Advances in Industrial and Manufacturing Engineering最新文献

{"title":"Life cycle assessment of metal products: A comparison between wire arc additive manufacturing and CNC milling","authors":"Rafaela C. Reis ,&nbsp;Samruddha Kokare ,&nbsp;J.P. Oliveira ,&nbsp;João C.O. Matias ,&nbsp;Radu Godina","doi":"10.1016/j.aime.2023.100117","DOIUrl":"10.1016/j.aime.2023.100117","url":null,"abstract":"<div><p>The industrial progress made throughout these years has led to great results in terms of producing fast and with good quality. However, the impacts related to that production, whether these are environmental, economic, or social have been, at times, neglected. The manufacturing sector, as one of the most polluting sector, felt the urge to adapt to this industrial progress and find ways to produce with improved sustainability goals without compromising the quality of the final product and the production time. Industry easily understood the benefits of this greener approach, and, with this, new sustainable technologies started to emerge. Additive Manufacturing (AM) is one of those technologies that provide alternative sustainable paths to traditional manufacturing. In order to generalize the benefits of AM production in terms of sustainability, when compared to traditional processes, further investigations must be conducted. In this sense, the proposed work has the intention of finding the environmental impacts associated with a particular AM technique for the fabrication of metal parts, Wire Arc Additive Manufacturing (WAAM). A practical work based on the production of three different complexity metal parts considering an additive (WAAM) and a subtractive (Computer Numerical Control (CNC) Milling) manufacturing process is developed. To quantify the environmental impacts of both processes, the author resorts to the Life Cycle Assessment (LCA) methodology. The assessment is conducted in the SimaPro 9.2 software, accordingly to ISO 14044:2006 standard. The results allow a comparison between both types of manufacturing and enable the suggestion of measures to decrease the environmental footprint of WAAM. It was found that WAAM approach leads to a material saving ranging between 40% and 70% and an environmental impact reduction in the range of 12%–47%, compared to the subtractive approach for fabricating the 3 geometries considered in this study. The conclusions obtained are specific to this particular application and, once more, it is acknowledged that in order to reach a global understanding relative to this technology's environmental implications, extra research still needs to be made.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100117"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47660365","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Energy consumption versus strength in MEΧ 3D printing of polylactic acid","authors":"Nectarios Vidakis ,&nbsp;Markos Petousis ,&nbsp;Emmanuel Karapidakis ,&nbsp;Nikolaos Mountakis ,&nbsp;Constantine David ,&nbsp;Dimitrios Sagris","doi":"10.1016/j.aime.2023.100119","DOIUrl":"10.1016/j.aime.2023.100119","url":null,"abstract":"<div><p>The cost-effectiveness and the environmental impact of Additive Manufacturing (AM) are nowadays two of the hottest process-related industrial and research topics. Energy efficiency is a strong claim, and so is the demand for durable and functional 3D-printed workpieces. These contradictory aspects usually require flexibility and compromises. Especially for Material Extrusion (MEX) 3D printing, the plurality of the control parameters makes such optimizations complicated. This research explores the effect of seven generic and machine-independent control factors (e.g., <em>Raster Deposition Angle; Orientation Angle; Layer Thickness; Infill Density; Nozzle Temperature; Bed Temperature, and Printing Speed</em>) on energy consumption of Polylactic Acid over the compressive response of MEX 3D printed specimens. To make it possible, a three-level L27 orthogonal array was compiled. Each experimental run included five specimen replicas (after the ASTM D695-02a standard) summing up 135 experiments. The fabrication time and the energy consumption were determined by the stopwatch method, whereas the compressive strength, elasticity modulus, and toughness were derived with compressive tests. The Taguchi analysis ranked the impact of each control parameter on each response metric. The printing speed and the layer thickness were the most influential control parameters on energy consumption. Furthermore, the <em>infill density</em> and <em>the orientation angle</em> were found as the most dominant factors in the compressive strength. Finally, Quadratic Regression Model (QRM) equations for each response metric over the seven control parameters were compiled and validated. Hereto, the best settlement between energy efficiency and mechanical strength is now possible, an option with great technological and industrial merit.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100119"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45437262","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Electromagnetic joining of aluminum and polycarbonate tubes","authors":"F. Weber ,&nbsp;Y. Lu ,&nbsp;F.J. Peterschilka ,&nbsp;M. Hahn ,&nbsp;A.E. Tekkaya","doi":"10.1016/j.aime.2022.100109","DOIUrl":"https://doi.org/10.1016/j.aime.2022.100109","url":null,"abstract":"<div><p>Lightweight constructions made of different materials are becoming increasingly important and joining of metal-plastic hybrids is a major challenge in this context. This paper investigates experimentally the electromagnetic joining of tubes made of aluminum alloy 6082 and thermoplastic polycarbonate. Therefore, electromagnetic joining tests, combined with destructive push-out tests and non-destructive computer tomography scans were conducted. The investigations showed a fundamental dependence of the joint strength on the diameter ratio of the inner joining partner. By increasing the ratio of inner to outer diameter, the transferable push-out force was increased by factor fifteen. Furthermore, for lower ratios, macroscopic cracks were detected that limited the transferable forces.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100109"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49712205","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Exploiting the technological capabilities of autonomous vehicles as assembly items to improve assembly performance","authors":"Tom Kathmann ,&nbsp;Daniel Reh ,&nbsp;Julia C. Arlinghaus","doi":"10.1016/j.aime.2022.100111","DOIUrl":"https://doi.org/10.1016/j.aime.2022.100111","url":null,"abstract":"<div><p>The automotive industry is on the brink of transitioning to autonomous vehicles (AVs). This will require highly flexible assembly systems. This paper focuses on exploiting the capabilities of the technology base, e.g., sensors and image recognition, of AVs as assembly items and employing their self-driving function in assembly systems. This fundamentally new approach to matrix manufacturing systems based on autonomously navigating automated guided vehicles (AGVs) and the elimination of set assembly sequences is a growing topic of discussion. This study develops a conceptual framework, based on a systematic literature review and interviews with fifteen experts from three carmakers, for exploring the field of research and assessing the feasibility of employing the technology base of autonomous driving instead of AGVs. This study is intended for assembly planners and researchers of assembly systems in automotive manufacturing.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100111"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49761708","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multi-criteria and real-time control of continuous battery cell production steps using deep learning","authors":"Erik Rohkohl ,&nbsp;Malte Schönemann ,&nbsp;Yury Bodrov ,&nbsp;Christoph Herrmann","doi":"10.1016/j.aime.2022.100108","DOIUrl":"10.1016/j.aime.2022.100108","url":null,"abstract":"<div><p>Electric vehicles driven by batteries are a key part of a sustainable mobility sector. Unfortunately, battery cell production is still associated with various negative environmental impacts, the use of critical raw materials and high manufacturing costs. The rising battery demand forces automotive original equipment manufacturers to drastically increase their capabilities over the next decades while fulfilling economical and ecological requirements. Continuous production technologies bear the potential to meet future battery cell demands by enabling higher throughputs compared to established batch processes. The control and optimization of continuous battery cell production steps with respect to product quality, manufacturing costs and environmental impacts is challenging due to high parameter spaces as well as temporal dependencies of production processes. Therefore, this study develops a controller that performs real-time optimization by proposing set parameters leading to desired quality, minimal costs and impacts of manufacturing activity. The controller is implemented using a deep learning model incorporating sequential information of the production process. A continuous mixing process with data acquired from a battery cell pilot line is used to validate the outlined controller. As result, the implementation for this use case achieves a relative error of 7.63% across all controllable parameters.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100108"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45652209","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Introducing a general-purpose augmented reality platform for the use in engineering education","authors":"Joshua Grodotzki,&nbsp;Benedikt Tobias Müller,&nbsp;A. Erman Tekkaya","doi":"10.1016/j.aime.2023.100116","DOIUrl":"10.1016/j.aime.2023.100116","url":null,"abstract":"<div><p>There is a lack of a universal Augmented Reality platform which can be used in manufacturing engineering and other education fields to display models, processes, animations and simulations alike. Such a platform has been developed as part of this contribution and enables instructors to manage online courses, teaching units and even entire study programs. To enhance the teaching in the classroom by using Augmented Reality visualizations, a new application has been developed, which runs on iOS as well as Android systems and displays the various objects along with additional information uploaded by the instructors. A novel storage format was devised which reduces the storage size of various models significantly wherefore performance on the phone's end is improved. Various common 3D file formats, such as STL, OFF and OBJ, can be imported and automatically converted to this new format. The same applies for results from FEM software Abaqus, MoldFlow and HyperXtrude. Results formatted to be analyzed by the popular pre-/post-processor GiD can also be uploaded at no additional expense. The users of the smartphone app can view, inspect and interact with the models and animations. The platform and app are designed for an easy-to-use setup by the educators and an intuitive use by the students.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100116"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47659959","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigations on the thermal conditions during laser beam welding of high-strength steel 100Cr6","authors":"Eric Wasilewski,&nbsp;Nikolay Doynov,&nbsp;Ralf Ossenbrink,&nbsp;Vesselin Michailov","doi":"10.1016/j.aime.2023.100118","DOIUrl":"10.1016/j.aime.2023.100118","url":null,"abstract":"<div><p>This study examines the thermal conditions during laser beam welding of 100Cr6 high-strength steel using a TruDisk5000 disc laser with a continuous adjustable power range of 100–5000 W. Two parameter sets, characterized by laser power and welding speeds, were analyzed by thermal-metallurgical FE simulations to determine their impact on the thermal conditions during welding. The results show a significant shift in heat coupling, with conduction transitioning to deep penetration welding. As a result of the high welding speeds and reduced energy input, extremely high heating rates up to 2∙10⁴ K s⁻¹ (set A) respectively 4∙10⁵ K s⁻¹ (set B) occur. Both welds thus concern a range of temperature state values for which conventional Time-Temperature-Austenitization (TTA) diagrams are currently not defined, requiring calibration of the material models through general assumptions. Also, the change in energy input and welding speed causes significantly steep temperature gradients with a slope of approximately 5∙10³ K mm⁻¹ and strong drops in the temperature rates, particularly in the heat affected zone. The temperature cycles also show very different cooling rates for the respective parameter sets, although in both cases they are well below a cooling time t_8/5 of 1 s, so that the phase transformation always leads to the formation of martensite. Since the investigated parameters are known to cause a loss of technological strength and conditionally result in cold cracks, these results will be used for further detailed experimental and numerical investigation of microstructure, hydrogen distribution, and stress-strain development at different restraint conditions.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100118"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46357741","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Creation of self-hardening aluminum phosphate binders for manufacturing foundry cores","authors":"I. Petryk ,&nbsp;R. Liutyi ,&nbsp;А. Kocheshkov ,&nbsp;A. Myslyvchenko ,&nbsp;D. Liuta","doi":"10.1016/j.aime.2023.100114","DOIUrl":"10.1016/j.aime.2023.100114","url":null,"abstract":"<div><p>The aims of this publication is to study the physical and chemical conditions of formation of self-hardening aluminum phosphate binders based on orthophosphoric acid and fine-grained aluminum powder, research of its chemical structure and properties of core mixtures for foundry production.</p><p>The methods used in the work are: X-ray phase analysis on the Rigaku Ultima IV, differential thermogravimetric analysis on the STA 449 C. Orthophosphoric acid 85% concentration and finely dispersed aluminum powder were used as materials. Samples of core mixtures were made on the basis of quartz sand with an average particle size of 0.2 … 0.3 mm.</p><p>As a result of the experiments, it was established that in the system of orthophosphoric acid and finely dispersed aluminum powder, a chemical interaction occurs at ambient temperature, which leads to the formation of a phosphate binder. It has been confirmed that it is aluminum orthophosphate in the form of berlinite, and it does not undergo phase transformations, namely it is thermally stable when heated from 20 to 1000 оС. A significant advantage for core mixtures in foundry production is that the chemical interaction in this system does not begin immediately after mixing the components, but after 5 … 10 min, which is explained by the presence of protective oxide or hydroxide films on the aluminum particles. This ensures the period of technological suitability of the core mixture, and subsequently ensures its self-hardening.</p><p>In contrast to previously known aluminum phosphate binders, which required heating from 200 to 300 оС for their hardening, a self-hardening aluminum phosphate binders and the core mixture based on it were created for the first time.</p><p>With the amount of 2 … 3% of orthophosphoric acid and 1 … 2% of aluminum powder, after 1 h the strength indicators of the mixture based on quartz sand exceed 1 MPa, which is sufficient for the production of foundry cores.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100114"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48595337","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Impact of additive manufacturing on titanium supply chain: Case of titanium alloys in automotive and aerospace industries","authors":"Patricia Nyamekye ,&nbsp;Saeed Rahimpour Golroudbary ,&nbsp;Heidi Piili ,&nbsp;Pasi Luukka ,&nbsp;Andrzej Kraslawski","doi":"10.1016/j.aime.2023.100112","DOIUrl":"https://doi.org/10.1016/j.aime.2023.100112","url":null,"abstract":"<div><p>Additive manufacturing (AM) is a promising technology for designing complex metallic pieces for different sectors with resource and time effectiveness. Titanium (Ti) is an essential critical material for AM development. AM can produce intricate and cost-effective components with Ti alloys for the transportation sector which would not be possible with conventional manufacturing (CM) technologies. This study assesses the impact of AM on the life cycle of Ti and its alloys by using review (numerical data, case examples) and dynamics simulation modelling. This article quantifies potential environmental benefits and examines aspects related to using Ti alloys in the automotive and aerospace industries. Mass flow, energy consumption and related greenhouse gas (GHG) emissions are assessed by making a comparison between subcategories of AM including binder jetting (BJT), directed energy deposition (DED), electron beam-based powder bed fusion (EB-PBF), and laser-based powder bed fusion (L-PBF) and CM processes including forging, milling, machining, and die casting. The results show that the AM subcategories considered potentially reduce manufacturing phase energy consumption and GHG emissions except for L-PBF. The findings highlight that an inclusive consideration of all life cycle phases is needed to fully identify potential benefits of AM for industries. Also, the scenario analysis in this study proposes the opportunity for saving mass and minimizing energy consumption and GHG emissions by optimizing the structural design and manufacturing processes for Ti components.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100112"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49734266","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental investigation on surface topography in submerged abrasive waterjet cutting of Ti6Al4V","authors":"Paramjit Mahesh Thakur,&nbsp;Dadarao Niwrutti Raut","doi":"10.1016/j.aime.2023.100113","DOIUrl":"10.1016/j.aime.2023.100113","url":null,"abstract":"<div><p>Some of the key issues with AWJ technology are high roughness, low depth of smooth zone, and grit embedment. When compared to the unsubmerged AWJ, the submerged AWJ gives less divergence and produces higher energy at the cross section of the jet. Hence, this study examined the effects of pressure, traverse rate, and standoff distance on roughness, depth of smooth zone, and grit embedment in both AWJ conditions. Here, single factor experiments are conducted for experimental investigation wherein one factor is varied and the others are kept constant. In comparison, the submerged AWJ gave significant improvement in the roughness and depth of the smooth zone at lower levels of pressure (150 and 200 MPa), higher levels of traverse rate (300 and 350 mm/min) and standoff distance (4, 5 and 6 mm). The significant difference in grit embedment was observed at lower levels of traverse rate (150 and 200 mm/min), higher levels of pressure (300 and 350 MPa), and all the levels of standoff distance (2, 3, 4, 5, and 6 mm). The grit embedment in the submerged condition was lower due to the removal of initially embedded grits due to flushing action produced by cavitation initiation.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"6 ","pages":"Article 100113"},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45110732","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}