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Towards Sustainable Manufacturing Processes
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Towards Sustainable Manufacturing Processes

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: closed (31 January 2019) | Viewed by 50626

Special Issue Editor

Prof. Dr. Hossam Kishawy

E-Mail Website
Guest Editor
Department of Automotive, Mechanical and Manufacturing Engineering, Faculty of Engineering and Applied Science, University of Ontario Institute of Technology, 2000 Simcoe Street North, Oshawa, ON L1H 7K4, Canada
Interests: manufacturing; sustainable machining processes; modeling and optimization

Special Issue Information

Dear Colleagues, 

During the past decades, health and environmental concerns have arisen because of the pollution and consumption of natural resources. To address these concerns and provide effective solutions, sustainability has become an essential feature of modern manufacturing. Providing environmentally friendly processes and optimizing energy consumption are two essential requirements to achieve sustainable manufacturing. The concept of sustainable manufacturing is described and analyzed at three main levels, namely, product, process, and system. The interaction among the three levels paves the road to achieve the desired goals.  Environmental, economic, and social aspects of sustainability have to be taken into account to ensure an effective utilization of the available resources.

With this in mind, a Special Issue entitled “Towards Sustainable Manufacturing Processes” is being launched. This Special Issue includes high-quality papers dealing with modeling, simulation, optimization, and assessment of sustainable manufacturing processes. Both original research articles as well as review articles are welcome.

Prof. Hossam Kishawy
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Published Papers (6 papers)

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Research

Jump to: Review, Other

12 pages, 2758 KiB  
Article
Sustainability Assessment during Machining Ti-6Al-4V with Nano-Additives-Based Minimum Quantity Lubrication
by Hossam A. Kishawy, Hussien Hegab, Ibrahim Deiab and Abdelkrem Eltaggaz
J. Manuf. Mater. Process. 2019, 3(3), 61; https://doi.org/10.3390/jmmp3030061 - 24 Jul 2019
Cited by 46 | Viewed by 4298
Abstract
The implementation of sustainable machining process can be accomplished by different strategies including process optimization and selection of the proper lubrication techniques and cutting conditions. The present study is carried out from the perspective of a sustainability assessment of turning Ti-6Al-4V by employing [...] Read more.
The implementation of sustainable machining process can be accomplished by different strategies including process optimization and selection of the proper lubrication techniques and cutting conditions. The present study is carried out from the perspective of a sustainability assessment of turning Ti-6Al-4V by employing minimum quantity lubrication (MQL) and MQL-nanofluid with consideration of the surface quality, tool wear, and power consumption. A sustainability assessment algorithm was used to assess the cutting processes of Ti-6Al-4V alloy under a minimum quantity of lubrication–nanofluid to estimate the levels of sustainable design variables. The assessment included the sustainable indicators as well as the machining responses in a single integrated model. The sustainable aspects included in this study were; environmental impact, management of waste, and safety and health issues of operators. The novelty here lies in employing a comprehensive sustainability assessment model to discuss and understand the machining process with MQL-nanofluid, by not only considering the machining quality characteristics, but also taking into account different sustainability indicators. In order to validate the effectiveness of the sustainability results, a comparison between the optimal and predicted responses was conducted and a good agreement was noticed. It should be stated that MQL-nanofluid showed better results compared to the cutting tests conducted under using classical MQL. Full article
(This article belongs to the Special Issue Towards Sustainable Manufacturing Processes)
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11 pages, 11965 KiB  
Article
Laser Surface Structuring of Cemented Carbide for improving the Strength of Induction Brazed Joints
by Ammar Ahsan, Igor Kryukov and Stefan Böhm
J. Manuf. Mater. Process. 2019, 3(2), 44; https://doi.org/10.3390/jmmp3020044 - 3 Jun 2019
Cited by 5 | Viewed by 3825
Abstract
The effect of micro patterning of cemented carbide surface using nanosecond diode pumped solid-state pulsed laser on the strength of induction brazed carbide and steel joints has been investigated. Surface patterns increase the total surface area of the joint and, for an originally [...] Read more.
The effect of micro patterning of cemented carbide surface using nanosecond diode pumped solid-state pulsed laser on the strength of induction brazed carbide and steel joints has been investigated. Surface patterns increase the total surface area of the joint and, for an originally hydrophilic surface, increase the wettability of a liquid on a solid surface such that, instead of building droplets, the liquid spreads and flows on the surface. Microcomputed tomography (µ-CT) was used to observe the filler/carbide interface after brazing and to analyze the presence of porosity or remnant flux in the joint. Microstructures of the brazed joints with various surface patterns were analyzed using scanning electron microscopy. The strength of the joints was measured using shear tests. Results have shown that the groove pattern on the surface of carbide increases the joint strength by 70–80%, whereas, surface patterns of bi-directional grooves (grid) reduced the joint strength drastically. Dimples on the carbide surface did not show any improvement in the strength of the brazed joints compared to samples with no surface pattern. Full article
(This article belongs to the Special Issue Towards Sustainable Manufacturing Processes)
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12 pages, 3537 KiB  
Article
Effect of Water-Based Nanolubricants in Ultrasonic Vibration Assisted Grinding
by Mir Majid Molaie, Ali Zahedi and Javad Akbari
J. Manuf. Mater. Process. 2018, 2(4), 80; https://doi.org/10.3390/jmmp2040080 - 3 Dec 2018
Cited by 14 | Viewed by 3720
Abstract
Currently, because of stricter environmental standards and highly competitive markets, machining operations, as the main part of the manufacturing cycle, need to be rigorously optimized. In order to simultaneously maximize the production quality and minimize the environmental issues related to the grinding process, [...] Read more.
Currently, because of stricter environmental standards and highly competitive markets, machining operations, as the main part of the manufacturing cycle, need to be rigorously optimized. In order to simultaneously maximize the production quality and minimize the environmental issues related to the grinding process, this research study evaluates the performance of minimum quantity lubrication (MQL) grinding using water-based nanofluids in the presence of horizontal ultrasonic vibrations (UV). In spite of the positive impacts of MQL using nanofluids and UV which are extensively reported in the literature, there is only a handful of studies on concurrent utilization of these two techniques. To this end, for this paper, five kinds of water-based nanofluids including multiwall carbon nanotube (MWCNT), graphite, Al2O3, graphene oxide (GO) nanoparticles, and hybrid Al2O3/graphite were employed as MQL coolants, and the workpiece was oscillated along the feed direction with 21.9 kHz frequency and 10 µm amplitude. Machining forces, specific energy, and surface quality were measured for determining the process efficiency. As specified by experimental results, the variation in the material removal nature made by ultrasonic vibrations resulted in a drastic reduction of the grinding normal force and surface roughness. In addition, the type of nanoparticles dispersed in water had a strong effect on the grinding tangential force. Hybrid Al2O3/graphite nanofluid through two different kinds of lubrication mechanisms—third body and slider layers—generated better lubrication than the other coolants, thereby having the lowest grinding forces and specific energy (40.13 J/mm3). It was also found that chemically exfoliating the graphene layers via oxidation and then purification prior to dispersion in water promoted their effectiveness. In conclusion, UV assisted MQL grinding increases operation efficiency by facilitating the material removal and reducing the use of coolants, frictional losses, and energy consumption in the grinding zone. Improvements up to 52%, 47%, and 61%, respectively, can be achieved in grinding normal force, specific energy, and surface roughness compared with conventional dry grinding. Full article
(This article belongs to the Special Issue Towards Sustainable Manufacturing Processes)
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14 pages, 3670 KiB  
Article
A Computer-Aided Sustainable Modelling and Optimization Analysis of CNC Milling and Turning Processes
by Karmjit Singh and Ibrahim A. Sultan
J. Manuf. Mater. Process. 2018, 2(4), 65; https://doi.org/10.3390/jmmp2040065 - 27 Sep 2018
Cited by 13 | Viewed by 3881
Abstract
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 [...] Read more.
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. Full article
(This article belongs to the Special Issue Towards Sustainable Manufacturing Processes)
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Review

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23 pages, 6052 KiB  
Review
Support Structures for Additive Manufacturing: A Review
by Jingchao Jiang, Xun Xu and Jonathan Stringer
J. Manuf. Mater. Process. 2018, 2(4), 64; https://doi.org/10.3390/jmmp2040064 - 20 Sep 2018
Cited by 366 | Viewed by 27956
Abstract
Additive manufacturing (AM) has developed rapidly since its inception in the 1980s. AM is perceived as an environmentally friendly and sustainable technology and has already gained a lot of attention globally. The potential freedom of design offered by AM is, however, often limited [...] Read more.
Additive manufacturing (AM) has developed rapidly since its inception in the 1980s. AM is perceived as an environmentally friendly and sustainable technology and has already gained a lot of attention globally. The potential freedom of design offered by AM is, however, often limited when printing complex geometries due to an inability to support the stresses inherent within the manufacturing process. Additional support structures are often needed, which leads to material, time and energy waste. Research in support structures is, therefore, of great importance for the future and further improvement of additive manufacturing. This paper aims to review the varied research that has been performed in the area of support structures. Fifty-seven publications regarding support structure optimization are selected and categorized into six groups for discussion. A framework is established in which future research into support structures can be pursued and standardized. By providing a comprehensive review and discussion on support structures, AM can be further improved and developed in terms of support waste in the future, thus, making AM a more sustainable technology. Full article
(This article belongs to the Special Issue Towards Sustainable Manufacturing Processes)
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Other

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27 pages, 25817 KiB  
Data Descriptor
Full-Density Fused Deposition Modeling Dimensional Error as a Function of Raster Angle and Build Orientation: Large Dataset for Eleven Materials
by Sherri L. Messimer, Tais Rocha Pereira, Albert E. Patterson, Maliha Lubna and Fabiano O. Drozda
J. Manuf. Mater. Process. 2019, 3(1), 6; https://doi.org/10.3390/jmmp3010006 - 14 Jan 2019
Cited by 41 | Viewed by 6301
Abstract
This paper describes the collection of a large dataset (6930 measurements) on dimensional error in the fused deposition modeling (FDM) additive manufacturing process for full-density parts. Three different print orientations were studied, as well as seven raster angles ( 0 ∘ , [...] Read more.
This paper describes the collection of a large dataset (6930 measurements) on dimensional error in the fused deposition modeling (FDM) additive manufacturing process for full-density parts. Three different print orientations were studied, as well as seven raster angles ( 0 ∘ , 15 ∘ , 30 ∘ , 45 ∘ , 60 ∘ , 75 ∘ , and 90 ∘ ) for the rectilinear infill pattern. All measurements were replicated ten times on ten different samples to ensure a comprehensive dataset. Eleven polymer materials were considered: acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), high-temperature PLA, wood-composite PLA, carbon-fiber-composite PLA, copper-composite PLA, aluminum-composite PLA, high-impact polystyrene (HIPS), polyethylene terephthalate glycol-enhanced (PETG), polycarbonate, and synthetic polyamide (nylon). The samples were ASTM-standard impact-testing samples, since this geometry allows the measurement of error on three different scales; the nominal dimensions were 3.25 mm thick, 63.5 mm long, and 12.7 mm wide. This dataset is intended to give engineers and product designers a basis for judging the accuracy and repeatability of the FDM process for use in manufacturing of end-user products. Full article
(This article belongs to the Special Issue Towards Sustainable Manufacturing Processes)
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