Search results for: aerospace manufacturing

Authors: Franziska Moser, Martin Trautz, Anna-Lena Beger, Manuel Löwer, Jörg Feldhusen, Jürgen Prell, Alexandra Wormit, Björn Usadel, Christoph Kämpfer, Thomas-Benjamin Seiler, Henner Hollert

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The demand for bio-based materials and components in architecture has increased in recent years due to society’s heightened environmental awareness. Nowadays, most components are being developed via a substitution approach, which aims at replacing conventional components with natural alternatives who are then being processed, shaped and manufactured to fit the desired application. This contribution introduces a novel approach to the development of bio-based products that decreases resource consumption and increases recyclability. In this approach, natural organisms like plants or trees are not being used in a processed form, but grow into a near net shape before then being harvested and utilized as building components. By minimizing the conventional production steps, the amount of resources used in manufacturing decreases whereas the recyclability increases. This paper presents the approach of technical product harvesting, explains the theoretical basis as well as the matching process of product requirements and biological properties, and shows first results of the growth manipulation studies.

Keywords: design with nature, eco manufacturing, sustainable construction materials, technical product harvesting

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Authors: Yunhan Zhang, Xiaopeng Li, Zhongxiao Peng

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Additive manufacturing (AM) possesses several key characteristics, including high design freedom, energy-efficient manufacturing process, reduced material waste, high resolution of finished products, and excellent performance of finished products. These advantages have garnered widespread attention and fueled rapid development in recent decades. AM has significantly broadened the spectrum of available materials in the manufacturing industry and is gradually replacing some traditionally manufactured parts. Similar to components produced via traditional methods, products manufactured through AM are susceptible to degradation caused by wear during their service life. Given the prevalence of 316L stainless steel (SS) parts and the limited research on the tribological behavior of 316L SS samples or products fabricated using AM technology, this study aims to investigate the degradation process and wear mechanisms of 316L SS disks fabricated using AM technology. The wear mechanisms and tribological performance of these AM-manufactured samples are compared with commercial 316L SS samples made using conventional methods. Additionally, methods to enhance the tribological performance of additive-manufactured SS samples are explored. Four disk samples with a diameter of 75 mm and a thickness of 10 mm are prepared. Two of them (Group A) are prepared from a purchased SS bar using a milling method. The other two disks (Group B), with the same dimensions, are made of Gas Atomized 316L Stainless Steel (size range: 15-45 µm) purchased from Carpenter Additive and produced using Laser Powder Bed Fusion (LPBF). Pin-on-disk tests are conducted on these disks, which have similar surface roughness and hardness levels. Multiple tests are carried out under various operating conditions, including varying loads and/or speeds, and the friction coefficients are measured during these tests. In addition, the evolution of the surface degradation processes is monitored by creating moulds of the wear tracks and quantitatively analyzing the surface morphologies of the mould images. This analysis involves quantifying the depth and width of the wear tracks and analyzing the wear debris generated during the wear processes. The wear mechanisms and wear performance of these two groups of SS samples are compared. The effects of load and speed on the friction coefficient and wear rate are investigated. The ultimate goal is to gain a better understanding of the surface degradation of additive-manufactured SS samples. This knowledge is crucial for enhancing their anti-wear performance and extending their service life.

Keywords: degradation process, additive manufacturing, stainless steel, surface features

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Authors: Ben Chater, Jingbang Pan, Mark Evernden, Jie Wang

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Traditional structural steel manufacturing routes normally produce prismatic members with flat plate elements. In these members, plate instability in the lowest buckling mode often dominates failure. It is proposed in the current study to use a new technology of metal 3D printing to print steel-plated elements with predefined imperfection patterns that can lead to higher modes of failure with increased buckling resistances. To this end, a numerical modeling program is carried out to explore various combinations of predefined buckling waves with different amplitudes in stainless steel square hollow section stub columns. Their stiffness, strength, and material consumption against the traditional structural steel members with the same nominal dimensions are assessed. It is found that depending on the slenderness of the plate elements; it is possible for an ‘imperfect’ steel member to achieve up to a 30% increase in strength with just a 3% increase in the material consumption. The obtained results shed some light on the significant potential of the new metal 3D printing technology in achieving unprecedented material efficiency and economical design in the future steel construction industry.

Keywords: 3D printing, additive manufacturing, buckling resistance, steel plate buckling, structural optimisation

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Authors: Mohammad Syed Ali Molla, Mohammed Azim, Mohammad Esharuzzaman

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Centrifugal-casting machine is used in manufacturing special machine components like multi-layer journal bearing used in all internal combustion engine, steam, gas turbine and air craft turboengine where isotropic properties and high precisions are desired. Moreover, this machine can be used in manufacturing thin wall hightech machine components like cylinder liners and piston rings of IC engine and other machine parts like sleeves, and bushes. Heavy-duty machine component like railway wheel can also be prepared by centrifugal casting. A lot of technological developments are required in casting process for production of good casted machine body and machine parts. Usually defects like blowholes, surface roughness, chilled surface etc. are found in sand casted machine parts. But these can be removed by centrifugal casting machine using rotating metallic die. Moreover, die rotation, its temperature control, and good pouring practice can contribute to the quality of casting because of the fact that the soundness of a casting in large part depends upon how the metal enters into the mold or dies and solidifies. Poor pouring practice leads to variety of casting defects such as temperature loss, low quality casting, excessive turbulence, over pouring etc. Besides these, handling of molten metal is very unsecured and dangerous for the workers. In order to get rid of all these problems, the need of an automatic pouring device arises. In this research work, a robot assisted pouring device and a centrifugal casting machine are designed, developed constructed and tested experimentally which are found to work satisfactorily. The robot assisted pouring device is further modified and developed for using it in actual metal casting process. Lot of settings and tests are required to control the system and ultimately it can be used in automation of centrifugal casting machine to produce high-tech machine parts with desired precision.

Keywords: bearing, centrifugal casting, cylinder liners, robot

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Authors: Rhadinia Tayag-Relanes, Felina C. Young

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This study was conducted to analyze the noodle production process at Yan Hu Food Manufacturing for the basis of production improvement. The study utilized the PDCA approach and record review in the gathering of data for the calendar year 2019 from August to October data of the noodle products miki, canton, and misua. Causal-comparative research was used in this study; it attempts to establish cause-effect relationships among the variables such as descriptive statistics and correlation, both were used to compute the data gathered. The study found that miki, canton, and misua production has different cycle time sets for each production and has different production outputs in every set of its production process and a different number of wastages. The company has not yet established its allowable rejection rate/ wastage; instead, this paper used a 1% wastage limit. The researcher recommended the following: machines used for each process of the noodle product must be consistently maintained and monitored; an assessment of all the production operators by checking their performance statistically based on the output and the machine performance; a root cause analysis for finding the solution must be conducted; and an improvement on the recording system of the input and output of the production process of noodle product should be established to eliminate the poor recording of data.

Keywords: continuous improvement, process, operations, PDCA

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Authors: Saad Nawaz, Yu Gang, Miao Haibin

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Titanium alloys are attractive materials for aerospace industry due to their exceptional strength to weight ratio that is maintained at elevated temperatures and their good corrosion resistance. Major applications of titanium alloys were military aerospace industry, but since last decade the trend has now shifted towards commercial industry. On the other hand, titanium alloys are notorious for being poor thermal conductor that leads to them being difficult materials for machining. In this experimental study, Stellram Indexable milling cutter XDLT09-D41 is used for rough down milling of Ti6Al4V for small depth of cut under different combinations of parameters and application of high-pressure coolant. The machining performance was evaluated in terms of tool wear, tool life, and thermal crack. The tool wear was mostly observed at the tool tip and at bottom part of tool thermal deformations were observed which propagated with respect to time. Flank wear due to scratching of the cutting chips and diffusion wear because of high thermal stresses were observed specially at the bottom of the cutting tool. It was found that maximum tool life was obtained at the speed of 40m/min, feed rate of 358mm/min and depth of cut of 0.8mm. In the end, it was concluded that machining of Ti6Al4V is a thermally dominant process which leads to high thermal stresses in machining zone that results in increasing tool wear rate and deformation propagation.

Keywords: tool wear, cutting speed, flank wear , tool life

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Authors: C. Bay, A. Mahr, H. Groneberg, F. Döpper

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Additive Manufacturing processes are becoming increasingly established in the industry for the economic production of complex prototypes and functional components. Laser beam melting (LBM), the most frequently used Additive Manufacturing technology for metal parts, has been gaining in industrial importance for several years. The LBM process chain – from material storage to machine set-up and component post-processing – requires many manual operations. These steps often depend on the manufactured component and are therefore not standardized. These operations are often not performed in a standardized manner, but depend on the experience of the machine operator, e.g., levelling of the build plate and adjusting the first powder layer in the LBM machine. This lack of standardization limits the reproducibility of the component quality. When processing metal powders with inhalable and alveolar particle fractions, the machine operator is at high risk due to the high reactivity and the toxic (e.g., carcinogenic) effect of the various metal powders. Faulty execution of the operation or unintentional omission of safety-relevant steps can impair the health of the machine operator. In this paper, all the steps of the LBM process chain are first analysed in terms of their influence on the two aforementioned challenges: reproducibility and work safety. Standardization to avoid errors increases the reproducibility of component quality as well as the adherence to and correct execution of safety-relevant operations. The corresponding lean method 5S will therefore be applied, in order to develop approaches in the form of recommended actions that standardize the work processes. These approaches will then be evaluated in terms of ease of implementation and their potential for improving reproducibility and work safety. The analysis and evaluation showed that sorting tools and spare parts as well as standardizing the workflow are likely to increase reproducibility. Organizing the operational steps and production environment decreases the hazards of material handling and consequently improves work safety.

Keywords: additive manufacturing, lean production, reproducibility, work safety

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Authors: Tippawan Nasawan

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The objective of this study is to find the replenishment policy in Assembly-to-Order manufacturing (ATO) which some of the major components have lead-time longer than customer lead-time. The variety of products, independent component demand, and long component lead-time are the difficulty that has resulted in the overstock problem. In addition, the ordering cost is trivial when compared to the cost of material of the major component. A conceptual design of the Decision Supporting System (DSS) has introduced to assist the replenishment policy. Component replenishment by using the variable which calls Available to Promise (ATP) for making the decision is one of the keys. The Poisson distribution is adopted to realize demand patterns in order to calculate Safety Stock (SS) at the specified Customer Service Level (CSL). When distribution cannot identify, nonparametric will be applied instead. The test result after comparing the ending inventory between the new policy and the old policy, the overstock has significantly reduced by 46.9 percent or about 469,891.51 US-Dollars for the cost of the major component (material cost only). Besides, the number of the major component inventory is also reduced by about 41 percent which helps to mitigate the chance of damage and keeping stock.

Keywords: Assembly-to-Order, Decision Supporting System, Component replenishment , Poisson distribution

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Authors: Hussain Bohra, Pradyuman Sharma

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This study highlights the significance of Balance Sheet Indicators on the corporate performance in the case of Indian manufacturing companies. Balance sheet indicators show the actual financial health of the company and it helps to the external investors to choose the right company for their investment and it also help to external financing agency to give easy finance to the manufacturing companies. The period of study is 2000 to 2014 for 813 manufacturing companies for which the continuous data is available throughout the study period. The data is collected from PROWESS data base maintained by Centre for Monitoring Indian Economy Pvt. Ltd. Panel data methods like fixed effect and random effect methods are used for the analysis. The Likelihood Ratio test, Lagrange Multiplier test and Hausman test results proof the suitability of the fixed effect model for the estimation. Return on assets (ROA) is used as the proxy to measure corporate performance. ROA is the best proxy to measure corporate performance as it already used by the most of the authors who worked on the corporate performance. ROA shows return on long term investment projects of firms. Different ratios like Current Ratio, Debt-equity ratio, Receivable turnover ratio, solvency ratio have been used as the proxies for the Balance Sheet Indicators. Other firm specific variable like firm size, and sales as the control variables in the model. From the empirical analysis, it was found that all selected financial ratios have significant and positive impact on the corporate performance. Firm sales and firm size also found significant and positive impact on the corporate performance. To check the robustness of results, the sample was divided on the basis of different ratio like firm having high debt equity ratio and low debt equity ratio, firms having high current ratio and low current ratio, firms having high receivable turnover and low receivable ratio and solvency ratio in the form of firms having high solving ratio and low solvency ratio. We find that the results are robust to all types of companies having different form of selected balance sheet indicators ratio. The results for other variables are also in the same line as for the whole sample. These findings confirm that Balance sheet indicators play as significant role on the corporate performance in India. The findings of this study have the implications for the corporate managers to focus different ratio to maintain the minimum expected level of performance. Apart from that, they should also maintain adequate sales and total assets to improve corporate performance.

Keywords: balance sheet, corporate performance, current ratio, panel data method

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Authors: Bader Al-Mannai, Saad Sulieman, Yaser Al-Alawi

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Research studies worldwide undoubtedly demonstrated that the implementation of Total Quality Management (TQM) program can improve organizations competitive abilities and provide strategic quality advances. However, limited empirical studies and research are directed to measure the effectiveness of TQM implementation on the industrial and manufacturing organizations performance. Accordingly, this paper is aimed at discussing “the degree of TQM implementation in Bahrain industries and its effect on their performance”. The paper will present the measurement indicators and success factors that were used to assess the degree of TQM implementation in Bahrain industry, and the main performance indicators that were affected by TQM implementation. The adopted research methodology in this study was a survey that was based on self-completion questionnaire. The sample population represented the industrial and manufacturing organizations in Bahrain. The study led to the identification of the operational and strategic measurement indicators and success factors that assist organizations in realizing successful TQM implementation and performance improvement. Furthermore, the research analysis confirmed a positive and significant relationship between the examined performance indicators in Bahrain industry and TQM implementation. In conclusion the investigation of the relationship revealed that the implementation of TQM program has resulted into remarkable improvements on workforce, sales performance, and quality performance indicators in Bahrain industry.

Keywords: performance indicators, success factors, TQM implementation, Bahrain

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Authors: R. Meier, M. Pander

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In accordance with the industry 4.0 concept, manufacturing process steps as well as the materials themselves are going to be more and more digitalized within the next years. The “digital twin” representing the simulated and measured dataset of the (semi-finished) product can be used to control and optimize the individual processing steps and help to reduce costs and expenditure of time in product development, manufacturing, and recycling. In the present work, two material characterization methods based on Lamb waves were evaluated and compared. For demonstration purpose, both methods were shown at a standard industrial product - copper ribbons, often used in photovoltaic modules as well as in high-current microelectronic devices. By numerical approximation of the Rayleigh-Lamb dispersion model on measured phase velocities second order elastic constants (Young’s modulus, Poisson’s ratio) were determined. Furthermore, the effective third order elastic constants were evaluated by applying elastic, “non-destructive”, mechanical stress on the samples. In this way, small microstructural variations due to mechanical preconditioning could be detected for the first time. Both methods were compared with respect to precision and inline application capabilities. Microstructure of the samples was systematically varied by mechanical loading and annealing. Changes in the elastic ultrasound transport properties were correlated with results from microstructural analysis and mechanical testing. In summary, monitoring the elastic material properties of plate-like structures using Lamb waves is valuable for inline and non-destructive material characterization and manufacturing process control. Second order elastic constants analysis is robust over wide environmental and sample conditions, whereas the effective third order elastic constants highly increase the sensitivity with respect to small microstructural changes. Both Lamb wave based characterization methods are fitting perfectly into the industry 4.0 concept.

Keywords: lamb waves, industry 4.0, process control, elasticity, acoustoelasticity, microstructure

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Authors: Ibrahim Bashir, Yahaya Y. Yusuf

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The ongoing shift towards Industry 4.0 represents a critical growth factor in the industrial enterprise, where the digital transformation of industries is increasingly seen as a crucial element for competitiveness. This transformation holds substantial potential, yet its full benefits have yet to be realized due to the fragmented approach to introducing Industry 4.0 technologies. Therefore, this pilot study aims to explore the individual and collective impact of Industry 4.0 technologies and digital transformation on organizational performance. Data were collected through a questionnaire-based survey across 51 companies in the manufacturing industry in the United Kingdom. The correlations and multiple linear regression analyses were conducted to assess the relationship and impact between the variables in the study. The results show that Industry 4.0 and digital transformation positively influence organizational performance and that Industry 4.0 technologies positively influence digital transformation. The results of this pilot study indicate that the implementation of Industry 4.0 technology is vital for increasing organizational performance; however, their roles differ largely. The differences are manifest in how the types of Industry 4.0 technologies correlate with how organizations integrate digital technologies into their operations. Hence, there is a clear indication of a strong correlation between Industry 4.0 technology, digital transformation, and organizational performance. Consequently, our study presents numerous pertinent implications that propel the theory of I4.0, digital business transformation (DBT), and organizational performance forward, as well as guide managers in the manufacturing sector.

Keywords: industry 4.0 technologies, digital transformation, digital integration, organizational performance

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Authors: S. Kadiyala, M. Berzins, D. Juba, W. Keyrouz

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This paper describes the Material Point Method (MPM) for simulating a single-track laser melting process on an IN718 solid plate. MPM, known for simulating challenging multiphysics problems, is used to model the intricate thermal, mechanical, and fluid interactions during the laser sintering process. This study analyzes the formation of single tracks, exploring the impact of varying laser parameters such as speed, power, and spot diameter on the melt pool and track formation. The focus is on MPM’s ability to accurately simulate and capture the transient thermo-mechanical and phase change phenomena, which are critical in predicting the cooling rates before and after solidification of the laser track and the final melt pool geometry. The simulation results are rigorously compared with experimental data (AMB2022 benchmarks), demonstrating the effectiveness of MPM in replicating the physical processes in laser sintering. This research highlights the potential of MPM in advancing the understanding and simulation of melt pool physics in metal additive manufacturing, paving the way for optimized process parameters and improved material performance.

Keywords: dditive manufacturing simulation, material point method, phase change, melt pool physics

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Authors: Rakesh Prajapati, Purvik Patel, Avadhoot Rajurkar

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Nowadays, manufacturing industries augment their production lines with modern machining centers backed by CAM software. Several attempts are being made to cut down the programming time for machining complex geometries. Special programs/software have been developed to generate the digital numerical data and to prepare NC programs by using suitable post-processors for different machines. By selecting the tools and manufacturing process then applying tool paths and NC program are generated. More and more complex mechanical parts that earlier were being cast and assembled/manufactured by other processes are now being machined. Majority of these parts require lots of pocketing operations and find their applications in die and mold, turbo machinery, aircraft, nuclear, defense etc. Pocketing operations involve removal of large quantity of material from the metal surface. The modeling of warm cast and clamping a piece of food processing parts which the used of Pro-E and MasterCAM^® software. Pocketing operation has been specifically chosen for toolpath optimization. Then after apply Pocketing toolpath, Multi Tool Selection and Reduce Air Time give the results of software simulation time and experimental machining time.

Keywords: toolpath, part program, optimization, pocket

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Authors: Dimitrios Kafetzopoulos

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Nowadays, companies are more concerned with adopting their own strategies for increased efficiency and sustainability. Dynamic environments are fertile fields for developing operational changes. For this purpose, organizations need to implement an advanced management philosophy that boosts changes to companies’ operation. Changes refer to new applications of knowledge, ideas, methods, and skills that can generate unique capabilities and leverage an organization’s competitiveness. So, in order to survive and compete in the global and niche markets, companies should incorporate the adoption of operational changes into their strategy with regard to their products and their processes. Creating the appropriate culture for changes in terms of products and processes helps companies to gain a sustainable competitive advantage in the market. Thus, the purpose of this study is to investigate the role of both incremental and radical changes into operations of a company, taking into consideration not only product changes but also process changes, and continues by measuring the impact of these two types of changes on business efficiency and sustainability of Greek manufacturing companies. The above discussion leads to the following hypotheses: H1: Radical operational changes have a positive impact on firm efficiency. H2: Incremental operational changes have a positive impact on firm efficiency. H3: Radical operational changes have a positive impact on firm sustainability. H4: Incremental operational changes have a positive impact on firm sustainability. In order to achieve the objectives of the present study, a research study was carried out in Greek manufacturing firms. A total of 380 valid questionnaires were received while a seven-point Likert scale was used to measure all the questionnaire items of the constructs (radical changes, incremental changes, efficiency and sustainability). The constructs of radical and incremental operational changes, each one as one variable, has been subdivided into product and process changes. Non-response bias, common method variance, multicollinearity, multivariate normal distribution and outliers have been checked. Moreover, the unidimensionality, reliability and validity of the latent factors were assessed. Exploratory Factor Analysis and Confirmatory Factor Analysis were applied to check the factorial structure of the constructs and the factor loadings of the items. In order to test the research hypotheses, the SEM technique was applied (maximum likelihood method). The goodness of fit of the basic structural model indicates an acceptable fit of the proposed model. According to the present study findings, radical operational changes and incremental operational changes significantly influence both efficiency and sustainability of Greek manufacturing firms. However, it is in the dimension of radical operational changes, meaning those in process and product, that the most significant contributors to firm efficiency are to be found, while its influence on sustainability is low albeit statistically significant. On the contrary, incremental operational changes influence sustainability more than firms’ efficiency. From the above, it is apparent that the embodiment of the concept of the changes into the products and processes operational practices of a firm has direct and positive consequences for what it achieves from efficiency and sustainability perspective.

Keywords: incremental operational changes, radical operational changes, efficiency, sustainability

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Authors: Pankaj Prashar, Bimlesh Kumar, Ankita Sood, Anamika Gautam

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Pharmacovigilance (PV) is a rapidly growing discipline in pharmaceutical industries as an integral part of clinical research and drug development over the past few decades. PV carries a breadth of scope from drug manufacturing to its regulation with safer utilization. The fundamental steps of PV not only includes data collection and verification, coding of drugs with adverse drug reactions, causality assessment and timely reporting to the authorities but also monitoring drug manufacturing, safety issues, product quality and conduction of due diligence. Standardization of adverse event information, collaboration of multiple departments in different companies, preparation of documents in accordance to both governmental as well as non-governmental organizations (FDA, EMA, GVP, ICH) are the advancements in discipline of PV. De-harmonization, lack of predictive drug safety models, improper funding by government, non-reporting, and non-acceptability of ADRs by developing countries and reports directly from patients to the monitoring centres respectively are the major road backs of PV. Mandatory pharmacovigilance reporting, frequent inspections, funding by government, educating and training medical students, pharmacists and nurses in this segment can bring about empowerment in PV. This area needs to be addressed with a sense of urgency for the safe utilization of pharmaceuticals.

Keywords: pharmacovigilance, regulatory, adverse event, drug safety

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Authors: Mehrnoosh Askarizadeh

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People, process and IT are the most important assets of any organization. Optimal utilization of these resources has been the question of research in business for many decades. The business world have responded by inventing various methodologies that can be used for addressing problems of quality improvement, efficiency of processes, continuous improvement, reduction of waste, automation, strategy alignments etc. Some of these methodologies can be commonly called as Business Process Quality Management methodologies (BPQM). In essence, the first references to the process management can be traced back to Frederick Taylor and scientific management. Time and motion study was addressed to improvement of manufacturing process efficiency. The ideas of scientific management were in use for quite a long period until more advanced quality management techniques were developed in Japan and USA. One of the first prominent methods had been Total Quality Management (TQM) which evolved during 1980’s. About the same time, Six Sigma (SS) originated at Motorola as a separate method. SS spread and evolved; and later joined with ideas of Lean manufacturing to form Lean Six Sigma. In 1990’s due to emerging IT technologies, beginning of globalization, and strengthening of competition, companies recognized the need for better process and quality management. Business Process Management (BPM) emerged as a novel methodology that has taken all this into account and helped to align IT technologies with business processes and quality management. In this article we will study various aspects of above mentioned methods and identified their relations.

Keywords: e-process, quality, TQM, BPM, lean, six sigma, CPI, information technology, management

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Authors: Jaroslaw Mizera, Pawel Wisniewski, Ryszard Sitek

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Selective Laser Melting (SLM) is an advanced additive manufacturing technique used for producing parts made of wide range of materials such as: austenitic steel, titanium, nickel etc. In the our experiment we produced a Ti-AlN composite from a mixture of titanium and aluminum nitride respectively 70% at. and 30% at. using SLM technique. In order to define the size of powder particles, laser diffraction tests were performed on HORIBA LA-950 device. The microstructure and chemical composition of the composite was examined by Scanning Electron Microscopy (SEM). The chemical composition in micro areas of the obtained samples was determined by of EDS. The phase composition was analyzed by X-ray phase analysis (XRD). Microhardness Vickers tests were performed using Zwick/Roell microhardness machine under the load of 0.2kG (HV0.2). Hardness measurements were made along the building (xy) and along the plane of the lateral side of the cuboid (xz). The powder used for manufacturing of the samples had a mean particle size of 41μm. It was homogenous with a spherical shape. The specimens were built chiefly from Ti, TiN and AlN. The dendritic microstructure was porous and fine-grained. Some of the aluminum nitride remained unmelted but no porosity was observed in the interface. The formed material was characterized by high hardness exceeding 700 HV0.2 over the entire cross-section.

Keywords: Selective Laser Melting, Composite, SEM, microhardness

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Authors: Ajay Kumar Choubey, Geeta Agnihotri, C. Sasikumar, Rashmi Dwivedi

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Deep-drawing operations are performed widely in industrial applications. It is very important for efficiency to achieve parts with no or minimum defects. Deep drawn parts are used in high performance, high strength and high reliability applications where tension, stress, load and human safety are critical considerations. Wrinkling is a kind of defect caused by stresses in the flange part of the blank during metal forming operations. To avoid wrinkling appropriate blank-holder pressure/force or drawbead can be applied. Now-a-day computer simulation plays a vital role in the field of manufacturing process. So computer simulation of manufacturing has much advantage over previous conventional process i.e. mass production, good quality of product, fast working etc. In this study, a two dimensional elasto-plastic Finite Element (F.E.) model for Mild Steel material blank has been developed to study the behavior of the flange wrinkling and deep drawing parameters under different Blank-Holder Pressure (B.H.P.). For this, commercially available Finite Element software ANSYS 14 has been used in this study. Simulation results are critically studied and salient conclusions have been drawn.

Keywords: ANSYS, deep drawing, BHP, finite element simulation, wrinkling

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Authors: Eugene Ivanov, Eduardo del-Rio, Igor Kapchenko, Maija Nystrӧm, Juha Kotila

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Series of low modulus beta Ti alloy billets and powders can be produced in commercial quantities using a combination of electron beam melting (EBM) and EIGA atomization processes. In the present study, TNZT alloy powder was produced and processed in the EOSINT M290 laser sintering system to produce parts for mechanical testing. Post heat treatments such as diffusion annealing to reduce internal stresses or hot isostatic pressing to remove closed pores were not applied. The density can visually be estimated to be > 99,9 %. According to EDS study Nb, Zr, and Ta are distributed homogeneously throughout the printed sample. There are no indications for any segregation or chemical inhomogeneity, i.e. variation of the element distribution. These points to the fact that under the applied experimental conditions the melt generated by the laser rapidly cools down in the SLM (Selective Laser Melting) process. The selective laser sintering yielded dense structures with relatively good surface quality. The mechanical properties, especially the elongation (24%) along with tensile strength ( > 500MPa) and modulus of elasticity (~60GPa), were found to be promising compared to titanium alloys in general.

Keywords: beta titanium alloys, additive manufacturing, powder, implants

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Authors: Maja Sajdak

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The aim of this paper is to present the concept of an agile enterprise model and to initiate discussion on the research assumptions of the model presented. The implementation of the research project "The agility of enterprises in the process of adapting to the environment and its changes" began in August 2014 and is planned to last three years. The article has the form of a work-in-progress paper which aims to verify and initiate a debate over the proposed research model. In the literature there are very few publications relating to research into agility; it can be concluded that the most controversial issue in this regard is the method of measuring agility. In previous studies the operationalization of agility was often fragmentary, focusing only on selected areas of agility, for example manufacturing, or analysing only selected sectors. As a result the measures created to date can only be treated as contributory to the development of precise measurement tools. This research project aims to fill a cognitive gap in the literature with regard to the conceptualization and operationalization of an agile company. Thus, the original contribution of the author of this project is the construction of a theoretical model that integrates manufacturing agility (consisting mainly in adaptation to the environment) and strategic agility (based on proactive measures). The author of this research project is primarily interested in the attributes of an agile enterprise which indicate that the company is able to rapidly adapt to changing circumstances and behave pro-actively.

Keywords: agile company, acuity, entrepreneurship, flexibility, research model, strategic leadership

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Authors: Robiul Islam, Monjurul Hasan, Rezaul Karim, M. F. M. Zain

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Coal fly ash, an industrial by product of coal combustion thermal power plants is considered as a hazardous material and its improper disposal has become an environmental issue. On the other hand, manufacturing conventional clay bricks involves on consumption of large amount of clay and leads substantial depletion of topsoil. This paper unveils the possibility of using fly ash as a partial replacement of clay for brick manufacturing considering the local technology practiced in Bangladesh. The effect of fly ash with different replacing ratio (0%, 20%, 30%, 40% and 50% by volume) of clay on properties of bricks were studied. Bricks were made in the field parallel to ordinary bricks marked with specific number for different percentage to identify them at time of testing. No physical distortion is observed in fly ash brick after burning in the kiln. Results from laboratory test show that compressive strength of brick is decreased with the increase of fly ash and maximum compressive strength is found to be 19.6 MPa at 20% of fly ash. In addition, water absorption of fly ash brick is increased with the increase of fly ash. The abrasion value and Specific gravity of coarse aggregate prepared from brick with fly ash also studied and the results of this study suggests that 20% fly ash can be considered as the optimum fly ash content for producing good quality bricks utilizing present practiced technology.

Keywords: Bangladesh brick, fly ash, clay brick, physical properties, compressive strength

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Authors: Nivatha Elangovan, Lakshman Neelakantan, Murugaiyan Amirthalingam

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Magnesium and its alloys are widely used for various lightweight engineering and biomedical applications as they render high strength to low weight ratio and excellent corrosion resistance. These alloys possess good bio-compatibility and similar mechanical properties to natural bone. However, manufacturing magnesium alloy components by conventional formative and subtractive methods is challenging due to their poor castability, oxidation potential, and machinability. Therefore, efforts are made to produce complex-design containing magnesium alloy components by additive manufacturing (AM). Arc-wire directed energy deposition (AW-DED), also known as wire arc additive manufacturing (WAAM), is more attractive to produce large volume components with increased productivity than any other AM technique. In this research work, efforts were made to optimise the deposition parameters to build thick-walled (about 10 mm) AZ31 magnesium alloy components by a gas metal arc (GMA) based AW-DED process. By using controlled dip short-circuiting metal transfer in a GMA process, depositions were carried out without defects and spatter formation. Current and voltage waveforms were suitably modified to achieve stable metal transfer. Moreover, the droplet transfer behaviour was analysed using high-speed image analysis and correlated with arc energy. Optical and scanning electron microscopy analyses were carried out to correlate the influence of deposition parameters with the microstructural evolution during deposition. The investigation reveals that by carefully controlling the current-voltage waveform and droplet transfer behaviour, it is possible to stabilise equiaxed grain microstructures in the deposited AZ31 components. The printed component exhibited an improved mechanical property as equiaxed grains improve the ductility and enhance the toughness. The equiaxed grains in the component improved the corrosion-resistant behaviour of other conventionally manufactured components.

Keywords: arc wire directed energy deposition, AZ31 magnesium alloy, equiaxed grain, corrosion

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Authors: Shengping Zhong, Qimin Shi, Yaling Deng, Shoufeng Yang

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Additive manufacturing has exerted a tremendous fascination on the development of the manufacturing and materials industry in the past three decades. Zirconia-based advanced ceramic has been poured substantial attention in the interest of structural and functional ceramics. As a novel material jetting process for selectively depositing nanoparticles, NanoParticle Jetting™ is capable of fabricating dense zirconia components with a high-detail surface, precisely controllable shrinkage, and remarkable mechanical properties. The presence of NPJ™ gave rise to a higher elevation regarding the printing process and printing accuracy. Emphasis is placed on the performance evaluation of NPJ™ printed ceramic components by which the physical, chemical, and mechanical properties are evaluated. The experimental results suggest the Y₂O₃-stabilized ZrO₂ boxes exhibit a high relative density of 99.5%, glossy surface of minimum 0.33 µm, general linear shrinkage factor of 17.47%, outstanding hardness and fracture toughness of 12.43±0.09 GPa and 7.52±0.34 MPa·m¹/², comparable flexural strength of 699±104 MPa, and dense and homogeneous grain distribution of microstructure. This innovative NanoParticle Jetting system manifests an overwhelming potential in dental, medical, and electronic applications.

Keywords: nanoparticle jetting, ZrO₂ ceramic, materials jetting, performance evaluation

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Authors: Mayandi Ramanathan

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Gas turbine blades see the most aggressive thermal stress conditions within the engine, due to Turbine Entry Temperatures in the range of 1500 to 1600°C, but in synchronization with other functional components, they must readily deliver efficient performance, whilst incurring minimal overhaul and repair costs during its service life up to 5 million flying miles. The blades rotate at very high rotation rates and remove significant amount of thermal power from the gas stream. At high temperatures the major component failure mechanism is creep. During its service over time under high temperatures and loads, the blade will deform, lengthen and rupture. High strength and stiffness in the longitudinal direction up to elevated service temperatures are certainly the most needed properties of turbine blades. The proposed advanced Ti alloy material needs a process that provides strategic orientation of metallic ordering, uniformity in composition and high metallic strength. 25% Ta/(Al+Ta) ratio ensures TaAl3 phase formation, where as 51% Al/(Al+Ti) ratio ensures formation of α-Ti3Al and γ-TiAl mixed phases fand the three phase combination ensures minimal Al excess (~1.4% Al excess), unlike Ti-47Al-2Cr-2Nb which has significant excess Al (~5% Al excess) that could affect the service life of turbine blades. This presentation will involve the summary of additive manufacturing and heat treatment process conditions to fabricate turbine blade with Ti-43Al matrix alloyed with optimized amount of refractory Ta metal. Summary of thermo-mechanical test results such as high temperature tensile strength, creep strain rate, thermal expansion coefficient and fracture toughness will be presented. Improvement in service temperature of the turbine blades and corrosion resistance dependence on coercivity of the alloy material will be reported. Phase compositions will be quantified, and a summary of its correlation with creep strain rate will be presented.

Keywords: gas turbine, aerospace, specific strength, creep, high temperature materials, alloys, phase optimization

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Authors: Marianna Maiaru, Gregory M. Odegard, Josh Kemppainen, Ivan Gallegos, Michael Olaya

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Ceramic matrix composites (CMCs) are typically used in applications that require long-term mechanical integrity at elevated temperatures. CMCs are usually fabricated using a polymer precursor that is initially polymerized in situ with fiber reinforcement, followed by a series of cycles of pyrolysis to transform the polymer matrix into a rigid glass or ceramic. The pyrolysis step typically generates volatile gasses, which creates porosity within the polymer matrix phase of the composite. Subsequent cycles of monomer infusion, polymerization, and pyrolysis are often used to reduce the porosity and thus increase the durability of the composite. Because of the significant expense of such iterative processing cycles, new generations of CMCs with improved durability and manufacturability are difficult and expensive to develop using standard Edisonian approaches. The goal of this research is to develop a computational process-modeling-based approach that can be used to design the next generation of CMC materials with optimized material and processing parameters for maximum strength and efficient manufacturing. The process modeling incorporates computational modeling tools, including molecular dynamics (MD), to simulate the material at multiple length scales. Results from MD simulation are used to inform the continuum-level models to link molecular-level characteristics (material structure, temperature) to bulk-level performance (strength, residual stresses). Processing parameters are optimized such that process-induced residual stresses are minimized and laminate strength is maximized. The multiscale process modeling method developed with this research can play a key role in the development of future CMCs for high-temperature and high-strength applications. By combining multiscale computational tools and process modeling, new manufacturing parameters can be established for optimal fabrication and performance of CMCs for a wide range of applications.

Keywords: digital engineering, finite elements, manufacturing, molecular dynamics

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Authors: Seulki Lee, Seoung Bum Kim

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Statistical process control (SPC) is a practical and effective method for quality control. The most important and widely used technique in SPC is a control chart. The main goal of a control chart is to detect any assignable changes that affect the quality output. Most conventional control charts, such as Hotelling’s T2 charts, are commonly based on the assumption that the quality characteristics follow a multivariate normal distribution. However, in modern complicated manufacturing systems, appropriate control chart techniques that can efficiently handle the nonnormal processes are required. To overcome the shortcomings of conventional control charts for nonnormal processes, several methods have been proposed to combine statistical learning algorithms and multivariate control charts. Statistical learning-based control charts, such as support vector data description (SVDD)-based charts, k-nearest neighbors-based charts, have proven their improved performance in nonnormal situations compared to that of the T2 chart. Beside the nonnormal property, time-varying operations are also quite common in real manufacturing fields because of various factors such as product and set-point changes, seasonal variations, catalyst degradation, and sensor drifting. However, traditional control charts cannot accommodate future condition changes of the process because they are formulated based on the data information recorded in the early stage of the process. In the present paper, we propose a SVDD algorithm-based control chart, which is capable of adaptively monitoring time-varying and nonnormal processes. We reformulated the SVDD algorithm into a time-adaptive SVDD algorithm by adding a weighting factor that reflects time-varying situations. Moreover, we defined the updating region for the efficient model-updating structure of the control chart. The proposed control chart simultaneously allows efficient model updates and timely detection of out-of-control signals. The effectiveness and applicability of the proposed chart were demonstrated through experiments with the simulated data and the real data from the metal frame process in mobile device manufacturing.

Keywords: multivariate control chart, nonparametric method, support vector data description, time-varying process

Procedia PDF Downloads 300

Authors: Sankar Majumder

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Development of Rural Entrepreneurs requires a holistic approach involving social, economic, political, technical, and environmental and many other issues. It needs a thorough understanding of the economy and society. It's true that agricultural development, rural development and many other social and right based development programmes have resulted in the growth of income in the rural sector. The development of rural entrepreneurs is necessary to utilise these opportunities. Many programmes and policies in the spheres of organisational, financial, infrastructural and technical supports have been taken to promote rural industries. But if one looks at the growth and development of rural industrial units, especially the manufacturing units, the picture is not promising. This paper aims at analysing the possible causes and its solutions in terms of (1) Mind set of the society towards business as a livelihood; (2) Sufficiency and appropriateness of the existing organisational, financial, infrastructural and technical supports. The paper is based on secondary data on various aspects of rural enterprises and the author’s experiences in the course of his work as a practitioner in this field. Growth of units and employment in the rural industries shows that the entrepreneurs are more inclined towards trading units than towards manufacturing ventures. The growth of rural industries is constrained not by the insufficiency of the supply of finance but by the insufficient demand for finance. The task is to increase the supply of entrepreneurs by creating an entrepreneurial environment. Incubation for rural entrepreneurs is the need of the hour.

Keywords: business mind set, entrepreneurial environment, supply of finance, technical support

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Authors: Emrah Yaliniz, Ali Kalkanli

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ZE41A magnesium alloy has been extensively used in aerospace industry, especially for use in rotorcraft transmission casings. Due to the improved mechanical properties, the latest generation of magnesium casting alloy EV31A-T6 (Elektron 21® specified in AMS 4429) is seen as a potential replacement for ZE41A in terms of strength. Therefore, the necessity of enhancement has been arisen for ZE41A in order to avoid fully replacement. The main element affecting the strength of ZE41A is Zirconium (Zr), which acts as a grain refiner. The specified range of Zr element for ZE41A alloy is between 0.4 wt % and 1.0 wt % (unless otherwise stated by weight percentage after this point) as stated in AMS 4439. This paper investigates the effects of Zr amount on tensile and metallurgical properties of ZE41A magnesium alloy. The Zr alloying amount for the research has been chosen as 0.5 % and 1 %, which are standard amounts in a commercial alloy (average of 0.4-0.6%) and maximum percent in the standard, separately. 1 % Zr amount has been achieved via Zirmax (66.7 Mg-33.3 Zr) master alloy addition. The ultimate tensile strength of ZE41A with 1% Zr has been increased up to about 220-225 MPa in comparison to 200 MPa given in AMS 4439. The reason for the increase in strength with the addition of Zirmax is based on the decrease in grain size, which was measured about 30 µm. Optical microscope, scanning electron microscopy (SEM) and X-ray Diffraction (XRD) were used to detect the change in the microstructural futures via alloying. The zirconium rich coring at the center of the grains was observed in addition to the grain boundary intermetallic phases and bulk Mg-rich matrix. The solidification characteristics were also identified by using the cooling curve obtained from the sand casting mold during cooling of the alloys.

Keywords: aerospace, grain refinement, magnesium, sand casting, ZE41A

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Authors: R. Noorani, K. Peerless, J. Mandrell, A. Lopez, R. Dalberto, M. Alzebaq

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Rapid prototyping (RP) is an additive manufacturing technology used in industry that works by systematically depositing layers of working material to construct larger, computer-modeled parts. A key challenge associated with this technology is that RP parts often feature undesirable levels of surface roughness for certain applications. To combat this phenomenon, an experimental technique called Design of Experiments (DOE) can be employed during the growth procedure to statistically analyze which RP growth parameters are most influential to part surface roughness. Utilizing DOE to identify such factors is important because it is a technique that can be used to optimize a manufacturing process, which saves time, money, and increases product quality. In this study, a four-factor/two level DOE experiment was performed to investigate the effect of temperature, layer thickness, infill percentage, and infill speed on the surface roughness of RP prototypes. Samples were grown using the sixteen different possible growth combinations associated with a four-factor/two level study, and then the surface roughness data was gathered for each set of factors. After applying DOE statistical analysis to these data, it was determined that layer thickness played the most significant role in the prototype surface roughness.

Keywords: rapid prototyping, surface roughness, design of experiments, statistical analysis, factors and levels

Procedia PDF Downloads 262