Search results for: laser additive manufacturing

Authors: M.St. Węglowski, D. Miara, S. Błacha, J. Dworak, J. Rykała, K. Kwieciński, J. Pikuła, G. Ziobro, A. Szafron, P. Zimierska-Nowak, M. Richert, P. Noga

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In the paper the results of welding of car’s air-conditioning elements are presented. These systems based on, mainly, the environmental unfriendly refrigerants. Thus, the producers of cars will have to stop using traditional refrigerant and to change it to carbon dioxide (R744). This refrigerant is environmental friendly. However, it should be noted that the air condition system working with R744 refrigerant operates at high temperature (up to 150 °C) and high pressure (up to 130 bar). These two parameters are much higher than for other refrigerants. Thus new materials, design as well as joining technologies are strongly needed for these systems. AISI 304 and 316L steels as well as aluminium alloys 5xxx are ranked among the prospective materials. As a joining process laser welding, plasma welding, electron beam welding as well as high rotary friction welding can be applied. In the study, the metallographic examination based on light microscopy as well as SEM was applied to estimate the quality of welded joints. The analysis of welding was supported by numerical modelling based on Sysweld software. The results indicated that using laser, plasma and electron beam welding, it is possible to obtain proper quality of welds in stainless steel. Moreover, high rotary friction welding allows to guarantee the metallic continuity in the aluminium welded area. The metallographic examination revealed that the grain growth in the heat affected zone (HAZ) in laser and electron beam welded joints were not observed. It is due to low heat input and short welding time. The grain growth and subgrains can be observed at room temperature when the solidification mode is austenitic. This caused low microstructural changes during solidification. The columnar grain structure was found in the weld metal. Meanwhile, the equiaxed grains were detected in the interface. The numerical modelling of laser welding process allowed to estimate the temperature profile in the welded joint as well as predicts the dimensions of welds. The agreement between FEM analysis and experimental data was achieved.  

Keywords: car’s air–conditioning, microstructure, numerical modelling, welding

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Authors: Yusri Yusof, Kamran Latif

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Computer Numeric Control (CNC) machine has been widely used in the industries since its inception. Currently, in CNC technology has been used for various operations like milling, drilling, packing and welding etc. with the rapid growth in the manufacturing world the demand of flexibility in the CNC machines has rapidly increased. Previously, the commercial CNC failed to provide flexibility because its structure was of closed nature that does not provide access to the inner features of CNC. Also CNC’s operating ISO data interface model was found to be limited. Therefore, to overcome that problem, Open Architecture Control (OAC) technology and STEP-NC data interface model are introduced. At present the Personal Computer (PC) has been the best platform for the development of open-CNC systems. In this paper, both ISO data interface model interpretation, its verification and execution has been highlighted with the introduction of the new techniques. The proposed is composed of ISO data interpretation, 3D simulation and machine motion control modules. The system is tested on an old 3 axis CNC milling machine. The results are found to be satisfactory in performance. This implementation has successfully enabled sustainable manufacturing environment.

Keywords: CNC, ISO 6983, ISO 14649, LabVIEW, open architecture control, reconfigurable manufacturing systems, sustainable manufacturing, Soft-CNC

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Authors: S. Vignesh, K. S. Rangasamy

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The paper deals with the device capable of detecting and disabling digital cameras. The system locates the camera and then neutralizes it. Every digital camera has an image sensor known as a CCD, which is retro-reflective and sends light back directly to its original source at the same angle. The device shines infrared LED light, which is invisible to the human eye, at a distance of about 20 feet. It then collects video of these reflections with a camcorder. Then the video of the reflections is transferred to a computer connected to the device, where it is sent through image processing algorithms that pick out infrared light bouncing back. Once the camera is detected, the device would project an invisible infrared laser into the camera's lens, thereby overexposing the photo and rendering it useless. Low levels of infrared laser neutralize digital cameras but are neither a health danger to humans nor a physical damage to cameras. We also discuss the simplified design of the above device that can used in theatres to prevent piracy. The domains being covered here are optics and image processing.

Keywords: CCD, optics, image processing, D3CIP

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Authors: A. Arya, R. Laha, V. R. Dantham

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We report the enhancement of Raman scattering signal by one order of magnitude using photonic nanojet (PNJ) of a lollipop shaped dielectric microstructure (LSDM) fabricated by a pulsed CO₂ laser. Here, the PNJ is generated by illuminating sphere portion of the LSDM with non-resonant laser. Unlike the surface enhanced Raman scattering (SERS) technique, this technique is simple, and the obtained results are highly reproducible. In addition, an efficient technique is proposed to enhance the SERS signal with the help of high quality factor optical resonance (whispering gallery mode) of a LSDM. From the theoretical simulations, it has been found that at least an order of magnitude enhancement in the SERS signal could be achieved easily using the proposed technique. We strongly believe that this report will enable the research community for improving the Raman scattering signals.

Keywords: localized surface plasmons, photonic nanojet, SERS, whispering gallery mode

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Authors: Hyomin Lee, Jinhyun Lee, Jinyeon Hwang, Younghoon Choi, Byeongseo Son

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Global warming is a world-wide issue. Various carbon capture and storage (CCS) technologies for reducing CO2 concentration in the atmosphere have been increasingly studied. Mineral carbonation is one of promising method for CO2 sequestration. Waste cement generating from aggregate recycling processes of waste concrete is potentially a good raw material containing reactive components for mineral carbonation. The major goal of our long-term project is to developed effective methods for CO2 sequestration using waste cement. In the present study, the carbonation characteristics of hydrated cement were examined by conducting two different direct aqueous carbonation experiments. We also evaluate the influence of NaCl and MgCl2 as additives to increase mineral carbonation efficiency of hydrated cement. Cement paste was made with W:C= 6:4 and stored for 28 days in water bath. The prepared cement paste was pulverized to the size less than 0.15 mm. 15 g of pulverized cement paste and 200 ml of solutions containing additives were reacted in ambient temperature and pressure conditions. 1M NaCl and 0.25 M MgCl2 was selected for additives after leaching test. Two different sources of CO2 was applied for direct aqueous carbonation experiment: 0.64 M NaHCO3 was used for CO2 donor in method 1 and pure CO2 gas (99.9%) was bubbling into reacting solution at the flow rate of 20 ml/min in method 2. The pH and Ca ion concentration were continuously measured with pH/ISE Multiparameter to observe carbonation behaviors. Material characterization of reacted solids was performed by TGA, XRD, SEM/EDS analyses. The carbonation characteristics of hydrated cement were significantly different with additives. Calcite was a dominant calcium carbonate mineral after the two carbonation experiments with no additive and NaCl additive. The significant amount of aragonite and vaterite as well as very fine calcite of poorer crystallinity was formed with MgCl2 additive. CSH (calcium silicate hydrate) in hydrated cement were changed to MSH (magnesium silicate hydrate). This transformation contributed to the high carbonation efficiency. Carbonation experiment with method 1 revealed that that the carbonation of hydrated cement took relatively long time in MgCl2 solution compared to that in NaCl solution and the contents of aragonite and vaterite were increased as increasing reaction time. In order to maximize carbonation efficiency in direct aqueous carbonation with CO2 gas injection (method 2), the control of solution pH was important. The solution pH was decreased with injection of CO2 gas. Therefore, the carbonation efficiency in direct aqueous carbonation was closely related to the stability of calcium carbonate minerals with pH changes. With no additive and NaCl additive, the maximum carbonation was achieved when the solution pH was greater than 11. Calcium carbonate form by mineral carbonation seemed to be re-dissolved as pH decreased below 11 with continuous CO2 gas injection. The type of calcium carbonate mineral formed during carbonation in MgCl2 solution was closely related to the variation of solution pH caused by CO2 gas injection. The amount of aragonite significantly increased with decreasing solution pH, whereas the amount of calcite decreased.

Keywords: CO2 sequestration, Mineral carbonation, Cement and concrete, MgCl2 and NaCl

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Authors: Rajkishore Nayak, Tarun Panwar, Majo George

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The study focuses on investigating the factors that influence the growth of fashion and textile manufacturing in the Sub-Saharan Africa (SSA) countries. This paper endeavours to identify, analyse and evaluate the critical factors associated with the growth of fashion and textile manufacturing in SSA countries. This research has done a Strength, Weakness, Opportunity, and Threat (SWOT) analysis based on the available literature and the knowledge of authors in garment manufacturing and export. It was found that the SSA countries have shown little growth in fashion and textile manufacturing and export from the starting of the year 2000. Unlike the developing countries such as Vietnam and Bangladesh, the total export to the US, the EU and other parts of the world has declined. On the other hand, the total supply of fashion and textiles to the domestic market has been in rise. However, the local communities still need to rely on other countries to meet their demand. Availability of cheaper imported clothes from other countries such as Bangladesh, China and Vietnam have made it difficult for the local manufacturers to produce at a cheaper price.

Keywords: Sub-Saharan Africa, developing countries, apparel industry, fashion and textile, sustainable fashion

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Authors: Shashank Patidar, Sumit Kumar, Atul Srivastava, Suneet Singh

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Present work is concerned with the numerical investigation of thermal response of biological tissues during laser-based photo-thermal therapy for destroying cancerous/abnormal cells with minimal damage to the surrounding normal cells. Light propagation through the biological sample is mathematically modelled by transient radiative transfer equation. In the present work, application of the Lattice Boltzmann Method is extended to analyze transport of short-pulse radiation in a participating medium.In order to determine the two-dimensional temperature distribution inside the tissue medium, the RTE has been coupled with Penne’s bio-heat transfer equation based on Fourier’s law by several researchers in last few years.

Keywords: lattice Boltzmann method, transient radiation transfer equation, dual phase lag model

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Authors: Loganathan Kumaresan, Velusamy Chidambaram, Arumugam Velayutham Karthikeyani, Alex Cheru Pulikottil, Madhusudan Sau, Gurpreet Singh Kapur, Sankara Sri Venkata Ramakumar

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Environmentally driven regulations throughout the world stipulate dramatic improvements in the quality of transportation fuels and refining operations. The exhaust gases like CO, NOx, and SOx from stationary sources (e.g., refinery) and motor vehicles contribute to a large extent for air pollution. The refining industry is under constant environmental pressure to achieve more rigorous standards on sulphur content in the fuel used in the transportation sector and other off-gas emissions. Fluid catalytic cracking unit (FCCU) is a major secondary process in refinery for gasoline and diesel production. CO-combustion promoter additive and gasoline sulphur reduction (GSR) additive are catalytic systems used in FCCU to assist the combustion of CO to CO₂ in the regenerator and regulate sulphur in gasoline faction respectively along with main FCC catalyst. Effectiveness of these catalysts is governed by the active metal used, its dispersion, the type of base material employed, and retention characteristics of additive in FCCU such as attrition resistance and density. The challenge is to have a high-density microsphere catalyst support for its retention and high activity of the active metals as these catalyst additives are used in low concentration compare to the main FCC catalyst. The present paper discusses in the first part development of high dense microsphere of nanocrystalline alumina by hydro-thermal method for CO combustion promoter application. Performance evaluation of additive was conducted under simulated regenerator conditions and shows CO combustion efficiency above 90%. The second part discusses the efficacy of a co-precipitation method for the generation of the active crystalline spinels of Zn, Mg, and Cu with aluminium oxides as an additive. The characterization and micro activity test using heavy combined hydrocarbon feedstock at FCC unit conditions for evaluating gasoline sulphur reduction activity are studied. These additives were characterized by X-Ray Diffraction, NH₃-TPD & N₂ sorption analysis, TPR analysis to establish structure-activity relationship. The reaction of sulphur removal mechanisms involving hydrogen transfer reaction, aromatization and alkylation functionalities are established to rank GSR additives for their activity, selectivity, and gasoline sulphur removal efficiency. The sulphur shifting in other liquid products such as heavy naphtha, light cycle oil, and clarified oil were also studied. PIONA analysis of liquid product reveals 20-40% reduction of sulphur in gasoline without compromising research octane number (RON) of gasoline and olefins content.

Keywords: hydrothermal, nanocrystalline, spinel, sulphur reduction

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Authors: Hsu Yi-Chia, Hoy June-Hao

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FDM (Fused Deposition Modeling) is a rapid proofing method without mold, however, high material and time costs have always been a major disadvantage. Wire-printing is the next generation technology that can more flexible, and also easier to apply on a 3D printer and robotic arms printing. It can create its own construction methods. The research is mainly divided into three parts. The first is about the method of parameterizing the generated paths and the conversion of g-code to the wire-printing. The second is about material attempts and the application of effects. Third, is about the improvement of the operation of mechanical equipment and the design of robotic tool-head. The purpose of this study is to develop a new wire-print method that can efficiently generate line segments and paths in three- dimensions space. The parametric modeling software transforms the digital model into a 3D printer or robotic arms g-code, this article uses thermoplastics/ clay/composites materials for testing. The combination of materials and wire-print process makes architects and designers have the ability to research and develop works and construction in the future.

Keywords: parametric software, wire print, robotic arms fabrication, composite filament additive manufacturing

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Authors: Nadia Fatima Zahra Malki

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The aim of the study is to show the role of total Quality Management on firm performance, research relied on the views of a sample managers working in the Marinel pharmaceutical company. The research aims to achieve many objectives, including increasing awareness of the concepts of Total Quality Management on Firm Performance, especially in the manufacturing firm, providing a future vision of the possibility of success, and the actual application of the Principles of Total Quality Management in the manufacturing company. The research adopted a default model was built after a review and analysis of the literature review in the context of one hypothesis's main points at the origin of a group of sub-hypotheses. The research presented a set of conclusions, and the most important of these conclusions was that there is a relationship between the Principles of TQM and Firm Performance.

Keywords: total quality management, competitive advantage, companies, objectives

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Authors: S. Bayona, J. Nunez, D. Paez, C. Diaz

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The application of Lean manufacturing tools continues to be an effective solution for increasing productivity, reducing costs and eliminating waste in the manufacture of goods and services. This article analyzes the production process of a hot asphalt manufacturing company from an administrative and technical perspective. Three main phases were analyzed, the first phase was related to the determination of the risk priority number of the main operations in asphalt mix production process by an FMEA (Failure Mode Effects Analysis), in the second phase the Value Stream Mapping (VSM) of the production line was performed and in the third phase a SWOT (Strengths, Weaknesses Opportunities, Threats) matrix was constructed. Among the most valued failure modes were the lack training of workers in occupational safety and health issues, the lack of signaling and classification of granulated material, and the overweight of vehicles loaded. The analysis of the results in the three phases agree on the importance of training operational workers, improve communication with external actors in order to minimize delays in material orders and strengthen control suppliers.

Keywords: asphalt, lean manufacturing, productivity, process

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Authors: Przemyslaw Nogly, Tobias Weinert, Daniel James, Sergio Carbajo, Dmitry Ozerov, Antonia Furrer, Dardan Gashi, Veniamin Borin, Petr Skopintsev, Kathrin Jaeger, Karol Nass, Petra Bath, Robert Bosman, Jason Koglin, Matthew Seaberg, Thomas Lane, Demet Kekilli, Steffen Brünle, Tomoyuki Tanaka, Wenting Wu, Christopher Milne, Thomas A. White, Anton Barty, Uwe Weierstall, Valerie Panneels, Eriko Nango, So Iwata, Mark Hunter, Igor Schapiro, Gebhard Schertler, Richard Neutze, Jörg Standfuss

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Ultrafast isomerization of retinal is the primary step in a range of photoresponsive biological functions including vision in humans and ion-transport across bacterial membranes. We studied the sub-picosecond structural dynamics of retinal isomerization in the light-driven proton pump bacteriorhodopsin using an X-ray laser. Twenty snapshots with near-atomic spatial and temporal resolution in the femtosecond regime show how the excited all-trans retinal samples conformational states within the protein binding pocket prior to passing through a highly-twisted geometry and emerging in the 13-cis conformation. The aspartic acid residues and functional water molecules in proximity of the retinal Schiff base respond collectively to formation and decay of the initial excited state and retinal isomerization. These observations reveal how the protein scaffold guides this remarkably efficient photochemical reaction.

Keywords: bacteriorhodopsin, free-electron laser, retinal isomerization mechanism, time-resolved crystallography

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Authors: Axel Thallemer, Aleksandar Kostadinov, Abel Fam, Alex Teo

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For centuries, the forming processes in nature served as a source of inspiration for both architects and designers. It seems as most human artifacts are based on ideas which stem from the observation of the biological world and its principles of growth. As a fact, in the cultural history of Homo faber, materials have been mostly used in their solid state: From hand axe to computer mouse, the principle of employing matter has not changed ever since the first creation. In the scope of history only recently and by the help of additive-generative fabrication processes through Computer Aided Design (CAD), designers were enabled to deconstruct solid artifacts into an outer skin and an internal lattice structure. The intention behind this approach is to create a new topology which reduces resources and integrates functions into an additively manufactured component. However, looking at the currently employed lattice structures, it is very clear that those lattice structure geometries have not been thoroughly designed, but rather taken out of basic-geometry libraries which are usually provided by the CAD. In the here presented study, a group of 20 industrial design students created new and unique lattice structures using natural paragons as their models. The selected natural models comprise both the animate and inanimate world, with examples ranging from the spiraling of narwhal tusks, off-shooting of mangrove roots, minimal surfaces of soap bubbles, up to the rhythmical arrangement of molecular geometry, like in the case of SiOC (Carbon-Rich Silicon Oxicarbide). This ideation process leads to a design of a geometric cell, which served as a basic module for the lattice structure, whereby the cell was created in visual analogy to its respective natural model. The spatial lattices were fabricated additively in mostly [X]3 by [Y]3 by [Z]3 units’ volumes using selective powder bed melting in polyamide with (z-axis) 50 mm and 100 µm resolution and subdued to mechanical testing of their elastic zone in a biomedical laboratory. The results demonstrate that additively manufactured lattice structures can acquire different properties when they are designed in analogy to natural models. Several of the lattices displayed the ability to store and return kinetic energy, while others revealed a structural failure which can be exploited for purposes where a controlled collapse of a structure is required. This discovery allows for various new applications of functional lattice structures within industrially created objects.

Keywords: bio-inspired, biomimetic, lattice structures, additive manufacturing

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Authors: Fawad Hussain, Mohammad Basir Bin Saud, Mohd Azwardi Md Isa

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The aim of this study is to empirically investigate the mediating impact of export performance (EP) between technological advancement capabilities (TAC) and business performance (BP) of Malaysian manufacturing MSME’s. Firm’s technological advancement resources are hypothesized as a platform to enhance both exports and business performance of manufacturing MSMEs in Malaysia. This study is twofold, primary it has investigated that technological advancement capabilities helps to appreciates main performance measures noted in terms of export performance and Secondly it investigates that how efficiently and effectively technological advancement capabilities can contributes in overall Malaysian MSME’s business performance. Smart PLS-3 statistical software is used to know the association between technological advancement capabilities, MSME’s export performance and business performance. In this study the data was composed from Malaysian manufacturing MSME’s in east coast industrial zones known as manufacturing hub of MSMEs. Seven Hundred and Fifty (750) questionnaires were distributed but only 148 usable questionnaires are returned. The finding of this study indicated that technological advancement capabilities helps to strengthen the export in term of time and cost efficient and it plays a significant role in appreciating their business performance. This study is helpful for small and medium enterprises owners who intent to expand their business overseas and though smart technological advancement resources they can achieve their business competitiveness and excellence both at local and international markets.

Keywords: technological advancement capabilities, export performance, business performance, small and medium manufacturing enterprises, malaysia

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Authors: Mahsa Kangazian Kangazi, Ali Akbar Ghareh Aghaji, Majid Montazer

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Nowadays, silica nanofibers are highly regarded among the inorganic nanofibers due to the high reactivity and availability of silicon compounds in nature. Sol-gel process is required for electrospinning of silica nanofibers in which a metal alkoxide is hydrolyzed, and the viscosity is increased. In this study, silica nanofibers containing silver nanoparticles were synthesized and electrospun from a mixture of silica sol with an easy spinnable polymer (PVA) as an additive. The silica sol contains tetraethyl orthosilicate (TEOS), silver nitrate, distilled water, nitric acid, and ethanol. Nanofibers were formed through electrospinning setup. The nanofibers were calcinated to remove the solvent and additive polymer. Consequently, pure silica nanofibers were produced. FTIR analysis indicated entire removal of polyvinyl alcohol from the structure and formation of silan groups. The presence of silver, silica and oxygen was confirmed by EDX. Also, XRD patterns revealed the presence of silver nanoparticles with a mean crystal size of 18 nm. FESEM images showed that adding silver nitrate into the sol-gel, resulted in lower nanofibers diameter from 286 to 136 nm. Furthermore, the electrospun nanofibers were more resistance in acidic media than alkaline media.

Keywords: in situ synthesis of silver nanoparticles, silica nanofibers, sol-gel, tetraethyl orthosilicate

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Authors: Cansu Kandemir, Marco Franchino

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To attain sustainability goals, the manufacturing industries must assess and improve their processes, adopt the latest technologies, and ensure minimal environmental impact. Ongoing debates claim that the definition of sustainability and its assessment is vague. Companies struggle with understanding which processes they should prioritise and necessitate a methodology to aid decision-making. For that reason, our investigation focused on defining a prioritisation guide to help to manufacture engineers identify areas of a facility to prioritise de-carbonisation efforts based on existing sources of data. The authors at the University of Sheffield Advanced Manufacturing Research Centre (AMRC) worked with a range of major businesses, including Food and Drink (Moy Park), Automotive (Nissan), Aerospace and Defence (BAE, Meggitt, Leonardo, and GKN) and Technology (Accenture and Intellium AI). Collected information has been integrated into a prioritisation guide framework that helps process comparison and decision-making. The framework developed in this study aims to ensure that companies have guidance on where to focus their efforts whilst striving to fulfil their environmental and societal obligations.

Keywords: decision making, sustainability, carbon emissions, manufacturing

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Authors: Ahmad Yame, Ahad Ali, Badih Jawad, Daw Al-Werfalli Mohamed Nasser, Sabah Abro

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Industries in general have a lot of waste. Wool textile company, Baniwalid, Libya has many complex problems that led to enormous waste generated due to the lack of lean strategies, expertise, technical support and commitment. To successfully address waste at wool textile company, this study will attempt to develop a methodical approach that integrates lean manufacturing tools to optimize performance characteristics such as lead time and delivery. This methodology will utilize Value Stream Mapping (VSM) techniques to identify the process variables that affect production. Once these variables are identified, Design of Experiments (DOE) Methodology will be used to determine the significantly influential process variables, these variables are then controlled and set at their optimal to achieve optimal levels of productivity, quality, agility, efficiency and delivery to analyze the outputs of the simulation model for different lean configurations. The goal of this research is to investigate how the tools of lean manufacturing can be adapted from the discrete to the continuous manufacturing environment and to evaluate their benefits at a specific industrial.

Keywords: lean manufacturing, DOE, value stream mapping, textiles

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Authors: Mohammed Alharbi, Clare Wood, Vasileios Samaras

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Sustainability leadership is a controversial topic, particularly in the engineering context. The theoretical and practical technical focus of the engineering profession impacts our lives. Technologically, engineers significantly contribute to our modern civilization. Industrial revolutions are among the top engineering accomplishments that have contributed to the flourishing of our life. However, engineers have not always received the credit they deserve; instead, they have been blamed for the advent of various global issues, among them the global warming phenomena that are believed to be a result of the industrial revolutions. Global challenges demand engineers demonstrate more than their technical skills for effective contribution to a sustainable future. As a result, engineering leadership has emerged as a new research field. Sustainable manufacturing is a cornerstone for sustainable development. Investigating the change to more sustainable manufacturing practices is a significant issue for all, and even more in the field of engineering leadership. Engineers dominate the manufacturing industry; however, one of the main criticism of engineers is the lack of leadership skills. The literature on engineering leadership has not highlighted enough the engineers' leadership ability in leading sustainable manufacturing. Since we are at the cusp of a new industrial revolution -Industry 4.0, it is vital to investigate the ability of engineers to lead the industry towards a sustainable future. The primary purpose of this paper is to evaluate engineers' sustainability leadership competencies utilizing The Cambridge University Behavioral Competency Model. However, the practical application of the Cambridge model is limited due to the absence of a reliable measurement tool. Therefore, this study developed a valid and reliable survey instrument tool compatible with the Cambridge model as a secondary objective. More than 300 Saudi engineers from the manufacturing industry responded to an online questionnaire collected through the Qualtrics platform and analyzed using SPSS software. The findings provide a contemporary understanding of engineers' mindset related to sustainability leadership. The output of this research study could be valuable in designing effective engineering leadership programs in academia or industry, particularly for enhancing a sustainable manufacturing environment.

Keywords: engineer, leadership, manufacturing, sustainability

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Authors: J. H. Park, S. K. Lee, Y. W. Kim, D. C. Ko

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A large variety of pipe flange is required in marine and construction industry.Pipe flanges are usually welded or screwed to the pipe end and are connected with bolts.This approach is very simple and widely used for a long time, however, it results in high development cost and low productivity, and the productions made by this approach usually have safety problem at the welding area.In this research, a new approach of forming pipe flange based on cold forging and floating die concept is presented.This innovative approach increases the effectiveness of the material usage and save the time cost compared with conventional welding method. To ensure the dimensional accuracy of the final product, the finite element analysis (FEA) was carried out to simulate the process of cold forging, and the orthogonal experiment methods were used to investigate the influence of four manufacturing factors (pin die angle, pipe flange angle, rpm, pin die distance from clamp jig) and predicted the best combination of them. The manufacturing factors were obtained by numerical and experimental studies and it shows that the approach is very useful and effective for the forming of pipe flange, and can be widely used later.

Keywords: cold forging, FEA (finite element analysis), forge-3D, rotating forming, tubes

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Authors: Malki Nadia Fatima Zahra, Kellal Cheimaa, Brahimi Houria

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Aim of the study is to show the role of total Quality Management on firm performance; the research relied on the views of sample managers working in the Marinel pharmaceutical company. The research aims to achieve many objectives, including increasing awareness of the concepts of Total Quality Management on Firm Performance, especially in the manufacturing firm, providing a future vision of the possibility of success, and the actual application of the Principles of Total Quality Management in the manufacturing company. The research adopted a default model was built after a review and analysis of the literature review in the context of one hypothesis main points at the origin of a group of sub-hypotheses. The research presented a set of conclusions, and the most important of these conclusions was there is a relationship between the Principles of TQM and Firm Performance.

Keywords: total quality management, TQM dimension, firm performance, strategies

Procedia PDF Downloads 68

Authors: Tom Wanyama

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We have developed a weight-based parts inventory monitoring system utilizing the Industrial Internet of Things (IIoT) to enhance operational efficiencies in manufacturing. The system addresses various challenges, including eliminating downtimes caused by stock-outs, preventing human errors in parts delivery and product assembly, and minimizing motion waste by reducing unnecessary worker movements. The system incorporates custom QR codes for simplified inventory tracking and retrieval processes. The generated data serves a dual purpose by enabling real-time optimization of parts flow within manufacturing facilities and facilitating retroactive optimization of stock levels for informed decision-making in inventory management. The pilot implementation at SEPT Learning Factory successfully eradicated data entry errors, optimized parts delivery, and minimized workstation downtimes, resulting in a remarkable increase of over 10% in overall equipment efficiency across all workstations. Leveraging the IIoT features, the system seamlessly integrates information into the process control system, contributing to the enhancement of product quality. This approach underscores the importance of effective tracking of parts inventory in manufacturing to achieve transparency, improved inventory control, and overall profitability. In the broader context, our inventory monitoring system aligns with the evolving focus on optimizing supply chains and maintaining well-managed warehouses to ensure maximum efficiency in the manufacturing industry.

Keywords: industrial Internet of things, industrial systems integration, inventory monitoring, inventory control in manufacturing

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Authors: James Q. Feng

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Pneumatic nebulizers (as variations based on the Collison nebulizer) have been widely used for producing fine aerosol droplets from a liquid material. As qualitatively described by many authors, the basic working principle of those nebulizers involves utilization of the negative pressure associated with an expanding gas jet to syphon liquid into the jet stream, then to blow and shear into liquid sheets, filaments, and eventually droplets. But detailed quantitative analysis based on fluid mechanics theory has been lacking in the literature. The purpose of present work is to investigate the nature of negative pressure distribution associated with compressible gas jet flow in the Collison nebulizer by a computational fluid dynamics (CFD) analysis, using an OpenFOAM® compressible flow solver. The value of the negative pressure associated with a gas jet flow is examined by varying geometric parameters of the jet expansion channel adjacent to the jet orifice outlet. Such an analysis can provide valuable insights into fundamental mechanisms in liquid aspiration process, helpful for effective design of the pneumatic atomizer in the Aerosol Jet® direct-write system for micro-feature, high-aspect-ratio material deposition in additive manufacturing.

Keywords: collison nebulizer, compressible gas jet flow, liquid aspiration, pneumatic atomization

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Authors: Gichun Cha, Dongwan Lee, Junkyeong Kim, Aoqi Zhang, Seunghee Park

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All the world are studying the construction technology of double deck tunnel in order to respond to the increasing urban traffic demands and environmental changes. Advanced countries have the construction technology of the double deck tunnel structure. but the domestic country began research on it. Construction technologies are important. But Safety evaluation of structure is necessary to prevent possible accidents during construction. Thus, the double deck tunnel was required the shape management of middle slabs. The domestic country is preparing the construction of double deck tunnel for an alternate route and a pleasant urban environment. Shape management of double deck tunnel has been no research because it is a new attempted technology. The present, a similar study is bridge structure for the shape management. Bridge is implemented shape model using terrestrial laser scanning(TLS). Therefore, we proceed research on the bridge slabs because there is a similar structure of double deck tunnel. In the study, we develop shape management method of bridge slabs using TLS. We select the Test-bed for measurement site. This site is bridge located on Sungkyunkwan University Natural Sciences Campus. This bridge has a total length of 34m, the vertical height of 8.7m from the ground. It connects Engineering Building #1 and Engineering Building #2. Point cloud data for shape management is acquired the TLS and We utilized the Leica ScanStation C10/C5 model. We will confirm the Maximum displacement area of middle slabs using Least-Squares Fitting. We expect to raise stability for double deck tunnel through shape management for middle slabs.

Keywords: bridge slabs, least squares, safety evaluation, shape management method, terrestrial laser scanning

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Authors: Donghwan Lee, Gichun Cha, Jooyoung Park, Junkyeong Kim, Seunghee Park

Abstract:

3D shape models of the existing structure are required for many purposes such as safety and operation management. The traditional 3D modeling methods are based on manual or semi-automatic reconstruction from close-range images. It occasions great expense and time consuming. The Terrestrial Laser Scanner (TLS) is a common survey technique to measure quickly and accurately a 3D shape model. This TLS is used to a construction site and cultural heritage management. However there are many limits to process a TLS point cloud, because the raw point cloud is massive volume data. So the capability of carrying out useful analyses is also limited with unstructured 3-D point. Thus, segmentation becomes an essential step whenever grouping of points with common attributes is required. In this paper, members segmentation algorithm was presented to separate a raw point cloud which includes only 3D coordinates. This paper presents a clustering approach based on a fuzzy method for this objective. The Fuzzy C-Means (FCM) is reviewed and used in combination with a similarity-driven cluster merging method. It is applied to the point cloud acquired with Lecia Scan Station C10/C5 at the test bed. The test-bed was a bridge which connects between 1st and 2nd engineering building in Sungkyunkwan University in Korea. It is about 32m long and 2m wide. This bridge was used as pedestrian between two buildings. The 3D point cloud of the test-bed was constructed by a measurement of the TLS. This data was divided by segmentation algorithm for each member. Experimental analyses of the results from the proposed unsupervised segmentation process are shown to be promising. It can be processed to manage configuration each member, because of the segmentation process of point cloud.

Keywords: fuzzy c-means (FCM), point cloud, segmentation, terrestrial laser scanner (TLS)

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Authors: Chukwumeka Daniel Ezeliora

Abstract:

The Nigerian manufacturing sector plays a pivotal role in the country's economic growth and development. However, it faces numerous challenges, including operational inefficiencies and inherent risks that hinder its sustainable growth. This research aims to address these challenges by exploring the integration of Lean and Six Sigma methodologies into the manufacturing processes, ultimately enhancing operational effectiveness and risk mitigation. The core of this research involves the development of a sustainable Lean Six Sigma framework tailored to the specific needs and challenges of Nigeria's manufacturing environment. This framework aims to streamline processes, reduce waste, improve product quality, and enhance overall operational efficiency. It incorporates principles of sustainability to ensure that the proposed methodologies align with environmental and social responsibility goals. To validate the effectiveness of the integrated Lean Six Sigma approach, case studies and real-world applications within select manufacturing companies in Nigeria will be conducted. Data were collected to measure the impact of the integration on key performance indicators, such as production efficiency, defect reduction, and risk mitigation. The findings from this research provide valuable insights and practical recommendations for selected manufacturing companies in South East Nigeria. By adopting sustainable Lean Six Sigma methodologies, these organizations can optimize their operations, reduce operational risks, improve product quality, and enhance their competitiveness in the global market. In conclusion, this research aims to bridge the gap between theory and practice by developing a comprehensive framework for the integration of Lean and Six Sigma methodologies in Nigeria's manufacturing sector. This integration is envisioned to contribute significantly to the sector's sustainable growth, improved operational efficiency, and effective risk mitigation strategies, ultimately benefiting the Nigerian economy as a whole.

Keywords: lean six sigma, manufacturing, risk mitigation, sustainability, operational efficiency

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Authors: George Nyori Makari

Abstract:

Data on 92 industrial organizations point to the existence of relationships between advanced manufacturing technology (AMT) adoption and some aspects of organizational structure, including the number of specialized sub-units, the number of levels of authority, span of control, degree of role programming specification, degree of communication programming specification and the degree of output programming. Primary finding is that as the investments and integration of AMTs increases, the more likely the foregoing aspects of structure increase. The findings hold with size and a number of other organizational variables controlled. The results indicate that a company’s capacity to assimilate technology depends on its organizational capabilities. The study encapsulates the need for companies to increase their organizational capabilities during investment and integration of AMTs.

Keywords: advanced manufacturing technology, adoption, organizational structure, Kenya

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Authors: Tariq Aljuneidi, Akif Asil Bulgak

Abstract:

Remanufacturing may be defined as the process of bringing used products to “like-new” functional state with warranty to match, and it is one of the most popular product end-of-life scenarios. An efficient remanufacturing network lead to an efficient design of sustainable manufacturing enterprise. In remanufacturing network, products are collected from the customer zone, disassembled and remanufactured at a suitable remanufacturing facility. In this respect, another issue to consider is how the returned product to be remanufactured, in other words, what is the best layout for such facility. In order to achieve a sustainable manufacturing system, Cellular Manufacturing System (CMS) designs are highly recommended, CMSs combine high throughput rates of line layouts with the flexibility offered by functional layouts (job shop). Introducing the CMS while designing a remanufacturing network will benefit the utilization of such a network. This paper presents and analyzes a comprehensive mathematical model for the design of Dynamic Cellular Remanufacturing Systems (DCRSs). In this paper, the proposed model is the first one to date that consider CMS and remanufacturing system simultaneously. The proposed DCRS model considers several manufacturing attributes such as multi-period production planning, dynamic system reconfiguration, duplicate machines, machine capacity, available time for workers, worker assignments, and machine procurement, where the demand is totally satisfied from a returned product. A numerical example is presented to illustrate the proposed model.

Keywords: cellular manufacturing system, remanufacturing, mathematical programming, sustainability

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Authors: Sina Fatolahzadeh, Sergio A. Sepúlveda

Abstract:

This paper presents advanced developments in close-range, terrestrial remote sensing techniques to enhance the characterization of rock masses. The study integrates two state-of-the-art laser-scanning technologies, the HandySCAN and GeoSLAM laser scanners, to extract high-resolution geospatial data for rock mass analysis. These instruments offer high accuracy, precision, low acquisition time, and high efficiency in capturing intricate geological features in small to medium size outcrops and slope cuts. Using the HandySCAN and GeoSLAM laser scanners facilitates real-time, three-dimensional mapping of rock surfaces, enabling comprehensive assessments of rock mass characteristics. The collected data provide valuable insights into structural complexities, surface roughness, and discontinuity patterns, which are essential for geological and geotechnical analyses. The synergy of these advanced remote sensing technologies contributes to a more precise and straightforward understanding of rock mass behavior. In this case, the main parameters of RQD, joint spacing, persistence, aperture, roughness, infill, weathering, water condition, and joint orientation in a slope cut along the Sea-to-Sky Highway, BC, were remotely analyzed to calculate and evaluate the Rock Mass Rating (RMR) and Geological Strength Index (GSI) classification systems. Automatic and manual analyses of the acquired data are then compared with field measurements. The results show the usefulness of the proposed remote sensing methods and their appropriate conformity with the actual field data.

Keywords: remote sensing, rock mechanics, rock engineering, slope stability, discontinuity properties

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Authors: Manoj Kumar Gupta, Jayashree Bijwe

Abstract:

Additives in lubricating oils are the focus of research attention since the further reduction in friction and wear properties of oils would lead to the further saving of tribo-materials and energy apart from improving their efficiency. Remarkable tribo-performance enhancement is reported in the literature due to addition of particles of solid lubricants in lubricating oils; especially that of nano-sizes. In the present work graphite nano-particles (NPs) in various amounts (1, 2, 3 and 4 wt. %) were used to explore the possible anti-wear (AW) performance enhancement in Group III oil. Polyisobutylene succinimide (PIBSI- 1 wt. %) was used as a dispersant for dispersing these NPs and to enhance the stability of these nano-suspensions. It was observed that PIBSI inclusion enhanced the stability of oil almost by eight times. NPs in all amounts enhanced the AW performance of oil considerably. The optimum amount was three wt. %, which led to the highest enhancement under all loads. The extent of benefits, however, were dependent on load. At the lowest (392 N) and highest loads (784 N), the benefits were not profound. At moderate load (588 N), highest improvement (around 60 %) was recorded. The SEM and AFM studies were done on the worn ball surfaces to reveal the detailed features of films transferred and proved useful to correlate the wear performance of oils.

Keywords: dispersant, graphite, nano-lubricant, anti-wear additive

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Authors: L. Shafiq, A. Rigby

Abstract:

All polyethylene processes are highly exothermic, and the safe removal of the heat of reaction is a fundamental issue in the process design. In slurry and gas processes, the velocity of the polymer particles in the reactor and external coolers can be very high, and under certain conditions, this can lead to static charging of these particles. Such static charged polymer particles may start building up on the reactor wall, limiting heat transfer, and ultimately leading to severe reactor fouling and forced reactor shut down. Statsafe™ is an FDA approved anti-fouling additive currently used around the world for polyolefin production as an anti-fouling additive. The unique polymer chemistry aids static discharge, which prevents the build-up of charged polyolefin particles, which could lead to fouling. Statsafe™ is being used and trailed in gas, slurry, and a combination of these technologies around the world. We will share data to demonstrate how the use of Statsafe™ allows more stable operation at higher solids level by eliminating static, which would otherwise prevent closer packing of particles in the hydrocarbon slurry. Because static charge generation depends also on the concentration of polymer particles in the slurry, the maximum slurry concentration can be higher when using Statsafe™, leading to higher production rates. The elimination of fouling also leads to less downtime. Special focus will be made on the impact anti-static additives have on catalyst performance within the polymerization process and how this has been measured. Lab-scale studies have investigated the effect on the activity of Ziegler Natta catalysts when anti-static additives are used at various concentrations in gas and slurry, polyethylene and polypropylene processes. An in-depth gas phase study investigated the effect of additives on the final polyethylene properties such as particle size, morphology, fines, bulk density, melt flow index, gradient density, and melting point.

Keywords: anti-static additives, catalyst performance, FDA approved anti-fouling additive, polymerisation

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