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17 pages, 4328 KiB

Open AccessArticle

Parameter Optimization and Surface Roughness Prediction for the Robotic Adaptive Hydraulic Polishing of NAK80 Mold Steel

by Dequan Shi, Xiongyawei Zeng, Xuhui Wang and Huajun Zhang

Processes 2025, 13(4), 991; https://doi.org/10.3390/pr13040991 - 26 Mar 2025

Viewed by 211

Abstract

Pneumatic polishing tools are commonly used in traditional robot mold polishing systems, but they have problems with the stable control of mold surface roughness due to low precision and poor adaptability in polishing force adjustment. The integration of an adaptive hydraulic polishing (AHP) [...] Read more.

Pneumatic polishing tools are commonly used in traditional robot mold polishing systems, but they have problems with the stable control of mold surface roughness due to low precision and poor adaptability in polishing force adjustment. The integration of an adaptive hydraulic polishing (AHP) tool and robot system effectively solves the above problems, providing a robust solution for the high-precision polishing of various molds. This study systematically investigates the robotic polishing of NAK80 mold steel using an AHP-equipped robotic platform with 3M abrasive discs of progressively refined grit sizes (P180, P400, P800). Through single-factor experiments and response surface methodology, the effects of polishing force, rotational speed, and feeding speed on surface roughness were quantitatively analyzed. The relationship between surface roughness and the polishing parameters was derived to elucidate the roughness evolution before and after over-polishing. Orthogonal experiments combined with range analysis identified optimal parameter combinations for P180 (20 N polishing force, 5000 RPM rotational speed, and 5 mm·s⁻¹ feeding speed) and P400 abrasives (10 N polishing force, 4000 RPM rotational speed, and 5 mm·s⁻¹ feeding speed), achieving minimum surface roughness values of 0.08 µm and 0.044 µm, respectively. For P800 abrasives, a central composite design was used to develop a roughness prediction model with a ≤7.14% relative error, and the optimal parameters are a 20 N polishing force, a 5000 RPM rotational speed, and a 5 mm·s⁻¹ feeding speed. The sequential application of the optimized parameters across all the grit sizes can reduce the surface roughness from an initial 0.4 µm to a final 0.017 µm, representing a 95.75% improvement in the surface finish. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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18 pages, 5517 KiB

Open AccessArticle

Numerical Analysis on Mechanical Properties of 3D Five-Directional Circular Braided Composites

by Weiliang Zhang, Chunlei Li, Liang Li, Wei Wang, Lei Yang, Chaohang Zhang and Xiyue Zhang

Processes 2025, 13(3), 800; https://doi.org/10.3390/pr13030800 - 9 Mar 2025

Viewed by 632

Abstract

Based on the analysis of the motion law of 3D five-directional circular transverse braided fibers, this paper obtains the angle calculation formula between fibers and the local polar coordinate system in various cell models by transforming the position coordinates of fiber nodes. The [...] Read more.

Based on the analysis of the motion law of 3D five-directional circular transverse braided fibers, this paper obtains the angle calculation formula between fibers and the local polar coordinate system in various cell models by transforming the position coordinates of fiber nodes. The stress transformation matrix between the local coordinate system and the global coordinate system of any fiber in the circular braided single cell is derived without considering the physical force on the single-cell micro-hexahedron unit. The calculation formulas of braided parameters such as the overall stiffness matrix and fiber volume content of the circular braided composite material after considering the matrix are derived by using the volume average method; the length of braided knuckles is 2 mm, the inner diameter of inner cells is 7 mm, the number of radial and axial braided yarns is 80, the height of inner cells is 0.5 mm, and the filling coefficient is 0.61. Comparing the results of the numerical prediction model with the experimental results in reference, it is found that the error of the numerical prediction model deduced in this paper is small. Therefore, this model can be used to fully study the effects of braided parameters such as cell inner diameter, cell height, and node length on the mechanical properties of composites. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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19 pages, 7258 KiB

Open AccessArticle

Exploring Post-Machining Alternatives Under Dry Conditions for Thin-Walled Additive Manufacturing Components Aided by Infrared Thermography

by Eduard Garcia-Llamas, Giselle Ramirez, Miguel Fuentes, Eduard Vidales and Jaume Pujante

Processes 2025, 13(3), 717; https://doi.org/10.3390/pr13030717 - 1 Mar 2025

Viewed by 735

Abstract

Additive manufacturing (AM) techniques have transformed the production of parts and components with intricate geometries and customized designs, driving innovation in sustainable manufacturing practices. The additive manufacturing technology used in this work was selective laser melting (SLM), a process that uses laser energy [...] Read more.

Additive manufacturing (AM) techniques have transformed the production of parts and components with intricate geometries and customized designs, driving innovation in sustainable manufacturing practices. The additive manufacturing technology used in this work was selective laser melting (SLM), a process that uses laser energy to sinter powdered metals into solid structures. Among the various materials utilized in AM, Ti6Al4V titanium alloys are of particular interest due to their favorable mechanical properties, corrosion resistance, biocompatibility, and potential for reducing material waste. However, the machining of additively manufactured titanium parts presents challenges due to the material’s low conductivity, elastic modulus, and chemical affinity with cutting tools, which impact tool wear and surface finish quality. Milling, a commonly employed process for finishing titanium parts, often involves significant energy use and tool wear, highlighting the need for optimized and eco-conscious machining strategies. This study aims to establish correlations among four key aspects: (1) surface finish of machined Ti6Al4V AM parts, (2) cutting tool damage, (3) dry milling parameters including different cutting tools, and (4) variation of temperature at the contact surface of AM parts and tools using infrared thermography. By examining parameters such as feed per tooth (Fz), axial depth of cut (Ap), spindle trajectories (trochoidal, helicoidal, and linear), and cutting tool diameters, this work identifies conditions that enhance process efficiency while reducing environmental impact. Infrared thermography provides insights into temperature variations during milling, correlating these changes to surface roughness and critical machining parameters, thus contributing to the development of sustainable and high-performance manufacturing practices. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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28 pages, 24348 KiB

Open AccessArticle

TopADDPi: An Affordable and Sustainable Raspberry Pi Cluster for Parallel-Computing Topology Optimization

by Zhi-Dong Zhang, Dao-Yuan Yu, Osezua Ibhadode, Liang Meng, Tong Gao, Ji-Hong Zhu and Wei-Hong Zhang

Processes 2025, 13(3), 633; https://doi.org/10.3390/pr13030633 - 24 Feb 2025

Viewed by 676

Abstract

Parallel-Computing Topology Optimization (PCTO) has gained importance, especially with the advancement of additive manufacturing (AM), due to its ability to tackle high-dimensional, high-resolution challenges. PCTO is highly relevant to sustainable manufacturing processes and technologies, enabling resource-efficient designs, reduced emissions, and advancements in Industry [...] Read more.

Parallel-Computing Topology Optimization (PCTO) has gained importance, especially with the advancement of additive manufacturing (AM), due to its ability to tackle high-dimensional, high-resolution challenges. PCTO is highly relevant to sustainable manufacturing processes and technologies, enabling resource-efficient designs, reduced emissions, and advancements in Industry 4.0 integration. However, PCTO poses difficulties for newcomers or researchers, mainly because of its reliance on non-traditional computing environments and the limited availability of high-performance computing (HPC) resources. Addressing this, the study introduces TopADDPi, a Raspberry Pi-based cluster system, which has been purpose-built to facilitate learning and research in PCTO. It provides detailed instructions for assembling and configuring a Raspberry Pi cluster, with a focus on cost-effectiveness and ease of use. The study thoroughly investigates how different hardware and software configurations affect computing efficiency. In addition, through extensive numerical testing, the performance, energy consumption, and environmental impact of the Raspberry Pi cluster are benchmarked against conventional computing systems. The findings demonstrate the cluster’s advantages in handling parallel computing, its indispensable role in debugging, its remarkable energy efficiency, and its significantly reduced carbon footprint compared to conventional systems. These attributes establish the Raspberry Pi cluster as an invaluable tool for both educational and research applications in structural engineering, offering an affordable, sustainable, and indispensable solution for PCTO. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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17 pages, 3446 KiB

Open AccessArticle

Quality Control of Electro-Discharge Texturing of Rolls Through Six Sigma

by Emil Evin, Vladimír Kokarda and Miroslav Tomáš

Processes 2025, 13(2), 450; https://doi.org/10.3390/pr13020450 - 7 Feb 2025

Viewed by 524

Abstract

This article presents the implementation of the Six Sigma methodology in the electro-discharge texturing process of cold mill work rolls. The final surface quality of sheet metal must meet the specific demands of car body part producers, which require a specific surface texture [...] Read more.

This article presents the implementation of the Six Sigma methodology in the electro-discharge texturing process of cold mill work rolls. The final surface quality of sheet metal must meet the specific demands of car body part producers, which require a specific surface texture described by surface microgeometry parameters: the average roughness and the peak density. The requirements for the surface microgeometry of sheet metal are mainly related to improving the formability and adhesion of the paint in the body painting process. These microgeometry parameters can be controlled by the texture of work rolls: this texture is transferred onto the sheet metal surface. The electro-discharge texturing process allows for control of the average roughness and peak density according to individual customer specifications. In this study, a model is proposed to predict the average roughness based on the input parameters of the electro-discharge texturing process: current, voltage, and time. Compared to previous models, this model includes more input parameters. The process suitability was analyzed using control charts, capability indices, and Z scores. The modified weighted product method was used to create a purpose function describing the relationships between the input and output quality parameters. Based on the agreement of the target quality characteristics and the calculated values according to the models obtained, an algorithm to control the texturing process of the work rolls was designed. The proposed model was also validated on results published by other authors and demonstrated good agreement. This study should contribute to the philosophy of continuously improving the surface quality of cold-rolled sheet metal. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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35 pages, 3708 KiB

Open AccessArticle

Circularity and Digitalisation in German Textile Manufacturing: Towards a Blueprint for Strategy Development and Implementation

by Tina Wiegand and Martin Wynn

Processes 2024, 12(12), 2697; https://doi.org/10.3390/pr12122697 - 29 Nov 2024

Viewed by 1595

Abstract

Textile and clothing (T&C) production and consumption have been steadily increasing for many years, accompanied by significant resource consumption, waste generation, and environmental impact. Germany holds a pivotal position in the industry, both within the EU and globally, as a leading producer, importer, [...] Read more.

Textile and clothing (T&C) production and consumption have been steadily increasing for many years, accompanied by significant resource consumption, waste generation, and environmental impact. Germany holds a pivotal position in the industry, both within the EU and globally, as a leading producer, importer, and exporter of T&C. The circular economy (CE) concept has emerged as a promising solution to address the industry’s negative impacts by emphasising the reduction, reuse, and recycling of resources across the value chain. Digital technologies (DTs) are increasingly recognised as key enablers and facilitators of this transition, promoting both efficiency and circularity in manufacturing processes. However, the extent to which these are implemented in the German T&C industry remains largely underexplored. This study seeks to investigate the role of DTs in advancing CE practices within German T&C manufacturing. Employing process mapping and technology profiling, this research adopts an inductive, qualitative approach based on primary interview data to explore three key areas: (1) current CE practices, (2) the deployment of supportive DTs, and (3) the challenges in implementing the CE and DTs. The findings reveal that CE adoption is set to accelerate among T&C manufacturers, driven by regulatory compliance and market pressures, with DTs playing a critical role in enabling this transition. This study proposes a new operational framework designed to facilitate the shift towards a more circular textile sector, aligning with the ambitious goals of the European Union and broader environmental and societal objectives. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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26 pages, 6021 KiB

Open AccessArticle

Towards Sustainability in Hydraulic Machinery Manufacturing by 3D Printing

by Abel Remache, Modesto Pérez-Sánchez, Víctor Hugo Hidalgo, Helena M. Ramos and Francisco-Javier Sánchez-Romero

Processes 2024, 12(12), 2664; https://doi.org/10.3390/pr12122664 - 26 Nov 2024

Cited by 2 | Viewed by 4650

Abstract

Material wear, maintenance costs, performance, efficiency, and corrosion are some of the issues that turbomachinery impellers may encounter. The optimization of impellers through additive manufacturing (AM) has been the focus of extensive research, aiming to address these challenges in turbine, pump, compressor, fan, [...] Read more.

Material wear, maintenance costs, performance, efficiency, and corrosion are some of the issues that turbomachinery impellers may encounter. The optimization of impellers through additive manufacturing (AM) has been the focus of extensive research, aiming to address these challenges in turbine, pump, compressor, fan, and mixer components. This research aims to identify and analyze the main techniques currently being developed to tackle several of these issues. Evaluating the published research, the methodology highlights various AM techniques applied to impellers and related components, as well as the diverse materials used in functional system elements. The analysis revealed that the most commonly used additive manufacturing technologies for the production of turbomachinery components are FDM, with a 22% application rate, and powder bed fusion technology, accounting for 35%, utilized for high-complexity parts and even superalloys. Although more expensive, these technologies employ materials with superior resistance capabilities, surpass the limitations of conventional machining, optimize manufacturing times, and allow for the fine-tuning of multiple parameters. In terms of wear and corrosion resistance, materials such as Inconel 718 exhibited a loss of less than 0.1 mpy (mils per year) in highly corrosive environments, representing a significant improvement over traditional materials. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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16 pages, 3236 KiB

Open AccessArticle

Mathematical Model of the Electronic Cam in Terms of Application in a Dosing Machine

by Karol Wójkowski, Krzysztof Talaśka and Dominik Wilczyński

Processes 2024, 12(9), 1909; https://doi.org/10.3390/pr12091909 - 5 Sep 2024

Viewed by 866

Abstract

The article analyses the use of servomotors in the control systems of industrial equipment, focusing on the alternative offered by position and speed synchronization in relation to classical mechanical mechanisms. A complete methodology is presented to determine the dynamic parameters of the adopted [...] Read more.

The article analyses the use of servomotors in the control systems of industrial equipment, focusing on the alternative offered by position and speed synchronization in relation to classical mechanical mechanisms. A complete methodology is presented to determine the dynamic parameters of the adopted kinematic system using electronic motion profiles. The results obtained constitute a mathematical model of the execution chain and an analysis of the basic quantities for linear motion, supported by actual measurements of the drive parameters. The merit of the article is to show that the servomotors can significantly simplify the design of the device, make it more flexible in adaptation to different assortments, and allow integration with systems predicting the technical condition of the device. The analysis of the results revealed significant differences in the constant rotational speed of the servomotor, which do not align with previous findings. The results suggest that changing the angular working range of the assembly to the range (205°;270°) could significantly affect the generated linear acceleration, reducing the risk of stalling. The calculations and graphs conducted allowed for the accurate representation of the actual mechanical system, considering its dynamic characteristics. The key conclusion is that precise mathematical modelling is essential to ensure the stability and durability of engineering components. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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20 pages, 3109 KiB

Open AccessArticle

Development of a Value Stream Map to Optimize the Production Process in a Luxury Metal Piece Manufacturing Company

by Beatriz Costa, José Varejão and Pedro Dinis Gaspar

Processes 2024, 12(8), 1612; https://doi.org/10.3390/pr12081612 - 31 Jul 2024

Cited by 1 | Viewed by 3777

Abstract

The current market is highly competitive, and customers are increasingly demanding. In this context, organizations need to adopt tools that enhance process efficiency to ensure competitiveness. This report aims to implement Lean tools, specifically Value Stream Mapping (VSM) and complementary tools, to optimize [...] Read more.

The current market is highly competitive, and customers are increasingly demanding. In this context, organizations need to adopt tools that enhance process efficiency to ensure competitiveness. This report aims to implement Lean tools, specifically Value Stream Mapping (VSM) and complementary tools, to optimize the production process in the metal treatment industry. A case study was conducted, beginning with a brief sector and process recognition, followed by an analysis of production stages using VSM. Value-added activities, non-value-added activities, and waste were identified. The current VSM revealed a Lead Time (LT) of approximately 336 h (14 days), value-added activities (VA) of 21 h, and a process cycle efficiency (PCE) of 6.29%. Improvement actions were proposed to reduce waste and increase competitiveness. After implementation, the LT decreased to approximately 318 h (13 days), VA increased to 23 h, and process efficiency improved to 7.15%. Despite the limitations of VSM in discontinuous flows, its use increased process efficiency, demonstrating its applicability in complex industrial contexts. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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20 pages, 2725 KiB

Open AccessArticle

A Hierarchical Axiomatic Evaluation of Additive Manufacturing Equipment and the 3D Printing Process Based on Sustainability and Human Factors

by Ismael Mendoza-Muñoz, Mildrend Ivett Montoya-Reyes, Aidé Aracely Maldonado-Macías, Gabriela Jacobo-Galicia and Olivia Yessenia Vargas-Bernal

Processes 2024, 12(6), 1083; https://doi.org/10.3390/pr12061083 - 25 May 2024

Cited by 1 | Viewed by 1432

Abstract

As interest in additive manufacturing (AM) continues to increase, it has become more important to have a robust method to help potential users select the AM process that best suits their technological needs while providing the greatest potential benefits in terms of sustainability [...] Read more.

As interest in additive manufacturing (AM) continues to increase, it has become more important to have a robust method to help potential users select the AM process that best suits their technological needs while providing the greatest potential benefits in terms of sustainability and its effect on people. This paper presents the development of a framework for selecting the best AM process for a given application by considering both sustainability and human factors through the combination of axiomatic design and the analytic hierarchy process. Thirty-one participants with varying levels of expertise (novice and advanced users) were involved in the study, considering the frequency of 3D printer usage (novice users: never, rarely; expert users: sometimes, almost always, always) for prototyping parts. They employed fused deposition modeling (FDM) and stereolithography (SLA) (both 3D desktop printers) and collected data on five evaluation criteria. The participation of experts helped establish a novel methodology, with material cost deemed most important (49.8%), followed by cycle time (28%), energy consumption (11.7%), error rate (6.6%), and equipment noise (3.9%). The results showed that FDM was the optimal equipment option for advanced users. By examining the information content of the other options, it was found that FDM demanded less information than SLA, regardless of the user’s level of expertise. The proposed method is appropriate to assess the sustainability aspect of FDM and SLA; however, it can be further improved by adding indicators such as environmental impact, recyclability, and ergonomic and occupational health factors. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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39 pages, 42293 KiB

Open AccessArticle

Biomimetic Approach for Enhanced Mechanical Properties and Stability of Self-Mineralized Calcium Phosphate Dibasic–Sodium Alginate–Gelatine Hydrogel as Bone Replacement and Structural Building Material

by Alberto T. Estevez and Yomna K. Abdallah

Processes 2024, 12(5), 944; https://doi.org/10.3390/pr12050944 - 7 May 2024

Cited by 3 | Viewed by 2312

Abstract

Mineralized materials are gaining increased interest recently in a number of fields, especially in bone tissue engineering as bone replacement materials as well as in the architecture-built environment as structural building materials. Until the moment, there has not been a unified sustainable approach [...] Read more.

Mineralized materials are gaining increased interest recently in a number of fields, especially in bone tissue engineering as bone replacement materials as well as in the architecture-built environment as structural building materials. Until the moment, there has not been a unified sustainable approach that addresses this multi-scale application objective by developing a self-mineralized material with minimum consumption of materials and processes. Thus, in the current study, a hydrogel developed from sodium alginate, gelatine, and calcium phosphate dibasic (CPDB) was optimized in terms of rheological properties and mineralization capacity through the formation of hydroxyapatite crystals. The hydrogel composition process adopted a three-stage, thermally induced chemical cross-linking to achieve a stable and enhanced hydrogel. The 6% CPDB-modified SA–gelatine hydrogel achieved the best rheological properties in terms of elasticity and hardness. Different concentrations of epigallocatechin gallate were tested as well as a rheological enhancer to optimize the hydrogel and to boost its anti-microbial properties. However, the results from the addition of EPGCG were not considered significant; thus, the 6% CPDB-modified SA–gelatine hydrogel was further tested for mineralization by incubation in various media, without and with cells, for 7 and 14 days, respectively, using scanning electron microscopy. The results revealed significantly enhanced mineralization of the hydrogel by forming hydroxyapatite platelets of the air-incubated hydrogel (without cells) in non-sterile conditions, exhibiting antimicrobial properties as well. Similarly, the air-incubated bioink with osteosarcoma SaOs-2 cells exhibited dense mineralized topology with hydroxyapatite crystals in the form of faceted spheres. Finally, the FBS-incubated hydrogel and FBS-incubated bioink, incubated for 7 and 14 days, respectively, exhibited less densely mineralized topology and less distribution of the hydroxyapatite crystals. The degradation rate of the hydrogel and bioink incubated in FBS after 14 days was determined by the increase in dimensions of the 3D-printed samples, which was between 5 to 20%, with increase in the bioink samples dimensions in comparison to their dimensions post cross-linking. Meanwhile, after 14 days, the hydrogel and bioink samples incubated in air exhibited shrinkage: a 2% decrease in the dimensions of the 3D-printed samples in comparison to their dimensions post cross-linking. The results prove the capacity of the developed hydrogel in achieving mineralized material with anti-microbial properties and a slow-to-moderate degradation rate for application in bone tissue engineering as well as in the built environment as a structural material using a sustainable approach. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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15 pages, 8324 KiB

Open AccessArticle

A Fuzzy Decision-Making Method for Green Design for Remanufacturability

by Yu Cai, Chao Ke and Qunjing Ji

Processes 2024, 12(5), 911; https://doi.org/10.3390/pr12050911 - 29 Apr 2024

Cited by 1 | Viewed by 1274

Abstract

Designs for remanufacturing (DfRem) consider the remanufacturability of the product in the early stages of product design, which can greatly increase the reusability of the products. However, product design schemes lack reasonable evaluation indicators for remanufacturability, and the decision-makers of the design scheme [...] Read more.

Designs for remanufacturing (DfRem) consider the remanufacturability of the product in the early stages of product design, which can greatly increase the reusability of the products. However, product design schemes lack reasonable evaluation indicators for remanufacturability, and the decision-makers of the design scheme have subjective preferences and vague hesitation. These result in inaccurate decision making on DfRem schemes that will affect the successful implementation of product remanufacturing. In order to improve the accuracy of the DfRem scheme decision, a fuzzy decision-making method for green design for remanufacturability is proposed. Firstly, an evaluation indicator system for green design schemes was established that takes into account remanufacturability, reliability, cost, and the environment, and the entropy weighting method is used to quantify and weigh the design scheme evaluation indicators. Then, the hesitation fuzzy set is applied to construct the set of evaluations and the optimal design scheme is selected by applying the comprehensive evaluation method. Finally, the feasibility of the above method is verified by using the green design of an injection mold as an example, and the results show that the above method is able to make accurate and effective design scheme decisions. This method has been implemented in a prototype system using Visual Studio 2022 and Microsoft SQL Server 2022. The results show that the fuzzy decision-making system is accurate and effective for rapidly generating a rational green design scheme for remanufacturability. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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18 pages, 4734 KiB

Open AccessArticle

Implementations of Digital Transformation and Digital Twins: Exploring the Factory of the Future

by Ramin Rahmani, Cristiano Jesus and Sérgio I. Lopes

Processes 2024, 12(4), 787; https://doi.org/10.3390/pr12040787 - 14 Apr 2024

Cited by 12 | Viewed by 4098

Abstract

In the era of rapid technological advancement and evolving industrial landscapes, embracing the concept of the factory of the future (FoF) is crucial for companies seeking to optimize efficiency, enhance productivity, and stay sustainable. This case study explores the concept of the FoF [...] Read more.

In the era of rapid technological advancement and evolving industrial landscapes, embracing the concept of the factory of the future (FoF) is crucial for companies seeking to optimize efficiency, enhance productivity, and stay sustainable. This case study explores the concept of the FoF and its role in driving the energy transition and digital transformation within the automotive sector. By embracing advancements in technology and innovation, these factories aim to establish a smart, sustainable, inclusive, and resilient growth framework. The shift towards hybrid and electric vehicles necessitates significant adjustments in vehicle components and production processes. To achieve this, the adoption of lighter materials becomes imperative, and new technologies such as additive manufacturing (AM) and artificial intelligence (AI) are being adopted, facilitating enhanced efficiency and innovation within the factory environment. An important aspect of this paradigm involves the development and utilization of a modular, affordable, safe human–robot interaction and highly performant intelligent robot. The introduction of this intelligent robot aims to foster a higher degree of automation and efficiency through collaborative human–robot environments on the factory floor and production lines, specifically tailored to the automotive sector. By combining the strengths of human and robotic capabilities, the future factory aims to revolutionize manufacturing processes, ultimately driving the automotive industry towards a more sustainable and technologically advanced future. This study explores the implementation of automation and the initial strides toward transitioning from Industry 4.0 to 5.0, focusing on three recognized, large, and automotive companies operating in the north of Portugal. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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30 pages, 12317 KiB

Open AccessArticle

Fabrication and Characterisation of Sustainable 3D-Printed Parts Using Post-Consumer PLA Plastic and Virgin PLA Blends

by Mohammad Raquibul Hasan, Ian J. Davies, Alokesh Paramanik, Michele John and Wahidul K. Biswas

Processes 2024, 12(4), 760; https://doi.org/10.3390/pr12040760 - 9 Apr 2024

Cited by 1 | Viewed by 2709

Abstract

Sustainable manufacturing practices are becoming increasingly necessary due to the growing concerns regarding climate change and resource scarcity. Consequently, material recycling technologies have gradually become preferred over conventional processes. This study aimed to recycle waste polylactic acid (PLA) from household-disposed cups and lids [...] Read more.

Sustainable manufacturing practices are becoming increasingly necessary due to the growing concerns regarding climate change and resource scarcity. Consequently, material recycling technologies have gradually become preferred over conventional processes. This study aimed to recycle waste polylactic acid (PLA) from household-disposed cups and lids to create 3D-printed parts and promote sustainable manufacturing practices. To achieve this, the current study utilised virgin and post-consumer PLA (PC-PLA) (sourced from household waste) blends. The PC-PLA wastes were shredded and sorted by size with the aid of a washing step, resulting in a filament with a 1.70 ± 0.5 mm diameter without fragmentation or dissolution. A 50:50 wt.% blend of virgin PLA (vPLA) and PC-PLA was selected as the standard recycling percentage based on previous research and resource conservation goals. The study investigated the impact of three 3D printing parameters (layer height (LH), infill density (I), and nozzle temperature (NT)) on the quality of 3D-printed parts using a three-level L9 Taguchi orthogonal array. The findings revealed that blending PC-PLA with vPLA led to significant improvements in tensile, flexural, and impact strengths by 18.40%, 8%, and 9.15%, respectively, compared to those of recycled PLA (rPLA). This conclusion was supported by the investigation of the fracture surface area, which revealed fractographic features associated with printing parameters, such as plastic deformation and interfilament debonding. An ANOVA analysis revealed a positive influence of a greater layer height and high nozzle temperature on mechanical properties. Subsequently, the optimal printing parameters (LH: 0.3 mm, I: 100%, and NT: 215 °C) were determined using the S/N ratio, and a confirmation test using the optimum printing parameters exhibited a strong correlation with the statistically predicted outcomes. Finally, the study used optimum printing parameters to fabricate 100% PC-PLA 3D-printed parts, demonstrating their potential for low-strength applications. The findings suggest that employing vPLA and PC-PLA blended filaments for fabricating 3D-printed components presents an effective means of promoting plastic recycling within a closed-loop recycling system and achieving a circular economy. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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Review

Jump to: Research

16 pages, 3595 KiB

Open AccessReview

Polycrystalline Diamond Composite Bit Technology for Sustainable Work

by Xiaoao Liu, Guodong Ji, Liyuan Yang, Haitao Ren, Qiang Wu, Jinping Yu and Kuilin Huang

Processes 2025, 13(2), 421; https://doi.org/10.3390/pr13020421 - 5 Feb 2025

Viewed by 646

Abstract

Reducing the auxiliary drilling time and improving the drilling efficiency are not only important technical means to enhance the development and deep exploration of oil and gas reserves, but also have significant implications for ensuring energy security. Bottom hole self-renewal drill bit technology [...] Read more.

Reducing the auxiliary drilling time and improving the drilling efficiency are not only important technical means to enhance the development and deep exploration of oil and gas reserves, but also have significant implications for ensuring energy security. Bottom hole self-renewal drill bit technology is a new technology that does not require the retrieval of drills from the well bottom, instead directly updating worn drill bits in place. Through the self-renewing structure of the drill bit, the sustainability of the drill bit can be increased. Conducting research on this technology is expected to overcome the technical issues related to the short useable life of drill bits, thus promoting single-trip drilling technology. This article summarizes the scientific progress made by researchers in self-renewal Polycrystalline Diamond Composite (PDC) drill bit technology; for example, the American National Oilwell Varco (NOV) company has developed a mobile self-renewal cone bit technology and introduced the structural characteristics and working principles of three types of rotating self-renewal drill bits: rack-driven, worm-driven, and ratchet-driven. This study compares and analyzes the advantages and disadvantages of these three rotary types of PDC drill bits, providing a detailed introduction to the working principles and modes of the triggering, transmission, limit and locking, and renewal structure devices of the drill bit. Relevant suggestions are proposed for the development of bottom hole self-renewal PDC drill bit technology; namely, strengthening research efforts relating to the intelligent judgment and recognition of cutting tooth wear of the drill bit, as well as the integration of multiple technologies. The sustainability of these novel bits can provide technical support for the development of single-trip drilling technology for deep formations, improve the service life of bits in deep formations that are difficult to drill, and contribute to the efficient development of deep-sea energy resources worldwide. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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32 pages, 4103 KiB

Open AccessFeature PaperEditor’s ChoiceReview

Strategic Selection of a Pre-Reduction Reactor for Increased Hydrogen Utilization in Hydrogen Plasma Smelting Reduction

by Bernhard Adami, Felix Hoffelner, Michael Andreas Zarl and Johannes Schenk

Processes 2025, 13(2), 420; https://doi.org/10.3390/pr13020420 - 5 Feb 2025

Viewed by 897

Abstract

The hydrogen plasma smelting reduction process has the potential to drastically reduce the CO₂ emissions of the steel industry by using molecular, atomic and ionized hydrogen as a reducing agent for iron ores. To increase the hydrogen and thermal efficiency of the [...] Read more.

The hydrogen plasma smelting reduction process has the potential to drastically reduce the CO₂ emissions of the steel industry by using molecular, atomic and ionized hydrogen as a reducing agent for iron ores. To increase the hydrogen and thermal efficiency of the process, a pre-reduction and pre-heating stage should be incorporated in a future upscaling of an existing HPSR demonstration plant within the scope of the “SuSteel follow-up” project to a target capacity of 200 kg/h of iron ore. The determination of the optimal process parameters is followed by a review of possible reactor types. A fluidized bed cascade, a cyclone cascade and a rotary kiln are compared for this purpose. Their applicability for the hydrogen plasma smelting is discussed, based on their fundamental design and operational procedures. Additionally, critical features of the different reactor types are outlined. A cyclone cascade with at least 3 stages is proposed to be the optimal reactor for pre-heating and pre-reducing the input material for the upscaled hydrogen plasma smelting reduction demonstration plant, based on the assessment. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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16 pages, 971 KiB

Open AccessReview

Sustainable Management of Manufacturing Processes: A Literature Review

by Lasma Tiuncika and Santa Bormane

Processes 2024, 12(6), 1222; https://doi.org/10.3390/pr12061222 - 14 Jun 2024

Cited by 2 | Viewed by 1471

Abstract

Industrial economic activity is one of the primary causes of environmental degradation and a source of issues related to social inequality. Nevertheless, research has shown that the application of the sustainable entrepreneurship model can significantly improve environmental and social conditions while maintaining continuous [...] Read more.

Industrial economic activity is one of the primary causes of environmental degradation and a source of issues related to social inequality. Nevertheless, research has shown that the application of the sustainable entrepreneurship model can significantly improve environmental and social conditions while maintaining continuous and sustainable economic growth. Despite that, statistics show relatively low engagement in sustainable entrepreneurship, potentially due to a lack of expertise among entrepreneurs. Due to the low engagement, available sustainability performance metrics are not a relevant measurement tool. Thus, the purpose of this study is to identify a set of criteria that evaluate expertise levels in sustainable entrepreneurship within the manufacturing industry. Through the application of monographic and secondary data analysis methods, the authors carried out a literature review. The findings indicated that sustainable management is a key component to the triple-bottom-line (TBL) framework that is used as a conceptual basis for sustainable entrepreneurship. Additionally, the authors identified 19 criteria of sustainable entrepreneurship within four dimensions of sustainability (environmental, social, economic, and management). Despite the limitations, with a more refined literature review, the criteria could be applied as a comprehensive resource to estimate expertise in sustainable entrepreneurship in future studies on small and medium enterprises (SMEs). Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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28 pages, 7430 KiB

Open AccessEditor’s ChoiceReview

Dry Machining Techniques for Sustainability in Metal Cutting: A Review

by Shailendra Pawanr and Kapil Gupta

Processes 2024, 12(2), 417; https://doi.org/10.3390/pr12020417 - 19 Feb 2024

Cited by 16 | Viewed by 3247

Abstract

Dry machining has gained significant importance in the last few years due to its promising contribution towards sustainability. This review study introduces dry machining, presents its benefits, and summarizes the recent technological developments that can facilitate dry machining. It aims to provide a [...] Read more.

Dry machining has gained significant importance in the last few years due to its promising contribution towards sustainability. This review study introduces dry machining, presents its benefits, and summarizes the recent technological developments that can facilitate dry machining. It aims to provide a concise overview of the current state of the art in dry machining to promote sustainability. This article synthesizes and emphasizes the useful information from the existing literature, and summarizes the methods and tools used to implement it. It also identifies some of the major problems and challenges and their potential solutions to make dry machining more viable and efficient. It concludes with some future research directions important for the scholars and researchers to establish the field further. From this review study, the major findings are: (1) tools with textures or patterns can enhance the cutting performance of dry machining for various materials, (2) tool coating is an effective way to lower the tool cost in dry machining and can achieve the required functionality for the cutting tool without affecting its core properties, (3) Alumina-based mixed ceramic tools with SiC whiskers have better fracture toughness, thermal shock resistance, and self-crack healing properties, (4) one effective method to improve the dry cutting of engineering materials is to apply external energy sources to assist the dry machining process, (5) by using microwave sintering, cutting tools with finer microstructures and higher densities can be produced, which improve their hardness, wear resistance, and thermal stability to perform well in dry machining conditions. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)

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