, economic aspects, and social aspects. These three aspects can be implemented in the machining process by optimizing machining parameters in multi-pass CNC turning. This research aims to optimize CNC turning machining parameters by considering energy consumption, carbon emissions, noise, and production cost. The model is solved using a Multi-objective Genetic Algorithm in Matlab 2016b then the transformation and weighting functions are carried out from the feasible value. Based on the optimization results, the total energy consumption value obtained is 2.50 MJ; total production cost is $ 2.19; total carbon emissions are 5.97 kgCO2, and noise is 236, 19 dB. The sensitivity analysis exhibits the machining parameters that affect the objective function: The cutting speed parameter and the feed rate parameter. This model can be used to improve the manufacturing process and support sustainable manufacturing.

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Ding, Lian, Xiao Li Qiu, Glen Mullineux, and Jason Matthews. "The Development of the Sustainable Manufacturing Processes." Advanced Materials Research 118-120 (June 2010): 767–74. http://dx.doi.org/10.4028/www.scientific.net/amr.118-120.767.

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Sustainable manufacturing will be the dominate factor in the design of the future factory. Any manufacturing operation within these factories will affect the environment, be it through the waste it creates, the resources it uses, or the energy it consumes. All can be significant, but not all have been properly examined or documented. This paper presents an initial investigation into these issues related to subtractive machining and evaluates research finding against the waste hierarchy. The paper concludes by discussing the findings and presents some requirements and suggestions for the factory of the future.

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Okokpujie, Imhade P., Jude E. Sinebe, Lagouge K. Tartibu, Adeyinka O. M. Adeoye, Sylvia E. Kelechi, and Esther T. Akinlabi. "Ratio Study of High-Pressure Lubrication and Cutting Parameters Effects on Machining Operations and Its Effect Towards Sustainable Machining: A Review." Journal Européen des Systèmes Automatisés 55, no. 2 (April 30, 2022): 197–205. http://dx.doi.org/10.18280/jesa.550206.

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Machining is the art of developing sustainable mechanical components by transforming solid raw materials into the finished product. Because for any Nation to achieve sustainable development, the Nation must have quality manufacturing industries. This paper summarizes existing articles on the effects of high-pressure lubrication conditions on chip formation and temperature distribution. Also, surface roughness, tool wear, and vibrations in machining operations when considering the current trend. Furthermore, the study of nano-lubricant and their application in reducing friction and temperature were also reviewed. The study also examined other lubrication conditions, cutting parameters with the high-pressure machining operations to draw a definite conclusion. The review confirms that applying a high-pressure lubrication system is very efficient. However, it has some challenges. Cooling technology is not built into the system, discovered during this review. Therefore, the study will recommend a developed machine that can function in multiple faces. Industrial 4.0 additive manufacturing techniques can build the cryogenic system—making the lubricant delivery machine a sustainable technology in machining operation. A high-pressure-cryogenic-MQL lubrication process is needed for sustainable machining operations of various alloys and metal composite materials for automobile, aerospace, and structural applications. The sustainable lubrication system will also help eradicate high-temperature occurrence in the machining region with a sustainable way of removing the chips without experiencing chip breakage at the cutting region.

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Ogedengbe, Temitayo Samson. "Sustainable Machining Processes through Optimization of Process Parameters." International Journal of Engineering Materials and Manufacture 4, no. 1 (March 1, 2019): 22–26. http://dx.doi.org/10.26776/ijemm.04.01.2019.03.

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Machining processes are a vital part of manufacturing activities in major industries that contributes to the growth of the economy. They mostly require high amount of electrical energy to power the various support modules installed on machine tools. Carrying out machining activities with a view to reducing energy consumption will therefore result in a lowered cost of production for manufactured products. Previous studies on some energy-saving methods adopted by researchers and the limitations faced in the reduction of energy consumption have been discussed. In this work, the effect of process parameters in the conservation of energy during machining processes was experimented. Results shows that much energy could be saved by optimizing parameters before machining.

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Chate, Ganesh R., Manjunath Patel G.C., Harsha H.M., Shubham U. Urankar, Salim A. Sanadi, Akshay P. Jadhav, Shubham Hiremath, and Anand S. Deshpande. "Sustainable machining: Modelling and optimization using Taguchi, MOORA and DEAR methods." Materials Today: Proceedings 46 (2021): 8941–47. http://dx.doi.org/10.1016/j.matpr.2021.05.365.

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Gupta, Kapil, and Rudolph F. Laubscher. "Sustainable machining of titanium alloys: A critical review." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 231, no. 14 (February 29, 2016): 2543–60. http://dx.doi.org/10.1177/0954405416634278.

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The three main pillars of sustainability are the society, the environment, and the economy (people, planet, and profit). The key drivers that sustain these three pillars are energy and resource efficiency, a clean and ‘green’ environment that incorporates effective waste reduction and management, and finally cost-effective production. Sustainable manufacturing implies technologies and/or techniques that target these key drivers during product manufacture. Because of the effort and costs involved in the machining of titanium and its alloys, there is significant scope for improved sustainable manufacturing of these materials. Titanium and its alloys are extensively used for specialized applications in aerospace, medical, and general industry because of their superior strength-to-weight ratio and corrosion resistance. They are, however, generally regarded as difficult-to-machine materials. This article presents an overview of previous and current work and trends as regards to sustainable machining of titanium and its alloys. This article focuses on reviewing previous work to improve the sustainable machining of titanium and its alloys with specific reference to the selection of optimum machining conditions, effect of tool materials and geometry, implementing advanced lubrication and/or cooling techniques, and employing advanced and hybrid machining strategies. The main motivation is to present an overview of the current state of the art to discuss the challenges and to suggest economic and environment-friendly ways for improving the machinability of titanium and its alloys.

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Gupta, Munish, Catalin Pruncu, Mozammel Mia, Gurraj Singh, Sunpreet Singh, Chander Prakash, P. Sood, and Harjot Gill. "Machinability Investigations of Inconel-800 Super Alloy under Sustainable Cooling Conditions." Materials 11, no. 11 (October 25, 2018): 2088. http://dx.doi.org/10.3390/ma11112088.

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With regard to the manufacturing of innovative hard-machining super alloys (i.e., Inconel-800), a potential alternative for improving the process is using a novel cutting fluid approach. Generally, the cutting fluids allow the maintenance of a better tool topography that can generate a superior surface quality of machined material. However, the chemical components of fluids involved in that process may produce harmful effects on human health and can trigger environmental concerns. By decreasing the cutting fluids amount while using sustainable methods (i.e., dry), Near Dry Machining (NDM) will be possible in order to resolve these problems. This paper discusses the features of two innovative techniques for machining an Inconel-800 superalloy by plain turning while considering some critical parameters such as the cutting force, surface characteristics (Ra), the tool wear rate, and chip morphology. The research findings highlight the near-dry machining process robustness over the dry machining routine while its great potential to resolve the heat transfer concerns in this manufacturing method was demonstrated. The results confirm other benefits of these methods (i.e., NDM) linked to the sustainability aspects in terms of the clean process, friendly environment, and permits as well as in terms of improving the manufacturing characteristics.

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Rakesh, P. R., and D. Chakradhar. "Machining performance comparison of Inconel 625 superalloy under sustainable machining environments." Journal of Manufacturing Processes 85 (January 2023): 742–55. http://dx.doi.org/10.1016/j.jmapro.2022.11.080.

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Choi, B. K., C. S. Lee, J. S. Hwang, and C. S. Jun. "Compound surface modelling and machining." Computer-Aided Design 20, no. 3 (April 1988): 127–36. http://dx.doi.org/10.1016/0010-4485(88)90020-6.

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Shaikh, Vasim A., and Nourredine Boubekri. "Using Vegetable-Oil-Based Sustainable Metal Working Fluids to Promote Green Manufacturing." International Journal of Manufacturing, Materials, and Mechanical Engineering 10, no. 1 (January 2020): 1–19. http://dx.doi.org/10.4018/ijmmme.2020010101.

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The ever-increasing awareness of the environmental and health hazards of petroleum and mineral-oil-based metalworking fluids (MWFs) is forcing the scientist and tribologists to develop alternative MWFs. Mineral and petroleum-oil based MWFs are also considered non-biodegradable which hinders their successful implementation in metal machining which requires regular disposal of used cutting fluids. On the other hand, vegetable-oil based MWFs are considered as sustainable green metalworking fluids/lubricants which are biodegradable and have superior cooling and lubricating properties. A review is done on current literature which shows that vegetable-oil based MWFs are not only better alternatives considering its eco-friendly nature but also offers better machining performance by enhancing the cutting tool lifetime and minimizing the cutting tool/workpiece interface temperature, friction and surface roughness. Different cutting methods like dry machining, flood cutting, and minimum quantity lubrication techniques are compared for a better understanding of the reported studies.

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Ishfaq, Kashif, Irfan Anjum, Catalin Iulian Pruncu, Muhammad Amjad, M. Saravana Kumar, and Muhammad Asad Maqsood. "Progressing towards Sustainable Machining of Steels: A Detailed Review." Materials 14, no. 18 (September 8, 2021): 5162. http://dx.doi.org/10.3390/ma14185162.

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Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.

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Lv, Lishu, Zhaohui Deng, Tao Liu, Linlin Wan, Wenliang Huang, Hui Yin, and Tao Zhao. "A Composite Evaluation Model of Sustainable Manufacturing in Machining Process for Typical Machine Tools." Processes 7, no. 2 (February 20, 2019): 110. http://dx.doi.org/10.3390/pr7020110.

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Machine tool is the basic manufacturing equipment in today’s mechanical manufacturing industry. A considerable amount of energy and carbon emission are consumed in machining processes, the realization of sustainable manufacturing of machine tools have become an urgent problem to be solved in the field of industry and academia. Therefore, five types of machine tools were selected for the typical machining processes (turning, milling, planning, grinding and drilling). Then the model of the energy efficiency, carbon efficiency and green degree model were established in this paper which considers the theory and experiment with the resource, energy and emission modeling method. The head frame spindle and head frame box were selected to verify the feasibility and practicability of the proposed model, based on the orthogonal experiment case of the key machining process. In addition, the influence rules of machining parameters were explored and the energy efficiency and green degree of the machine tools were compared. Finally, the corresponding strategies for energy conservation and emission reduction were proposed.

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Das, Anshuman, Smita Padhan, Sudhansu Ranjan Das, Mohammad S. Alsoufi, Ahmed Mohamed Mahmoud Ibrahim, and Ammar Elsheikh. "Performance Assessment and Chip Morphology Evaluation of Austenitic Stainless Steel under Sustainable Machining Conditions." Metals 11, no. 12 (November 29, 2021): 1931. http://dx.doi.org/10.3390/met11121931.

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Sustainable manufacturing has received great attention in the last few decades for obtaining high quality products with minimal costs and minimal negative impacts on environment. Sustainable machining is one of the main sustainable manufacturing branches, which is concerned with improving environmental conditions, reducing power consumption, and minimizing machining costs. In the current study, the performance of three sustainable machining techniques, namely dry, compressed air cooling, and minimum quantity lubrication, is compared with conventional flood machining during the turning of austenitic stainless steel (Nitronic 60). This alloy is widely used in aerospace engine components, medical applications, gas power industries, and nuclear power systems due to its superior mechanical and thermal properties. Machining was performed using SiAlON ceramic tool with four different cutting speeds, feeds and a constant depth of cut. Consequently, various chip characteristics such as chip morphology, chip thickness, saw tooth distance and chip segmentation frequency were analyzed with both optical and scanning electron microscopes. Performance assessment was performed under the investigated cutting conditions. Our results show that the tool life under MQL machining are 138%, 72%, and 11% greater than dry, compressed air, and flooded conditions, respectively. The use of SiAlON ceramic tool results is more economically viable under the MQL environment as the overall machining cost per component is lower ($0.27) as compared to dry ($0.36), compressed air ($0.31), and flooded ($0.29) machining conditions. The minimum quantity lubrication technique outperformed the other investigated techniques in terms of eco-friendly aspects, economic feasibility, and technical viability to improve sustainability.

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Modica, Francesco, Valeria Marrocco, Giacomo Copani, and Irene Fassi. "Sustainable Micro-Manufacturing of Micro-Components via Micro Electrical Discharge Machining." Sustainability 3, no. 12 (December 13, 2011): 2456–69. http://dx.doi.org/10.3390/su3122456.

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Bhanot, Neeraj, P. Venkateswara Rao, and S. G. Deshmukh. "Sustainable Manufacturing: An Interaction Analysis for Machining Parameters using Graph Theory." Procedia - Social and Behavioral Sciences 189 (May 2015): 57–63. http://dx.doi.org/10.1016/j.sbspro.2015.03.192.

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Peralta, M. E., M. Marcos, F. Aguayo, J. R. Lama, and A. Córdoba. "Sustainable Fractal Manufacturing: A New Approach to Sustainability in Machining Processes." Procedia Engineering 132 (2015): 926–33. http://dx.doi.org/10.1016/j.proeng.2015.12.579.

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Liu, X., and K. Cheng. "Modelling the machining dynamics of peripheral milling." International Journal of Machine Tools and Manufacture 45, no. 11 (September 2005): 1301–20. http://dx.doi.org/10.1016/j.ijmachtools.2005.01.019.

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Sun, Haiming, Conghu Liu, Jianqing Chen, Mengdi Gao, and Xuehong Shen. "A Novel Method of Sustainability Evaluation in Machining Processes." Processes 7, no. 5 (May 9, 2019): 275. http://dx.doi.org/10.3390/pr7050275.

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In order to quantitatively evaluate and improve the sustainability of machining systems, this paper presents an emergy (the amount of energy consumed in direct and indirect transformations to make a product or service) based sustainability evaluation and improvement method for machining systems, contributing to the improvement of energy efficiency, resource efficiency and environmental performance, and realizing the sustainability development. First, the driver and challenge are studied, and the scope and hypothesis of the sustainable machining system are illustrated. Then, the emergy-based conversion efficiency model is proposed, which are (1) effective emergy utilization rate (EEUR), (2) emergy efficiency of unit product (EEUP) and (3) emergy conversion efficiency (ECE), to measure and evaluate the sustainable machining system from the perspectives of energy, resource and environment. Finally, the proposed model is applied to a vehicle-bridge machining process, and the results show that this paper provides the theoretical and method support for evaluating and improving the sustainable machining processes to decouple the resources and development of the manufacturing industry.

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Chainawakul, Adirake, Koji Teramoto, and Hiroki Matsumoto. "Statistical Modelling of Machining Error for Model-Based Elastomer End-Milling." International Journal of Automation Technology 15, no. 6 (November 5, 2021): 852–59. http://dx.doi.org/10.20965/ijat.2021.p0852.

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Elastomer end-milling has attracted attention for use in the small-lot production of elastomeric fragments because the technique is an applicable method for a large variety of materials and does not require the preparation of expensive and time-consuming moulds. In order to effectively utilize elastomer end-milling, it is necessary to ensure the machining accuracy of elastomeric parts machined through this technique. However, the control method of machining error in the elastomer end-milling has not been presented since most machining services of the elastomeric part are based on enterprise-dependent dexterities or know-how. The objective of this paper is to construct and utilize a machining error model for elastomer end-milling. A statistical model based upon physical states and machining conditions is introduced and investigated. In this paper, a framework for modelling the machining error in elastomer end-milling is also proposed. In the framework, the candidates of model variables are evaluated based on the preliminary experiments. Moreover, a statistical model is constructed by using the selected variables. Candidate variables are cutting conditions and predictable physical state variables such as workpiece deformation and cutting force. The framework is investigated by evaluating error prediction with the experimental results. An identified error model from limited machining cases can estimate the machining error of different machining cases. The results indicate that the proposed modelling method is capable of supporting to achieve model-based precision elastomer end-milling.

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Danish, Mohd, Saeed Rubaiee, and Hassan Ijaz. "Predictive Modelling and Multi-Objective Optimization of Surface Integrity Parameters in Sustainable Machining Processes of Magnesium Alloy." Materials 14, no. 13 (June 25, 2021): 3547. http://dx.doi.org/10.3390/ma14133547.

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Magnesium alloys are widely used in numerous engineering applications owing to their superior structural characteristics. However, the machining of magnesium alloy is challenging because of its poor machinability characteristics. Therefore, this paper investigates the machining of magnesium alloys under different sustainable cooling conditions. The machining was performed by varying cutting velocity, feed rate, and depth of cut under dry and cryogenic cooling conditions. The primary focus of the paper is to develop a predictive model for surface roughness under different machining environments. The models developed were found to be in excellent agreement with experimental results, with only 0.3 to 1.6% error. Multi-objective optimization were also performed so that the best surface finish together with high material removal rate could be achieved. Furthermore, the various parameters of surface integrity (i.e., surface roughness, micro-hardness, micro-structures, crystallite size, and lattice strain) were also investigated.

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Singh, Karmjit, and Ibrahim Sultan. "Sustainable Manufacturing Modelling: A Case for Milling Process." International Journal of Materials, Mechanics and Manufacturing 7, no. 1 (February 2019): 46–50. http://dx.doi.org/10.18178/ijmmm.2019.7.1.427.

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Baldwin, James Scott, Peter M. Allen, Belinda Winder, and Keith Ridgway. "Modelling manufacturing evolution: thoughts on sustainable industrial development." Journal of Cleaner Production 13, no. 9 (July 2005): 887–902. http://dx.doi.org/10.1016/j.jclepro.2004.04.009.

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Despeisse, Mélanie, Michael R. Oates, and Peter D. Ball. "Sustainable manufacturing tactics and cross-functional factory modelling." Journal of Cleaner Production 42 (March 2013): 31–41. http://dx.doi.org/10.1016/j.jclepro.2012.11.008.

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Proud, Leon, Nikolaos Tapoglou, and Tom Slatter. "A Review of CO2 Coolants for Sustainable Machining." Metals 12, no. 2 (February 5, 2022): 283. http://dx.doi.org/10.3390/met12020283.

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In many machining operations, metalworking fluids (MWFs) play an invaluable role. Often, proper application of an intelligent MWF strategy allows manufacturing processes to benefit from a multitude of operational incentives, not least of which are increased tool life, improved surface integrity and optimised chip handling. Despite these clearly positive implications, current MWF strategies are often unable to accommodate the environmental, economic and social conscience of industrial environments. In response to these challenges, CO2 coolants are postulated as an operationally viable, environmentally benign MWF solution. Given the strong mechanistic rationale and historical evidence in support of cryogenic coolants, this review considers the technological chronology of cryogenic MWF’s in addition to the current state-of-the-art approaches. The review also focuses on the use of CO2 coolants in the context of the machining of a multitude of material types in various machining conditions. In doing so, cryogenic assisted machining is shown to offer a litany of performance benefits for both conventional emulsion (flood) cooling and near dry strategies, i.e., minimum quantity lubrication (MQL), as well as aerosol dry lubrication (ADL).

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Wang, Xiao Jun, Wen Hui Yue, and Zi Qiang Han. "Study on High Speed Cutting Technology for Green Manufacturing." Advanced Materials Research 305 (July 2011): 25–30. http://dx.doi.org/10.4028/www.scientific.net/amr.305.25.

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As a sustainable model of modern manufacturing industry, green manufacturing is one of the essential solutions of the manufacturing environment pollution problems. Green cutting technology is the base and key of green manufacturing and will be the inevitable trend of cutting technology. High speed machining technology is a kind of the advanced manufacturing technologies which have superiorities as low cost, high efficiency, good processing quality and are suitable for machining thin walled workpieces and difficult-to-cut materials, and the relative problem has attracted scholars' attention from all over the world. From the perspective of green manufacturing, research results of high speed machining hardened steels are reviewed, including cutting force, cutting temperature, selection and optimization of processing parameters and machining quality, and conclude that high speed cutting is one of the key technologies in implementing green manufacturing and cleaner production. Finally, its future works of the research are discussed.

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Garrido-Labrador, José Luis, Daniel Puente-Gabarri, José Miguel Ramírez-Sanz, David Ayala-Dulanto, and Jesus Maudes. "Using Ensembles for Accurate Modelling of Manufacturing Processes in an IoT Data-Acquisition Solution." Applied Sciences 10, no. 13 (July 2, 2020): 4606. http://dx.doi.org/10.3390/app10134606.

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The development of complex real-time platforms for the Internet of Things (IoT) opens up a promising future for the diagnosis and the optimization of machining processes. Many issues have still to be solved before IoT platforms can be profitable for small workshops with very flexible workloads and workflows. The main obstacles refer to sensor implementation, IoT architecture, and data processing, and analysis. In this research, the use of different machine-learning techniques is proposed, for the extraction of different information from an IoT platform connected to a machining center, working under real industrial conditions in a workshop. The aim is to evaluate which algorithmic technique might be the best to build accurate prediction models for one of the main demands of workshops: the optimization of machining processes. This evaluation, completed under real industrial conditions, includes very limited information on the machining workload of the machining center and unbalanced datasets. The strategy is validated for the classification of the state of a machining center, its working mode, and the prediction of the thermal evolution of the main machine-tool motors: the axis motors and the milling head motor. The results show the superiority of the ensembles for both classification problems under analysis and all four regression problems. In particular, Rotation Forest-based ensembles turned out to have the best performance in the experiments for all the metrics under study. The models are accurate enough to provide useful conclusions applicable to current industrial practice, such as improvements in machine programming to avoid cutting conditions that might greatly reduce tool lifetime and damage machine components.

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Celent, Luka, Marko Mladineo, Nikola Gjeldum, and Marina Crnjac Zizic. "Multi-Criteria Decision Support System for Smart and Sustainable Machining Process." Energies 15, no. 3 (January 21, 2022): 772. http://dx.doi.org/10.3390/en15030772.

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Sustainatableble development assumes the meeting of humanity’s everyday needs and development goals while sustaining the ability of nature to provide the resources and ecosystem on which the economy and society depend. It means that an increase of economic benefit cannot be a single optimization problem anymore, instead, the multi-criteria approach is used with the accent on ecology and social welfare. However, it is not easy to harmonize these aims with machining, which is a well known industrial pollutant. On the other hand, new industrial paradigms such as Industry 4.0/5.0, are driving toward the smart concept that collects data from the manufacturing process and optimizes it in accordance with productivity and/or ecologic aims. In this research, the smart concept is used through the development of the multi-criteria decision support system for the selection of the optimal machining process in terms of sustainability. In the case of milling process selection, it has been demonstrated that green machining, without a multi-criteria approach, will always remain an interesting research option, but not a replacement for conventional machining. However, when applying realistic ecological and social criteria, green machining becomes a first choice imperative. The multi-criteria decision-making PROMETHEE method is used for the comparison and ranking, and validation of results is made through criteria weights sensitivity analysis. The contribution of this concept is that it could also be applied to other manufacturing processes.

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Mortazavi, Mina, and Atanas Ivanov. "Sustainable μECM machining process: indicators and assessment." Journal of Cleaner Production 235 (October 2019): 1580–90. http://dx.doi.org/10.1016/j.jclepro.2019.06.313.

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Sterle, Luka, Damir Grguraš, Matjaž Kern, and Franci Pušavec. "Sustainability Assessment of Advanced Machining Technologies." Strojniški vestnik – Journal of Mechanical Engineering 65, no. 11-12 (November 18, 2019): 671–79. http://dx.doi.org/10.5545/sv-jme.2019.6351.

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Efficient cooling and lubrication techniques are required to obtain sustainable machining of difficult-to-cut materials, which are the pillars of aerospace, automotive, medical and nuclear industries. Cryogenic machining with the assistance of lubricated Liquid Carbon Dioxide (LCO2) is a novel approach for sustainable manufacturing without the use of harmful water-based metalworking fluids (MWFs). In case of unavoidable use of MWFs under high pressure, such as turning finishing processes of difficult-to-cut materials, the pulsating high pressure delivery of MWFs prolongs the tool life and enables the control over chip length to prevent surface damage of high value-added parts. In this paper, sustainability assessment of both advanced principles was carried out, considering overall costs and operational safety. Experimental tests were executed on difficult-to-cut materials in comparison to conventional flood lubrication. For both techniques, longer tool life compared to flood lubrication was observed additional cleaner production and higher part quality led to reduced long-term overall costs. These advanced machining technologies are also operation safe, proving to be a sustainable alternative to conventional machining.

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Walia, R. S., H. S. Shan, and P. Kumar. "Modelling of centrifugal-force-assisted abrasive flow machining." Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 223, no. 4 (September 18, 2009): 195–204. http://dx.doi.org/10.1243/09544089jpme284.

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EITobgy, M., E.-G. Ng, and M. A. Elbestawi. "Modelling of Abrasive Waterjet Machining: A New Approach." CIRP Annals 54, no. 1 (2005): 285–88. http://dx.doi.org/10.1016/s0007-8506(07)60104-8.

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Hoogstrate, A. M., B. Karpuschewski, C. A. van Luttervelt, and H. J. J. Kals. "Modelling of high velocity, loose abrasive machining processes." CIRP Annals 51, no. 1 (2002): 263–66. http://dx.doi.org/10.1016/s0007-8506(07)61513-3.

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Uhlmann, Eckart, and Simon Roßkamp. "Modelling of Material Removal in Abrasive Flow Machining." International Journal of Automation Technology 12, no. 6 (November 5, 2018): 883–91. http://dx.doi.org/10.20965/ijat.2018.p0883.

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Trends like lightweight construction and functional integration lead to more and more complex workpieces. Often, these workpieces must be finished after machining. Especially inner contours are difficult to finish. Hence, only a few manufacturing techniques are suitable for deburring, edge rounding and polishing of inner contours. An appropriate solution is abrasive flow machining (AFM), in which a highly viscous fluid with abrasive grains is used. Despite the wide usage of AFM in industry, the knowledge about the fundamentals of abrasive flow machining processes is limited. After elaborated test series new findings concerning the surface integrity are presented in this paper. This is done in terms of the regressive development of the surface roughness on the one hand and in terms of the generated edge rounding on the other hand. In this context, it is found that there is a factor of approximately 16 between the chipped material at the edge and the chipped material at the surface. This factor is nearly constant during the processing time. Finally, using the results of the studies, the correlation between the processing parameters, surface roughness, edge rounding, and material removal rate can be characterized. Moreover, these new findings can be transferred to a comprehensive process model, which is the basis for a reliable process simulation. Owing to this progress, predictions of the processing results of AFM will be possible.

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Journal articles on the topic 'Machining, modelling, sustainable manufacturing'

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