John W. Sutherland

John W. Sutherland
Purdue University | Purdue · Division of Environmental and Ecological Engineering

PhD

About

349
Publications
123,333
Reads
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12,608
Citations
Citations since 2016
134 Research Items
7997 Citations
201620172018201920202021202202004006008001,0001,2001,400
201620172018201920202021202202004006008001,0001,2001,400
201620172018201920202021202202004006008001,0001,2001,400
201620172018201920202021202202004006008001,0001,2001,400
Additional affiliations
August 2009 - present
Purdue University
Position
  • Professor and Fehsenfeld Family Head

Publications

Publications (349)
Article
Circularizing end of life products such as electronic waste can open a new source for rare earth elements (REEs) that will decrease the demand pressure on conventional virgin production. The last step to produce REEs consists of a refining process to convert rare earth oxide (REO) to REE metal. One promising technology is processing REO via a room...
Article
Geometric characteristics and curvature of free-form surfaces have a great influence on multi-axis computer numerical control (CNC) machining performances such as processing efficiency, surface quality and energy consumption. The conventional machining methods with the whole tool path generation results in poor low machining efficiency, surface qua...
Article
Forging is an industry with high emissions and high energy consumption. Due to the constant increase in the international energy price and the negative impact on the world's environment, researchers have begun to focus on transforming forging into information and sustainable development. However, there remains a substantial gap in the development o...
Conference Paper
The reliability of manufacturing equipment is critical for ensuring the productivity and energy efficiency of a manufacturing facility. An unexpected machine breakdown may lead to unexpected downtime, disruption of manufacturing schedule, lower production efficiency, higher operation and maintenance cost. The recent development in machine learning...
Article
Disassembly lines are the most effective way to address large-scale value recovery from end-of-life (EOL) products. Disassembly line balancing (DLB) greatly affects the economics and throughput of EOL product processing. Complete disassembly is generally not suitable for disassembly enterprises; most often, the maximum profit is realized through pa...
Article
Full-text available
Industrial symbiotic networks (ISNs) can support the transition from a conventional linear economy to a circular economy by using industrial waste and by-products as resources. However, the early design and development stages of ISNs are fraught with challenges as a result of limited information (supply, demand, potential synergies, etc.), and the...
Preprint
Full-text available
Smart manufacturing systems are being deployed at a growing rate because of their ability to interpret a wide variety of sensed information and act on the knowledge gleaned from system observations. In many cases, the principal goal of the smart manufacturing system is to rapidly detect (or anticipate) failures to reduce operational cost and elimin...
Article
The fast-growing market for electric vehicles (EVs) offers great potential for reducing the carbon footprint of the transportation sector but is heavily reliant on electric motors and batteries, which are in turn dependent on the availability of critical materials, e.g., rare earth elements and lithium. Such critical materials are subject to substa...
Article
Thanks to the development of new technologies such as sensor networks and advanced computational power, the research field of condition-based monitoring (CBM) has drawn increasing attention in manufacturing. With the aim of enhancing equipment reliability, leading to a reduction in maintenance costs, one of the most crucial challenges dealing with...
Article
Full-text available
Predictive maintenance (PdM) is an advanced technique to predict the time to failure (TTF) of a system. PdM collects sensor data on the health of a system, processes the information using data analytics, and then establishes data-driven models that can forecast system failure. Deep neural networks are increasingly being used as these data-driven mo...
Article
Much of the environmental footprint of a machine tool is due to the energy consumed during its use phase. A promising strategy for reducing this energy consumption is to minimize the mass of components through changes in the design of the machine tool. This paper explores the lightweighting of the machine slides (or tables) to achieve energy saving...
Article
Full-text available
Lightweighting is a design strategy to reduce energy consumption through the reduction of mass of a product. Lightweighting can be applied to machine tools to reduce the amount of energy consumed during the use phase. Thus, the energy cost of machine operation will be reduced. One might also hypothesize that since a lighter-weight machine tool requ...
Article
Full-text available
Greenhouse gas emissions have become one of the most prominent global concerns of sustainable development. To reduce product life cycle carbon footprint, planning should begin at embodiment design phase. The accurate assessment of carbon footprint is the foundation of carbon footprint reduction. However, existing carbon footprint models cannot be a...
Article
Full-text available
Prediction of manufacturing equipment’s energy consumption plays an important role in selecting appropriate process parameters for energy saving. However, it is difficult to model the energy consumption of metal forming equipment during the drawing process characterized by variable process parameters and dynamic loads. In this paper, a model was de...
Preprint
Full-text available
Predictive maintenance (PdM) is an advanced technique to predict the time to failure (TTF) of a system. PdM collects sensor data on the health of a system, processes the information using data analytics, and then establishes data-driven models that can forecast system failure. Deep neural networks are increasingly being used as these data-driven mo...
Article
Full-text available
Today's manufacturing industry still requires human labor and knowledge for Machining Process Identification (MPI). Before manufacturing a part, engineers need to judge the manufacturability and identify the machining processes according to CAD model, and then the customer needs to source for qualified suppliers based on the identified machining pr...
Article
Rare Earth Elements (REEs) are essential for sustainable energy technologies. Techno-economic Assessments (TEAs) have been conducted to evaluate innovative approaches to recover REEs from waste streams. However, most TEA studies do not consider the price volatility of REEs, which raises concern over the reliability of the analysis in an unpredictab...
Article
Reducing the energy consumption of machine tools is important from a sustainable manufacturing perspective. Much of a machine tool's environmental impact comes from the energy it consumes during its use phase. To move elements of a machine tool requires energy, and if the mass of those elements can be reduced, then the required energy would be redu...
Preprint
Full-text available
IoT systems have been facing increasingly sophisticated technical problems due to the growing complexity of these systems and their fast deployment practices. Consequently, IoT managers have to judiciously detect failures (anomalies) in order to reduce their cyber risk and operational cost. While there is a rich literature on anomaly detection in m...
Article
Full-text available
The application of cutting-edge technologies such as AI, smart sensors, and IoT in factories is revolutionizing the manufacturing industry. This emerging trend, so called smart manufacturing, is a collection of various technologies that support decision-making in real-time in the presence of changing conditions in manufacturing activities; this may...
Article
Full-text available
Rare earth elements (REEs) such as Neodymium (Nd) and Dysprosium (Dy) are used in Rare Earth Permanent Magnets (REPMs). Neodymium-iron-boron (NdFeB) magnets offer the strongest magnetic field per volume among all the magnets available in the market, which enables lightweight and compact product designs. NdFeB magnets have thus become indispensable...
Article
Full-text available
Rare earth elements (REEs) are becoming ever more important and broadly used in rare earth permanent magnets (REPMs) for electric vehicles, wind turbines, cell phones, etc. While neodymium-iron-boron (NdFeB) magnets are very popular, samarium cobalt (SmCo) magnets are increasingly being viewed as an alternative REPM option due their better resistan...
Article
Full-text available
Restaurants in China have recently begun offering group-buying (GB) options on the internet as a marketing and advertising tool to attract customers. GB coupon is available to parties of any size and the groups do not need to go together to the restaurants. Such restaurants serve two types of customers: GB customers with GB coupons and regular cust...
Article
Fossil fuel depletion, air pollution, and climate change are imposing great pressure on industrial sectors, especially for manufacturing sectors. Energy consumption modelling is an important measure to promote the energy efficiency in manufacturing, which offers the fundamental basis for energy efficiency-related optimization. Although dynamic char...
Article
The industrial internet of things allows manufacturers to acquire large amounts of data. This opportunity, assuming the right methods are available, allows manufacturers to find anomalies that arise during manufacturing system operation. Data acquired from a manufacturing system are usually in the forms of time series. This paper proposes a new met...
Article
In a circular economy, recovering materials from end of life (EoL) products without an appropriate estimation of the cost and revenue may result in unnecessary economic loss. Although research has been carried out on the economic analysis of value recovery from EoL products, few quantitative approaches have examined generalized revenue-cost models....
Article
Dimensional tolerance allocation is a very important and difficult task that traditionally seeks to balance cost/productivity and quality. Common tolerance allocation models have two shortcomings: i) they are overly reliant on models focused on minimizing cost and tend to ignore waste, and ii) they fail to connect to the root cause of many quality...
Article
The recent advances in flexible piezoelectric technologies have sparked a great interest in developing multifunctional next‐generation transducers, which are in high demand for various challenging applications. Here, novel quasi 1–3 piezoelectric films with record‐high piezoelectric voltage coefficients (g33), reaching up to 0.709 Vm N−1, ≈20% grea...
Article
Purpose The purpose of this study is to identify a comprehensive list of main enablers of successful implementation of green manufacturing (GM) practices in small and medium-sized enterprises (SMEs). Based on the inputs from Irish SMEs' experts, a validated conceptual hierarchy model of the identified enablers is developed to analyse and prioritise...
Article
Full-text available
A novel design of a vibration energy absorbing mechanism (VEAM) that is based on multi-physics (magnetic spring, hydraulic system, structural dynamics, etc.) for cable vibration is proposed. The minimum working force of the hydraulic cylinder has been exploited in this design in order to combine a non-linear stiffness vibration isolation module tha...
Article
Smart shared mobility is an emerging transportation strategy that promotes sustainable and intelligent transportation. As one mode of smart shared mobility bike sharing is gaining popularity in recent years. A daily rebalancing operation is commonly carried out to keep high level service of bike-sharing systems (BSSs). The static bike-sharing rebal...
Article
Society's consumption of natural resources and the impact of industrial activities on the environment has gained increasing attention over the last several decades. This paper provides a historical perspective on the origins of the environmental movement and its connection to industrial systems. Then, recent research related to product design, proc...
Article
Demanufacturing aims to recover value and conserve energy from end-of-life (EOL) products, contributing to sustainable manufacturing. To make the full use of EOL products, they are usually disassembled into components that have different values and embodied energy at different EOL options. This article studies a disassembly planning (DP) that integ...
Article
Full-text available
Tool wear is one of the consequences of a machining process. Excessive tool wear can lead to poor surface finish, and result in a defective product. It can also lead to premature tool failure, and may result in process downtime and damaged components. With this in mind, it has long been desired to monitor tool wear/tool condition. Kernel principal...
Article
With rising energy prices and environmental concerns, reduction of energy consumption has become a critical manufacturing focus. One appropriate way to reduce energy consumption in manufacturing systems is to develop energy-conscious optimization strategies for production planning. In a flexible machining job shop, this planning must accommodate co...
Article
The environmental performance of machining processes is of extreme importance in the field of sustainable manufacturing. The development of an environmental impact assessment method is a crucial strategy to realize energy and material efficient manufacturing, yet few studies have addressed energy and material flows using a common perspective. In pr...
Article
Life cycle assessment (LCA) can be a powerful tool in minimizing aggregate life cycle impacts if used during early stage research before materials, processes, and system designs are set. This study examines the life cycle effects of substituting two promising arsenic-containing polymorphs of Cu3AsS4 as the absorber layers in single junction thin-fi...
Article
As mechanical engineering is growing a current and urgent issue is rising in the manufacturing process, which is the ability to improve efficiency while reducing energy consumption during the processes. Cutting parameters are an important part of the computer numerical control (CNC) machining process, so a reasonable selection of cutting parameters...
Article
Disassembly planning (DP) is critical in remanufacturing and value recovery from end-of-life products and has attracted increasing attention due to the recent resurgence of research on circular economy. DP problem is NP-hard and its complexity increases exponentially with the size of problem. Sequence-dependent cost due to varying quality of the pa...
Article
Industry is increasingly interested in using less energy in order to enhance competitiveness and reduce environmental impact. To implement technologies and make decisions that lead to less energy demand, energy/power data is required. All too often however, energy data is either not available, or is available but too aggregated to be useful, or is...
Article
Smart shared mobility is an emerging transportation strategy that promotes sustainable and intelligent transportation. Bike sharing is one mode of smart shared mobility and is gaining popularity in recent years. To ensure a smooth operation of a bike sharing system (BSS), it is essential to redistribute the bicycles, which includes picking up retur...
Article
As society works to reduce its reliance on fossil fuels, the demand for renewable energy has grown rapidly in recent years. Photovoltaic (PV) solar power is one such source of renewable energy and has seen significant growth over the past several decades. While End of Life (EoL) PV volumes remain relatively small at this time, the number of EoL PVs...
Article
Full-text available
In a highly automated manufacturing plant, the reliability of manufacturing equipment is critical for normal operation. A sudden machine breakdown can bring unexpected downtime, shorter lifespan of equipment, and lower operational efficiency. Breakdowns can lead to defective parts and consume extra energy—issues that are undesirable from an environ...
Article
Full-text available
This paper builds on the previously developed maintenance strategy of predictive maintenance (PdM) that can detect the incipient breakdown of a system and determine the condition of in-service equipment to estimate the maintenance scheduling. Here, a new data-driven model based on Long Short-Term Memory (LSTM) Recurrent Neural Networks (RNN) algori...
Article
Full-text available
Manufacturing has evolved to become more automated in pursuit of higher quality, better productivity and lower cost. However, industrial logistics between the end customer and manufacturing supply chain still demands human labor and intelligence. This logistic work requires engineers with experienced knowledge to identify machining processes from t...
Article
Full-text available
Predictive maintenance (PdM) has been widely used in manufacturing to reduce maintenance cost and unexpected downtime. A common element within manufacturing equipment/machines is a motor. This paper aims to detect motor faults by collecting and analyzing vibration data with wireless sensors. A cloud-based motor condition monitoring system is also b...
Article
Full-text available
It's important to accurately and effectively estimate the overall machining energy consumption so as to compare and select the toolpath that uses the least amount of energy. To this end, a framework to model the energy consumption when machining a workpiece is proposed in this paper. This framework consists of a toolpath planning stage and an energ...
Article
Full-text available
This study applies design of experiments (DOE) methods in the conduct of a techno-economic assessment (TEA) on a newly developed rare-earth element (REE) recovery process. The goal of this effort is to identify main factors that affect the profitability of the process. We construct a factorial design with net profit as the response, where the exper...
Article
Full-text available
Purpose Investing in Industry 4.0 is an important consideration for manufacturing firms who strive to remain competitive in this global economy, but the uncertainty and complexity of where to focus technology investments is a problem facing many manufacturers. The purpose of this paper is to highlight a region of manufacturing firms in the Midwest...
Article
Cutting parameter selection is significant for process planning which directly affects product quality, production efficiency and cost. However, most literature does not consider both the cost and the carbon emissions as optimisation objectives for process evaluation. This paper presents a method for cutting parameter selection by considering both...
Article
Full-text available
This paper presents an overview of the first author’s research being conducted and future research plans for the rest of PhD career. The content of this paper was presented at the PHM 2019 Doctoral Symposium, which was a part of the program at the 11th Annual Conference of the Prognostic and Health Management Society held in Scottsdale, Arizona fro...
Article
Full-text available
Agricultural waste was used as substrate for fermentation by Gluconobacter oxydans to produce lixiviant for rare earth element (REE) recovery from industrial waste materials, i.e., spent fluid catalytic cracking (FCC) catalysts. Biolixiviant generated from potato wastes performed comparably to that generated from refined glucose. Corn stover yielde...
Article
An important production planning problem is how to best schedule jobs (or lots) when each job consists of a large number of identical parts. This problem is often approached by breaking each job/lot into sublots (termed lot streaming). When the total number of transfer sublots in lot streaming is large, the computational effort to calculate job com...