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Machines
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Sustainable Manufacturing and Green Processing Methods
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Sustainable Manufacturing and Green Processing Methods

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Material Processing Technology".

Deadline for manuscript submissions: closed (30 September 2024) | Viewed by 10152

Special Issue Editors

Prof. Dr. Ali Khalfallah

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Guest Editor
Departamento de Engenharia Mecânica, Faculdade de Ciências e Tecnologia, Pólo 2 da Universidade de Coimbra, Rua Luís Reis Santos, Pinhal de Marrocos, 3030-788 Coimbra, Portugal
Interests: multidisciplinary modeling of the mechanical behavior of materials; identification of thin-film properties; combination of computational physics, artificial intelligence, multi-scale simulations and materials characterization; recent exploration into tribology
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Carlos Leitao

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Guest Editor
Department of Mechanical Engineering, University of Coimbra, 3030-788 Coimbra, Portugal
Interests: friction stir welding; modelling; aluminum; mechanical characterization; digital image correlation; plasticity and microstructural characterization
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The field of material processing technology plays a pivotal role in shaping the future of numerous industries, ranging from electronics and aerospace to healthcare and energy. As advancements continue to drive innovation, there is an increasing need to address the environmental impact associated with processing methods. The urgent demand for sustainable manufacturing practices and the adoption of green processing technologies has propelled research endeavors aimed at minimizing the environmental footprint while maintaining or enhancing the performance of manufactured components.

This Special Issue aims to explore the latest developments and cutting-edge research in sustainable manufacturing and green processing methods within the domain of material processing technology. By focusing on mitigating the environmental impact of material processing, this Issue seeks to highlight the interdisciplinary efforts in designing eco-friendly approaches, novel energy-efficient processing methods, and innovative technologies to achieve sustainable and green manufacturing processes. Additionally, this Special Issue intends to foster an exchange of knowledge, ideas, and advancements among researchers, engineers, and practitioners working in the field of manufacturing. By featuring a diverse collection of high-quality contributions, we aspire to facilitate an in-depth understanding of sustainable manufacturing practices, green processing techniques, and their implications across various production systems and industries.

Potential topics include, but are not limited to:

eco-friendly manufacturing processing; energy-efficient manufacturing processes and technologies; waste reduction strategies and recycling methods; green solvents and chemicals in material processing; and life cycle assessment of manufacturing technologies.

Prof. Dr. Ali Khalfallah
Prof. Dr. Carlos Leitao
Guest Editors

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. Machines is an international peer-reviewed open access monthly 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 2400 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.

Keywords

  •  sustainable manufacturing
  •  green processing methods
  •  environmental impact
  •  eco-friendly processing technologies
  •  energy-efficient processes
  •  waste reduction
  •  recycling methods
  •  environmental footprint
  •  renewable resources
  •  carbon footprint
  •  resource efficiency
  •  process optimization for waste reduction
  •  environmental sustainability
  •  circular economy
  •  clean production

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Further information on MDPI's Special Issue polices can be found here.

Related Special Issue

Published Papers (6 papers)

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Editorial

Jump to: Research, Review

3 pages, 179 KiB  
Editorial
Sustainable Manufacturing and Green Processing Methods
by Ali Khalfallah and Carlos Leitão
Machines 2024, 12(11), 815; https://doi.org/10.3390/machines12110815 - 15 Nov 2024
Viewed by 535
Abstract
Sustainable manufacturing and green processing methods have gained immense relevance over recent years due to pressing concerns over environmental degradation, resource scarcity, and industrial waste [...] Full article
(This article belongs to the Special Issue Sustainable Manufacturing and Green Processing Methods)

Research

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15 pages, 14594 KiB  
Article
Enhancing Machinability and Sustainability: The Effects of Hybrid MQL+CO2 Cooling on the Drilling of AA7075T6 with TiO2 and C-Reinforced Composites
by Shaonan Chen, Shao He, Guisheng Zhao, Guodong Chen and Yapeng Xu
Machines 2024, 12(7), 449; https://doi.org/10.3390/machines12070449 - 29 Jun 2024
Cited by 2 | Viewed by 747
Abstract
This study investigates the impact of various auxiliary cooling techniques on machinability, energy consumption, carbon emissions, and economic factors in the drilling process of AA7075T6 aluminium alloy using TiO2 and C-reinforced composites. The study employed various cooling conditions (dry, MQL, CO2 [...] Read more.
This study investigates the impact of various auxiliary cooling techniques on machinability, energy consumption, carbon emissions, and economic factors in the drilling process of AA7075T6 aluminium alloy using TiO2 and C-reinforced composites. The study employed various cooling conditions (dry, MQL, CO2, and hybrid MQL+CO2), with different cutting speeds and feed rates, to evaluate their effects on drilling characteristics. The findings indicated that the combined MQL and CO2 cooling notably enhanced the drilling process by reducing cutting forces by 32% and surface roughness by 65% compared to dry cutting. This synergy between lubrication and cooling significantly improves machinability, resulting in higher-quality machining outputs with smoother surfaces and more precise circularity. Energy analysis revealed that the MQL+CO2 method reduces energy consumption to 64% observed under dry conditions, underscoring its efficiency through better heat dissipation and reduced friction. Furthermore, this method demonstrates a significant reduction in carbon emissions, contributing to environmental sustainability. Economically, although initial costs associated with the implementation of cooling systems are higher, they are offset by reduced tool wear and energy costs, making it a viable solution for sustainable manufacturing practices. Full article
(This article belongs to the Special Issue Sustainable Manufacturing and Green Processing Methods)
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46 pages, 4545 KiB  
Article
3D Printer Selection for the Sustainable Manufacturing Industry Using an Integrated Decision-Making Model Based on Dombi Operators in the Fermatean Fuzzy Environment
by Ömer Faruk Görçün, Sarfaraz Hashemkhani Zolfani, Hande Küçükönder, Jurgita Antucheviciene and Miroslavas Pavlovskis
Machines 2024, 12(1), 5; https://doi.org/10.3390/machines12010005 - 20 Dec 2023
Cited by 7 | Viewed by 2014
Abstract
Three-dimensional printers (3DPs), as critical parts of additive manufacturing (AM), are state-of-the-art technologies that can help practitioners with digital transformation in production processes. Three-dimensional printer performance mostly depends on good integration with artificial intelligence (AI) to outperform humans in overcoming complex tasks using [...] Read more.
Three-dimensional printers (3DPs), as critical parts of additive manufacturing (AM), are state-of-the-art technologies that can help practitioners with digital transformation in production processes. Three-dimensional printer performance mostly depends on good integration with artificial intelligence (AI) to outperform humans in overcoming complex tasks using 3DPs equipped with AI technology, particularly in producing an object with no smooth surface and a standard geometric shape. Hence, 3DPs also provide an opportunity to improve engineering applications in manufacturing processes. As a result, AM can create more sustainable production systems, protect the environment, and reduce external costs arising from industries’ production activities. Nonetheless, practitioners do not have sufficient willingness since this kind of transformation in production processes is a crucial and irrevocable decision requiring vast knowledge and experience. Thus, presenting a methodological frame and a roadmap may help decision-makers take more responsibility for accelerating the digital transformation of production processes. The current study aims to fill the literature’s critical theoretical and managerial gaps. Therefore, it suggests a powerful and efficient decision model for solving 3DP selection problems for industries. The suggested hybrid FF model combines the Fermatean Fuzzy Stepwise Weight Assessment Ratio Analysis (FF–SWARA) and the Fermatean Ranking of Alternatives through Functional mapping of criterion sub-intervals into a Single Interval (FF–RAFSI) approaches. The novel FF framework is employed to solve a critical problem encountered in the automobile manufacturing industry with the help of two related case studies. In addition, the criteria are identified and categorized regarding their influence degrees using a group decision approach based on an extended form of the Delphi with the aid of the Fermatean fuzzy sets. According to the conclusions of the analysis, the criteria “Accuracy” and “Quality” are the most effective measures. Also, the suggested hybrid model and its outcomes were tested by executing robustness and validation checks. The results of the analyses prove that the suggested integrated framework is a robust and practical decision-making tool. Full article
(This article belongs to the Special Issue Sustainable Manufacturing and Green Processing Methods)
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21 pages, 5006 KiB  
Article
Evaluation of Machining Variables on Machinability of Nickel Alloy Inconel 718 Using Coated Carbide Tools
by Muhammad Iftikhar Faraz and Jana Petru
Machines 2024, 12(1), 4; https://doi.org/10.3390/machines12010004 - 20 Dec 2023
Cited by 5 | Viewed by 1533
Abstract
The current work was undertaken with the research aim of experimental examination of tool wear, surface roughness and burr formation during the micro-milling of Inconel 718 using different coated tools. Inconel 718 is one of the most widely used materials for purpose-oriented utilization [...] Read more.
The current work was undertaken with the research aim of experimental examination of tool wear, surface roughness and burr formation during the micro-milling of Inconel 718 using different coated tools. Inconel 718 is one of the most widely used materials for purpose-oriented utilization owing to its preferred mechanical and physical properties, including high strength and corrosion resistance. On the opposite end, the machining of Inconel 718 poses certain machinability challenges, which significantly elevates tool wear and subsequently surface roughness. Cutting speed, feed rate and depth of cut were selected as variable machining inputs. With reference to tool wear, all input variables were found to be significant, with tool coating having the highest contribution ratio of 36.19%. In case of surface roughness, cutting speed and tool coating were identified as effective input parameters with contribution ratios of 51.24% and 34.27%, respectively. Similarly, depth of cut proved to be an influential factor for burr height formation (in both up-milling and down-milling), whereas feed rate had the highest contribution ratios for burr width formation during up-milling and down-milling, i.e., 39.28% and 36.26%, respectively. Consequently, contour plots for output responses were drawn between significant parameters to analyze machinability. One of the vital research outcomes was the identification of a tool coating parameter that is significant for all four analyzed aspects of burr formation. In addition, regression equations were formulated for machining responses. The best- and worst-case scenarios for individual input parameters, as identified from main effects plots, were validated during confirmatory experimentation. Moreover, effects of input variables on output response were characterized using close-up imagery, and dominant wear mechanisms were also identified. The utility of the research is underlined by the optimization of the sustainability and productivity of the manufacturing process. Full article
(This article belongs to the Special Issue Sustainable Manufacturing and Green Processing Methods)
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15 pages, 3557 KiB  
Article
Parametric Analysis of Tool Wear, Surface Roughness and Energy Consumption during Turning of Inconel 718 under Dry, Wet and MQL Conditions
by M. Zeeshan Siddique, Muhammad Iftikhar Faraz, Shahid Ikramullah Butt, Rehan Khan, Jana Petru, Syed Husain Imran Jaffery, Muhammad Ali Khan and Abdul Malik Tahir
Machines 2023, 11(11), 1008; https://doi.org/10.3390/machines11111008 - 3 Nov 2023
Cited by 9 | Viewed by 1838
Abstract
Economy and productivity are the two most important elements of modern manufacturing systems. Economy is associated with energy-efficient operations, which results in an overall high input-to-output ratio, while productivity is related to quality and quantity. This specific work presents experimental investigations of the [...] Read more.
Economy and productivity are the two most important elements of modern manufacturing systems. Economy is associated with energy-efficient operations, which results in an overall high input-to-output ratio, while productivity is related to quality and quantity. This specific work presents experimental investigations of the use of cooling conditions (dry, MQL and wet) as input variables alongside other input parameters, including depth of cut, feed and cutting speed. This research aimed to investigate the variation in output responses including tool wear, specific cutting energy, and surface roughness while machining Inconel 718, a nickel-based super alloy. For experimentation, three levels of depth of cut, feed, and cutting speed were chosen. The Taguchi method was used for the experimental design. The contribution ratio of each input parameter was ascertained through analysis of variance (ANOVA). Use of coolant showed a positive effect on process parameters, particularly MQL. By adapting the optimum machining conditions, specific cutting energy was improved by 27%, whereas surface roughness and tool wear were improved by 15% and 30%, respectively. Full article
(This article belongs to the Special Issue Sustainable Manufacturing and Green Processing Methods)
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Review

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18 pages, 1338 KiB  
Review
Industrial Metabolism: A Multilevel Characterization for Designing Sustainable Manufacturing Systems
by Alejandro M. Martín-Gómez, María Jesús Ávila-Gutiérrez, Juan Ramón Lama-Ruiz and Francisco Aguayo-González
Machines 2024, 12(1), 16; https://doi.org/10.3390/machines12010016 - 27 Dec 2023
Cited by 2 | Viewed by 2402
Abstract
The development of industrial manufacturing systems has significant implications for society and the environment, often resulting in substantial waste generation. To address this issue and promote sustainable growth, the concept of industrial metabolism offers a promising approach. Industrial metabolism facilitates the circularity of [...] Read more.
The development of industrial manufacturing systems has significant implications for society and the environment, often resulting in substantial waste generation. To address this issue and promote sustainable growth, the concept of industrial metabolism offers a promising approach. Industrial metabolism facilitates the circularity of energy and material flows within the industrial environment, contributing to the establishment of more sustainable manufacturing systems. This paper provides a comprehensive analysis of industrial metabolism, highlighting its analogy with natural systems and categorizing models based on their application at different levels: macro (national or regional), meso (eco-industrial park), and micro (manufacturing plant or line). The analysis emphasizes the importance of considering the trophic network and evaluating the efficiency, cyclicality, toxicity, and resilience of industrial metabolic pathways. The proposed characterization of bioinspired industrial metabolism is positioned within the industrial environment. This positioning facilitates the design of manufacturing systems that emphasize circularity, drawing on frameworks applied at different levels within industrial metabolism. Full article
(This article belongs to the Special Issue Sustainable Manufacturing and Green Processing Methods)
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