Sustainable Manufacturing
Abstract
According to the NACFAM (National Council for Advanced Manufacturing USA) Sustainable Manufacturing is defined as the creation of manufactured products that use processes that are non-polluting, conserve energy and natural resources, and are economically sound and safe for employees, communities, and consumers. The book covers Sustainable Manufacturing techniques such as materials and manufacturing for renewable energies; clean manufacturing technology; ecological manufacturing; energy-efficient manufacturing; remanufacturing; recycling of materials; environmentally conscious design and manufacturing processes; sustainable advanced manufacturing systems; manufacturability in sustainable product design; education and training for sustainable manufacturing.
... In addition, because of the challenges and widespread applications, sustainability concerns arise in machining aluminum alloys. For this reason, there is a requirement for advanced machining techniques that will enhance the sustainability [9,10] and efficacy of machining [11,12]. ...
... The established regression equations are given in Eqs. (8)(9)(10)(11)(12) and their adequacy is measured from the R 2 value. The R 2 values for F c , T c , R a , CE, and MC are 98.32%, 97.6%, 97.83%, 99.93% and 99.93%, respectively. ...
Aluminum 6082 alloys are commonly utilized in significant industries because of their unique characteristics. However, they exhibit poor machinability as a result of their high ductility, high thermal expansion coefficient, and tendency to built-up edge formation. Considering the alloy's widespread usage, the difficulty of machining it raises sustainability concerns. For this reason, although minimum quantity lubrication (MQL) methods using various nanoparticle-added nanofluids have been used to enhance machinability, the use of graphene nanoparticles (GNP) has been ignored. Furthermore, there has been a lack of sustainability assessment and optimization. In the presented study, MQL methods using various GNP-added nanofluid (N-MQL) was used for the first time in the milling of Al6082 alloy, and its machining responses (cutting temperature, cutting force, feed force, surface roughness, and chip morphology) and sustainability indicators (carbon emission and total machining cost) were determined and compared with dry-cutting and pure MQL utilizing vegetable cutting oil. The utilization of the N-MQL, as opposed to the dry-cutting with appropriate cutting parameters, resulted in improvements of 50.6% in cutting force, 65.4% in feed force, 50.6% in cutting temperature, 33.2% in chip width, 15.3% in chip length, 67.3% in surface roughness, 21.5% in carbon emissions, and 52.6% in machining cost. Finally, applying multi-objective optimization using NSGA-II (non-dominant sequencing genetic algorithm II) and the multi-criteria decision-making method using VIKOR, optimum process parameters were determined in terms of sustainability-weighed carbon emissions and total machining cost. From the sustainability-based optimization results, it was determined that the cutting speed should be selected between 36 and 40 m/min, the feed should be selected between 0.14 and 0.18 mm/rev, and the N-MQL method should be used. Using the N-MQL method at above-average cutting speeds and feed values are the most sustainable machining parameters and condition for milling of Al6082.
... By achieving these objectives, this study endeavors to make a substantial contribution to the field of sustainable manufacturing, particularly in aligning industrial processes with SDGs 9 and 12, which focus on building resilient infrastructure, promoting inclusive and sustainable industrialization, and fostering sustainable consumption and production patterns [14]. ...
... In this way, the study can look at all of the results from all of the different methods and add them to PCIM-MADM to make more accurate and reliable decisions. 5 3.800 2.400 4.700 3.300 FM 6 6.000 3.800 4.500 5.600 FM 7 6.200 4.100 4.500 5.500 FM 8 3.300 2.400 6.500 4.400 FM 9 3.100 2.400 5.500 3.900 FM 10 2.800 3.300 4.100 3.300 FM 11 4.100 3.800 3.400 4.700 FM 12 4.900 5.900 3.000 3.900 FM 13 3.600 3.400 4.900 3.200 FM 14 3.600 3.400 5.000 3.400 FM 15 3.800 2.600 5.100 3.800 FM 16 3.900 2.800 4.400 3.800 ...
In the realm of industrial development, steel has consistently played a pivotal role due to its extensive applications. This research aims to refine the process of steel plate manufacturing, focusing on reducing waste as a critical step towards embracing sustainable development and aligning with the Sustainable Development Goals (SDGs). Our approach integrates a hybrid analytical model grounded in Failure Mode and Effects Analysis (FMEA) to thoroughly investigate the waste-producing elements in steel plate production. The methodology of this study is structured in a three-pronged approach, as follows: Initially, it involves meticulous on-site inspections across various factories to pinpoint potential sources of waste. Subsequently, we employ the Decision-Making Trial and Evaluation Laboratory (DEMATEL) method to intricately analyze the interconnectedness and impact of various risk factors. The final phase utilizes the Performance Calculation technique within the Integrated Multiple Multi-Attribute Decision-Making (PCIM-MADM) framework for aggregating and evaluating risk scores. This multifaceted approach aids in establishing the priorities for corrective actions aimed at waste reduction. Our findings present innovative solutions for identifying and mitigating critical waste factors, contributing to a more efficient and sustainable steel manufacturing process. These strategies promise scalability and adaptability for broader industrial applications and provide critical insights into resource optimization. This research directly supports the objectives of SDG 9, which focuses on building resilient infrastructure and promoting sustainable industrialization. Furthermore, it resonates with SDG 12, advocating for sustainable consumption and production patterns. By enhancing the efficiency and cost effectiveness of steel plate production, this study significantly contributes to minimizing waste and elevating the sustainability of industrial practices.
... Such waste-to-energy streams will align with policy and industry trends and add more value to coal and its derivatives. Manufacturing sustainable building material is essential for ecological safety [17]. In this light, the CTC is produced using a hot-press manufacturing process with a relatively low temperature and pressure. ...
... Manufacturing sustainable building material is essential for ecological safety [17]. In this light, the CTC is produced using a hot-press manufacturing process with a relatively low temperature and pressure. ...
The exploitation of coal and the disposal of waste plastic present significant environmental and economic challenges that require sustainable and profitable solutions. In response, we propose a renewable construction composite material of coal-based thermoplastic composite (CTC) that can be made from low-grade coal and plastic waste. We developed and tested the hot-press fabrication method for this CTC, using coal with a maximum particle size of 4.75 mm and recycled high-density polyethylene (HDPE). The effects of the coal fraction (50–80 wt%) on compressive properties, thermal properties, microstructure, and ecological and economic efficiencies of the CTC were investigated. Test results revealed that the compressive strength and modulus decrease as the coal fraction increases. However, the thermal properties, including thermal conductivity and specific heat, increase with higher coal contents. Compared to concrete, the CTC has about half the thermal conductivity and twice the specific heat, making it a more energy-efficient construction material. Microstructure testing helped to reveal the mechanisms behind the above behaviors of CTC from the observation of binder volume, bonding quality between coal and HDPE, and porosity variation. The life cycle analysis indicated that the CTC production reduced embodied energy, carbon footprint, and cost by up to 84%, 73%, and 14%, respectively. Therefore, we recommend the CTC with 50–70% coal fraction as an innovative construction material with satisfied mechanical and thermal properties, better cost efficiency, and a reduced ecological impact.
... The direct societal benefits or lack thereof as related to gears and gear production falls outside the scope of this review. Sustainable manufacturing can be defined as the production of manufactured products that use processes which minimize negative environmental impacts, conserve energy and natural resources , are safe for employees, communities and consumers and are economically sound (Davim, 2010; Garetti and Taisch, 2012; Pusavec et al., 2010 ). It includes: (a) the manufacturing of " sustainable " products; and (b) the sustainable manufacturing of all products. ...
... According to Davim (2010) and Pusavec et al. (2010) lower machining costs, environmental-friendliness, minimum energy consumption, waste reduction and management, and personnel health and operational safety can be identified as the hallmarks of sustainable manufacturing. Globally these efforts by the manufacturing industries includes implementation of advanced lubrication and cooling technologies, use of vegetable oils and other environment-friendly cutting fluids, selection of advanced tooling and employing advanced and hybrid manufacturing processes etc. (Davim, 2010; Fratila, 2014). The following section highlights the challenges encountered in gear manufacturing and presents possible solutions in order to improve overall sustainability. ...
Environment awareness is of the utmost importance to all socially responsible manufacturers. To be competitive on a global scale manufacturing needs to be aligned with various strict environmental regulations. The manufacturing industry at large is striving to improve productivity and product quality while maintaining a clean and sustainable environment. This can only be achieved by adopting sustainable techniques of manufacturing which include minimizing the number of manufacturing steps by employing advanced and alternative methods, environment-friendly lubricants and lubrication techniques while machining, reducing wastage, active waste management and minimizing energy consumption etc. Gear manufacturing industries, the major service providers to all other industrial and manufacturing segments are also focusing on to implement the techniques targeting overall sustainability. Some of the recent developments to achieve sustainability in gear manufacturing can be summarized as: reducing the use of mineral-based cutting fluids by employing alternative lubrication techniques i.e. minimum quantity lubrication (MQL) and dry machining; material saving, waste reduction , minimizing energy consumption and maintaining economic efficiency by reducing the number of gear manufacturing stages; eliminating the necessity of finishing processes by utilizing advanced methods such as gear rolling and wire electric-discharge machining (WEDM) and finally increasing productivity by minimizing tool wear at high gear cutting speeds through the use of alternative tool materials and coatings. This paper reviews and amasses the current state of technology for sustainable manufacturing of gears and also recommends ways to improve the productivity and quality while simultaneously ensuring environmental sustainability.
... Hence, there is an urgent need to improve process efficiency and minimise energy consumption in manufacturing processes to make them more sustainable. Manufacturing products through processes that are environmentally friendly (non-polluting), consume fewer resources and energy, are economically sound, and provide a safe environment for workers, society, and consumers are referred to as sustainable manufacturing [3]. Consequently, many scholars have endeavoured to reduce energy consumption in machining. ...
... As explained by NACFAM (National Council for Advanced Manufacturing USA), sustainable manufacturing is described as the production of manufactured goods using nonpolluting, energy and resource efficient processes that are secure for workers, consumers, and communities [91]. The importance of sustainability in manufacturing is highlighted by global drivers, both as a means of reducing the effects of the drivers and due to the material and energy consumption of present production processes. ...
The study and implementation of ergonomics are vital for the growth of industries and improvement in work cultures. Sustainable manufacturing cannot be achieved without the implementation of human-factor ergonomics. Ergonomics is used to analyze the link between research studies and industrial practices in order to maximize the efficiency of processes by keeping in view the well-being of workforce. Designing tools, tasks, machines, systems, jobs, and settings for efficient, safe, and successful human usage involves applying knowledge about human behavior, abilities, and limitations. Workers are the backbone of the manufacturing economy. The review outlines significant advancements in preventing ergonomic problems during the design stage of the manufacturing process to achieve sustainability. The bibliometric analysis is used to identify the literature base for ergonomics. To maximize the benefits of ergonomics and to integrate sustainable practices, various methods are required to organize existing processes and technologies. The human-centered design identifies problems and aligns the output with the intended objectives of sustainability. The goal of human factors and ergonomics is to successfully integrate people into systems and develop the manufacturing processes around the well-being of workers and sustainability principles. Similarly, ergoecology, eco-ergonomics, and green ergonomics are frequently used for sustainable manufacturing. Achieving sustainability in manufacturing is not possible without considering human ergonomics. Ergonomists frequently research management, planning, and other topics to increase the efficiency of the manufacturing process. Efficient worker performance and quality of life can be enhanced through work design, management, and organizational ergonomics. Human ergonomics relates sustainability with cognitive variables such as situational awareness, human reliability, and decision-making abilities. This review explains the role of human factors and ergonomics for sustainable manufacturing.
... In addition, it offers various other benefits, including forming a fine and equiaxed grain microstructure, reduced residual stress, and energy efficiency. As a result of these advantages, industries are demonstrating a keen interest in adopting this process [11,12]. ...
The demand for novel laminated sheets encouraged using newer technologies to produce tailored materials for multipurpose applications. An inventive solid-state joining method: friction stir additive manufacturing, which offers several advantages over traditional lamination processes. In this study, the Al2O3 powder is used as reinforcement during AA6063/Al2O3/AA6063 composites fabrication. The fabricated specimen was characterized by bonding features such as thickness reduction, metallography, mechanical properties, and tribological performances and compared with sheet lamination and base metal. The optical microscope and scanning electron microscopic images showed that the Al2O3 powder is distributed within the composites. The structural analysis at the interface of the fabricated composite was conducted through X-ray diffraction, confirming the compounds like Mg2SiO4, Mg2Al4, and Al2O3 in the crystallographic planes. The microstructural and morphological results of the laminated composite showed the refined and equiaxed grains and also depicted the dispersion of the Al2O3 powder near the stir zone. The microhardness properties were enhanced and obtained as 91.2 HV and 77.5 HV with and without reinforcement, respectively. Further, the ultimate tensile strength with and without reinforcement is improved by 36.9% and 24.7% compared to the base metal. Furthermore, the tribological analysis was performed at variable process parameters. Taguchi's L9 orthogonal array and variance analysis (ANOVA) were done to analyze the effect of individual parameters and their significance. The obtained results showed that load and frequency are significant parameters during the tribology test. The laminated composite's specific wear rate, wear depth, and COF values are less than the sheet lamination and align with ANOVA test results. Furthermore, the wear mechanism was observed, and it was found that sheet lamination has high wear at increased load when compared to laminated composite parts. Therefore, the obtained results dictate that the addition of Al2O3 powder can significantly enhance the bonding strength, mechanical and tribological properties of the fabricated composites.
... The economic growth of the developed and developing countries relies on the manufacturing sector. The manufacturing system is a transformation process (Davim 2013); it converts valuable resources into usable goods. It is a value-added system with many factors that are directly and indirectly associated. ...
... The economic growth of the developed and developing countries relies on the manufacturing sector. The manufacturing system is a transformation process (Davim 2013); it converts valuable resources into usable goods. It is a value-added system with many factors that are directly and indirectly associated. ...
... The decrease in energy consumption helps in lowering the cost of machining and improving the sustainability of the process by reducing carbon footprints. Over the lifetime of the machine tool, the cost of the energy consumed by machine tool exceeds its purchasing cost by at least ten times (Davim, 2013). Hence, it is imperative to look at the energy consumption behavior of machine tools at different cutting parameters and cutting conditions to improve overall productivity and sustainability. ...
This study compares the turning performance of Nimonic 90 under indigenously developed cryogenic-ultrasonic assisted turning (CUAT) process and cryogenic assisted turning (CAT) process. CUAT process combines the advantages of CAT and ultrasonic-assisted turning (UAT) processes. Both CAT and UAT processes are proven sustainable machining techniques. Experiments are designed using the full factorial method. In this work, machinability is evaluated in terms of energy consumption, carbon emissions, machining characteristics and overall machining cost. It is found that the results under CUAT process are better as compared to the CAT process in terms of decreased energy consumption (up to 20%), carbon emissions and overall machining cost. Further, it is also observed that the surface finish also improved (up to 29%) under the CUAT process as compared to CAT process. These results advocate the sustainable gains of the CUAT process over the CAT process.
... Yüzey pürüzlülüğü kesme hızı, ilerleme hızı, kesici takım geometrisi, deney numunesinin mikro yapısı, deney numunesine uygulanan ısıl işlemler, kesme takımlarına uygulanan ısıl işlemler ve takım tezgahının rijitliği de dahil olmak üzere çeşitli faktörlerden etkilenir [8,9]. Bu parametrelerin yüzey kalitesi üzerindeki etkileri Taguchi yöntemi kullanılarak optimize edilebilir [10,11]. Son zamanlarda, Taguchi yöntemi, çeşitli endüstriyel alanlarda ve akademik araştırma çalışmalarında büyük ölçüde kullanılmaktadır [12][13][14][15][16][17][18][19][20]. ...
... The former includes exploring sources of renewable energy, green and social equity-related products. The main aspects concerned with the latter i.e. sustainable manufacturing of products are developing and establishing energy efficient, non-polluting, economical and viable processes for manufacturing of products [5, 6]. Furthermore, the implementation of such processes /techniques ensures the societal well-being and economic growth adopting the system-level approach throughout the whole life-cycle of a product [7, 8].Figure 1 displays the three pillars of sustainability (economy, environment and society) in context with the key drivers. ...
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.
... The Taguchi method has been widely used in the design of quality engineering and the parameter design plays an important role in modern engineering (Khattree and Rao, 2003). Moreover, the Taguchi method developed the procedures that apply orthogonal arrays (OA) of designed experiments to obtain the best model with a reduced number of experiments, thus minimising time and cost of experimentation (Davim, 2010). Recently, Taguchi method has been substantially used in several industrial fields and academic research works (Lin et al., 2009; Zhang et al., 2007; Pınar and Güllü, 2010; Mandal et al., 2011; Asiltürk and Neşeli, 2012; Günay and Yücel, 2013; Kurt et al., 2009). ...
Aluminium 5083-H111 alloy is used in many different sectors such as shipbuilding, rail cars and vehicle bodies. The use of this material in different sectors, its behaviours in the various machining operations have become important. In this study, face milling process was applied to AA5083-H111 material by using coated and uncoated cutting inserts. Experiments were performed on the basis of Taguchi's L18 orthogonal array (OA) at different levels of the cutting depth (0.08, 0.25 mm), the cutting inserts (uncoated carbide, PVD/TiA1N coated carbide, PVD/TiB2 coated carbide), the cutting speed (450, 550, 650 m/min) and the feed rate (0.08, 0.12, 0.25 mm/tooth) relating to a good surface quality. The obtained values at the end of the experiments were evaluated through the signal to noise (S/N) ratios, analysis of variance (ANOVA), 3D graphs and regression method. Through the confirmation experiments, the machining accuracy of 0.52 μm could be significantly improved to 0.24 μm with an enhanced performance of 53.84%.
Cryo-MQL is an impactful, sustainable cooling/lubrication approach that addresses constraints such as wheel loading and thermal damage of ground Inconel 625 caused by its low thermal conductivity and work hardening tendency. The present investigation explores the eco-friendly Cryo-MQL approach, i.e., LN2 with groundnut oil-based sustainable grinding, to enhance the grindability and surface integrity of Inconel 625. For confirmation, cryo-MQL outcomes, including grinding forces, roughness parameters, bearing area analysis, grinding temperature, surface morphology, and microhardness, have been compared with dry and MQL outcomes. The results indicate that cryo-MQL exhibits excellent surface tribological performance in lower skewness and kurtosis parameters with a higher bearing area ratio, i.e., 78.84%, and free-from grinding burn and redeposition layer formation. Besides, lower grinding forces and temperature with no significant microhardness change highlighted a better grindability of high-strength alloy. Finally, chip morphology investigations under various conditions have been performed to gain further insights into the grindability of Inconel 625 in terms of negligible wear tracks with long C-type microchips. Therefore, it can be concluded that cryo-MQL grinding safeguards the surface qualities of the ground surfaces and provides clean grinding conditions.
The rise of green manufacturing and the wide use of hard-to-cut materials put forward higher requirements for tool performance. Therefore, it is imperative to develop green and efficient technology to improve tool performance. In this paper, a coupled electromagnetic treatment (CEMT) which can improve the cutting performance of coated cemented carbide inserts is proposed, and the effect of this technology on the static and dynamic performance of coated carbide inserts is studied. The experimental results show that after CEMT, the cutting force of the tool is reduced by 5.7%, and the service life is increased by 40.2%. The bonding strength of the coating increased by 25.9%, the nanohardness increased by 29.6%, the friction coefficient decreased by 25.7%, and the wear rate decreased by 21.3%. Quasi-in situ elemental analysis showed that CEMT increased the width of the coating diffusion zone by 0.2 μm. The main reason for the improvement in tool performance is the higher coating bonding strength and hardness, which is a result of the diffusion of coating elements facilitated by CEMT. The electric field promotes the migration of elements, while the magnetic field increases the chemical potential gradient. CEMT realizes the synergistic effect of electric and magnetic fields, so the strengthening effect is better than a single electric or magnetic treatment. This work provides a clean and efficient method for improving the properties of coated cemented carbide.
div>The primary objective of this article is to study the improvement of machining efficiency of EN-31 steel by optimizing turning parameters using newly developed cutting fluids with different proportions of aloe vera gel and coconut oil, utilizing the Taguchi technique. Furthermore, performance metrics including material removal rate (MRR), surface roughness, and tool wear rate (TWR) were assessed. Analysis of variance (ANOVA) suggested that as cutting speed and feed increase, the MRR is positively influenced, but likewise tool wear is intensified. The surface roughness exhibited a positive correlation with cutting speed, and a negative correlation with increasing both cutting speed and feed. It was found that the maximum MRR value was attained at a cutting speed of 275 m/min, a feed rate of 1.00 mm/rev, and a cutting fluid composition of 30% aloe vera and 70% coconut oil. For the best surface smoothness, it is advisable to adjust the cutting speed to 350 m/min and the feed rate to 0.075 mm/rev. A cutting speed of 275 m/min and a feed rate of 1.00 mm/rev led to a lower TWR. The results suggest that the combined use of coconut oil and aloe vera as cutting fluids improves the turning quality of EN-31 steel, particularly when employing a combination of 30% aloe vera and 70% coconut oil. As a possible solution for performance problems in achieving desired results during the turning of EN-31 steels, these recommendations may be used in industries to enhance turning performance.</div
Sustainability is fundamental in the field of additive manufacturing (AM) for improving eco-consciousness and driving evolution toward environmentally responsible production methods. Compared to traditional manufacturing processes, AM technologies can be more resource-efficient and offer innovative solutions for creating eco-friendly processes and products. Nevertheless, there is significant potential for improvement in additive manufacturing sustainability. The key factors driving this improvement include design optimization and increased awareness. Designers and engineers can create designs that optimize material efficiency and reduce support structures. Raising awareness and educating stakeholders about the environmental benefits of AM can promote responsible choices throughout the industrial process. The development of a tool to assess the environmental impact of AM processes could be a significant contribution to advancing sustainability in the AM field. The EcoPrintAnalyzer, introduced as a complementary plugin for UltiMaker Cura, offers data on the equivalent carbon dioxide footprint and energy consumption in material extrusion additive manufacturing. This tool facilitates informed decision-making regarding materials, designs, and settings, enabling users to optimize their AM processes for reduced waste and enhanced energy efficiency. Beyond aiding decision-making, the EcoPrintAnalyzer fosters environmental consciousness and encourages the adoption of sustainable practices within the AM ecosystem. The efficacy of the tool is demonstrated through the 3DBenchy model case study, showcasing its intuitive interface and seamless integration within the AM process workflow for immediate and comparative environmental impact assessments across different process configurations.
Smart manufacturing has become a significant topic of interest among manufacturing industry professionals and researchers in recent times. Smart manufacturing involves the incorporation of cutting-edge technologies, including the Internet of things, cyber-physical systems, cloud computing, and big data. This is evident in the Industry 4.0 framework. Henceforth, next generation smart manufacturing showcases a deep amalgamation of artificial intelligence (AI) tech and highly developed production technologies. It is woven into each stage of the design, production, product, and service cycle and influences the entire life cycle. The subsequent form of smart manufacturing is the central propellant for the novel industrial revolution and is expected to be the principal catalyst for the transformation and betterment of the manufacturing industry for the generations ahead. Through this research, we proposed a ‘4*S Model’ via conceptualization of smart, sensorable, sustainable, and secure concepts at various stages of manufacturing. The evolution of smart manufacturing for Industry 4.0 is an ongoing process and this research will provide insights for further developments in manufacturing.
Despite the fact that titanium alloy micro-gear has superior performance and can withstand special conditions, it is difficult to machine due to its poor plasticity and high strength. We proposed an eco-friendly, efficient, and sustainable electric field assisted micro-plastic forming technology (micro-EFAPFT) for forming titanium alloy microparts. Ti-6Al-4 V alloy bars were extruded into micro-gears using an electrothermal coupling field and Joule heating in a graphite mold. The micro-gear has high precision, good surface quality, and a simple process. The whole process takes only 380 s. The findings demonstrate that the best gear forming degree, fewer microstructure defects, and hardness reaching 330.1 HV—4.4% higher than that of the raw material—occur when the pressure holding period is 120 s. During the plastic deformation process, phase transformation and recrystallization occur, increasing the fraction of α phase from 96.6–99.68% and increasing the grain orientation difference. The tooth tip has finer grains but longer dislocation lines. In conclusion, the electric field accelerates dislocation motion, reduces dislocation density, and increases material plasticity, allowing the Ti6Al4V micro-gear to be formed in a single step. The experimental results validate the feasibility of this technology for producing titanium alloy micro-gear and can be used to guide the production of different materials and shapes of microparts.
The base fluids of eco-friendly cutting fluids should contain some vegetable oil. Due to their eco-friendly, thermal, and tribological qualities, these types of machining fluids are becoming increasingly popular among researchers throughout the world. The authors summarized published research studies on the use of eco-friendly machining fluids (including nanofluids) in various metal removal processes such as turning, milling, grinding, and drilling in this review paper. The impact of several biodegradable oil-based machining fluids on performance metrics such as surface irregularity, machining force, tool wear, power demand, and temperature-induced during the machining process is also explored in this paper. According to the previous and current literature, using an eco-friendly nano machining fluid results in better surface features, less cutting tool wear, lower cutting force, less power required, and lower machining zone temperature during the machining operation due to superior cooling and lubrication properties.
Towards developing green composite through waste recycling, the main objective of this work was to produce an Al6113 hybrid composite via stir casting with a combination of two different reinforcements, such as waste glass powder (WGP) and snail shell ash (SSA) particles. Samples mixtures were prepared and labelled as groups A, B, C, and D. Group A samples were developed with the blend of 2, 4, 6, 8, and 10 wt% WGP and 3 wt% constant dose of SSA particles. Groups B, C, and D samples were prepared with the blend of the same proportion of WGP and 6, 9, and 12 wt% SSA. The mechanical properties of the composites were examined to determine the effect of reinforcement combination on the composites. It was observed that WGP inclusion enhanced tensile, impact, fracture , flexural, and compressive strength when combined with 3, 6, and 9 wt% SSA. Meanwhile, the blend of the WGP with 12 wt% SSA resulted in depreciation in strength. It is deduced that the properties of the composite can be improved by the dual presence of WGP and SSA in the proportions of 2-6 wt% WGP and 3-9 wt% SSA.
Purpose
Sustainable manufacturing may be defined as the creation of manufactured products that use processes that are non-polluting, conserve energy and natural resources, and are economically sound and safe for employees, communities and consumers. Recently, there have been several industrial and governmental endeavors to launch sustainable manufacturing initiatives. To support such initiatives and to prepare the next generation of scientists and engineers, academic institutions have a responsibility to introduce educational programs and tools in the area of sustainable manufacturing. The purpose of this paper is to report on the approach, progress and contributions of a US National Science Foundation-sponsored project titled: “The Sustainable Manufacturing Advances in Research and Technology Coordination Network (SMART CN)”.
Design/methodology/approach
The project aims to bridge the gap between the academic knowledge discovery and industrial technology innovation for sustainable manufacturing. Toward this goal, various research and educational activities have been undertaken to introduce Sustainable Manufacturing Case Studies for use by academic instructors to a diverse group of undergraduate, graduate and industry professionals.
Findings
In this paper, the need for education on sustainable manufacturing has been focused upon, followed by approaches toward addressing these needs, concluding with examples of case studies developed through the SMART-CN project framework.
Originality/value
This work provides the engineering community with structured modules for introducing the topic of sustainable manufacturing in the curriculum.
The increasing demands on earth's resources require the need for engineering disciplines to address the limitations of materials and energy as well as the need to reduce waste production. This requirement is particularly acute for material science engineers as their work has a lasting impact on our future sustainability. Recent developments and innovations in material science can be useful tools for achieving sustainable development, provided material science engineers are aware of the issues. They should be particularly aware of global sustainability challenges, and should be able to understand how they can contribute to the solutions of these problems. Therefore, this chapter discusses how sustainable engineering principles can be introduced into material science education. It also discusses the curriculum for the subject Sustainable Infrastructure that is offered at La Trobe University in Victoria (Australia) for senior Civil Engineering students.
In this contribution, we report the facile preparation of crosslinked polymerizable ionic liquid (PIL)-based nanoparticles via thiol−ene photopolymerization in a miniemulsion. The synthesized PIL nanoparticles with
a diameter of about 200 nm were fully characterized with regard to their chemical structures, morphologies, and properties using different techniques, such as Fourier transform infrared spectroscopy, thermogravimetric analysis, scanning electron microscopy, and transmission electron microscopy. To gain an in-depth understanding of the physical and morphological structures of the PIL nanoparticles in an emulsion, small-angle neutron scattering and ultra-smallangle neutron scattering were used. Neutron scattering studies revealed valuable information regarding the formation of cylindrical ionic micelles in the spherical
nanoparticles, which is a unique property of this system. Furthermore, the PIL nanoparticle emulsion was utilized as an inhibitor in a self-assembled nanophase particle (SNAP) coating. The corrosion protection ability of the resultant coating was examined using potentiodynamic polarization and electrochemical impedance spectroscopy. The results show that the PIL nanoparticle emulsion in the SNAP coating acts as an inhibitor of corrosion and is promising for fabricating advanced coatings with improved barrier function and corrosion protection.
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