Search results for: Environmentally benign manufacturing

Authors: Kwok Tak Kit

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With the increase of demand and popularity of ecotourism development to address the concern of carbon emission, the acceleration of development of the concept of net zero carbon ecotourism can increase international competitiveness, sustainability and productivity. This paper aims to outline the major key components and considerations in ecotourism development with integration of net zero strategy and provide recommendation and reference to government agents, Architecture, Engineering and Construction (AEC) industry and stakeholders to contribute to the target of net zero and environmentally friendly ecotourism development project. This paper explores the alternative to the reliance on local regulation and ecotourism certification programs as a base tool to achieve the higher standard of the reduction of the use of energy and natural resources in ecotourism development and to enhance their sustainability.

Keywords: Net zero ecotourism, sustainability, embodied carbon, Paris Agreement.

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Authors: Youngji Yoo, Seung Hwan Park, Daewoong An, Sung-Shick Kim, Jun-Geol Baek

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The yield management system is very important to produce high-quality semiconductor chips in the semiconductor manufacturing process. In order to improve quality of semiconductors, various tests are conducted in the post fabrication (FAB) process. During the test process, large amount of data are collected and the data includes a lot of information about defect. In general, the defect on the wafer is the main causes of yield loss. Therefore, analyzing the defect data is necessary to improve performance of yield prediction. The wafer bin map (WBM) is one of the data collected in the test process and includes defect information such as the fail bit patterns. The fail bit has characteristics of spatial point patterns. Therefore, this paper proposes the feature extraction method using the spatial point pattern analysis. Actual data obtained from the semiconductor process is used for experiments and the experimental result shows that the proposed method is more accurately recognize the fail bit patterns.

Keywords: Semiconductor, wafer bin map (WBM), feature extraction, spatial point patterns, contour map.

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Authors: Hamed Afrasiab, Saeed Khodaygan

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Prediction of machining process capability in the design stage plays a key role to reach the precision design and manufacturing of mechanical products. Inaccuracies in machining process lead to errors in position and orientation of machined features on the part, and strongly affect the process capability in the final quality of the product. In this paper, an efficient systematic approach is given to investigate the machining errors to predict the manufacturing errors of the parts and capability prediction of corresponding machining processes. A mathematical formulation of fixture locators modeling is presented to establish the relationship between the part errors and the related sources. Based on this method, the final machining errors of the part can be accurately estimated by relating them to the combined dimensional and geometric tolerances of the workpiece – fixture system. This method is developed for uncertainty analysis based on the Worst Case and statistical approaches. The application of the presented method is illustrated through presenting an example and the computational results are compared with the Monte Carlo simulation results.

Keywords: Process capability, machining error, dimensional and geometrical tolerances, uncertainty analysis.

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Authors: Phruksaphanrat B.

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This research presents a fuzzy multi-objective model for a machine selection problem in a flexible manufacturing system of a tire company. Two main objectives are minimization of an average machine error and minimization of the total setup time. Conventionally, the working team uses trial and error in selecting a pressing machine for each task due to the complexity and constraints of the problem. So, both objectives may not satisfy. Moreover, trial and error takes a lot of time to get the final decision. Therefore, in this research preemptive fuzzy goal programming model is developed for solving this multi-objective problem. The proposed model can obtain the appropriate results that the Decision Making (DM) is satisfied for both objectives. Besides, alternative choice can be easily generated by varying the satisfaction level. Additionally, decision time can be reduced by using the model, which includes all constraints of the system to generate the solutions. A numerical example is also illustrated to show the effectiveness of the proposed model.

Keywords: Machine Selection, Preemptive Fuzzy Goal Programming, Mixed Integer Programming, Application of Tire Industry.

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Authors: Manikandakumar Shunmugavel, Ashwin Polishetty, Moshe Goldberg, Junior Nomani, Guy Littlefair

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Selective laser melting (SLM), a promising additive manufacturing (AM) technology, has a huge potential in the fabrication of Ti-6Al-4V near-net shape components. However, poor surface finish of the components fabricated from this technology requires secondary machining to achieve the desired accuracy and tolerance. Therefore, a systematic understanding of the machinability of SLM fabricated Ti-6Al-4V components is paramount to improve the productivity and product quality. Considering the significance of machining in SLM fabricated Ti-6Al-4V components, this research aim is to study the influence of build orientation on machinability characteristics by performing low speed orthogonal cutting tests. In addition, the machinability of SLM fabricated Ti-6Al-4V is compared with conventionally produced wrought Ti-6Al-4V to understand the influence of SLM technology on machining. This paper is an attempt to provide evidence to the hypothesis associated that build orientation influences cutting forces, chip formation and surface integrity during orthogonal cutting of SLM Ti-6Al-4V samples. Results obtained from the low speed orthogonal cutting tests highlight the practical importance of microstructure and build orientation on machinability of SLM Ti-6Al-4V.

Keywords: Additive manufacturing, build orientation, machinability, titanium alloys (Ti-6Al-4V).

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Authors: Naci Kalkan, Ihsan Dagtekin

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Passive design responds to improve indoor thermal comfort and minimize the energy consumption. The present research analyzed the how efficiently passive solar technologies generate heating and cooling and provide the system integration for domestic applications. In addition to this, the aim of this study is to increase the efficiency of solar systems system with integration some innovation and optimization. As a result, outputs of the project might start a new sector to provide environmentally friendly and cheap cooling for domestic use.

Keywords: Passive Solar Systems, Heating, Cooling, Thermal Comfort, Ventilation Systems.

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Authors: Noor Azlina Mohd Salleh, Salmiah Kasolang, Ahmed Jaffar

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Green Lean Total Quality Management (TQM) System is a system comprises of Environmental Management System (EMS) practices which is integrated to TQM with Lean Manufacturing (LM) principles. The ultimate goal of this system is to focus on achieving total customer satisfaction and environmental care by removing eight wastes available in any process in an organization. A survey questionnaire was developed and distributed to 30 highly active automotive vendors in Malaysia and analyzed by SPSS v.17. It was found out that some vendors have been practicing TQM and LM while some have started to implement EMS. This study is only focusing on highly active companies that have been involved in MAJAICO Program and Proton Vendor Development Program. This is the first study conducted to know the current status of TQM, LM and EMS practices in highly active automotive companies in Malaysia. It was found out that EMS has been practiced by 16 companies out of 30. Within these 16 companies the approach is more holistic and green. This is a preliminary study that combined 4 awards practices, ISO/TS16949, Toyota Production System SAEJ4000, MAJAICO Lean Production System and EMS.

Keywords: Automotive Industry, Lean Manufacturing, Operational Engineering Management, Total Quality Management. Environmental Management System.

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Authors: Abdolamir Nekoubin

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In this paper the behavior of fixed series compensated extra high voltage transmission lines during faults is simulated. Many over-voltage protection schemes for series capacitors are limited in terms of size and performance, and are easily affected by environmental conditions. While the need for more compact and environmentally robust equipment is required. use of series capacitors for compensating part of the inductive reactance of long transmission lines increases the power transmission capacity. Emphasis is given on the impact of modern capacitor protection techniques (MOV protection). The simulation study is performed using MATLAB/SIMULINK®and results are given for a three phase and a single phase to ground fault.

Keywords: Series compensation, MOV - protected series capacitors, balanced and unbalanced faults

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Authors: Abdulmajeed Dabwan, Saqib Anwar, Ali Al-Samhan

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Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology, which uses computer-controlled electron beams to create fully dense three-dimensional near-net-shaped parts from metal powder. It gives the ability to produce any complex parts directly from a computer-aided design (CAD) model without tools and dies, and with a variety of materials. However, the quality of the surface finish in EBM process has limitations to meeting the performance requirements of additively manufactured components. The aim of this study is to investigate the cutting forces induced during milling Ti6Al4V produced by EBM as well as the surface quality of the milled surfaces. The effects of cutting speed and radial depth of cut on the cutting forces, surface roughness, and surface morphology were investigated. The results indicated that the cutting speed was found to be proportional to the resultant cutting force at any cutting conditions while the surface roughness improved significantly with the increase in cutting speed and radial depth of cut.

Keywords: Electron beam melting, additive manufacturing, Ti6Al4V, surface morphology.

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Authors: Racha Khairallah, Lamia Ben Hamida

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Our paper attempts to examine how Swiss manufacturing firms manage to learn from patent citations to improve their innovation performance. We argue that the assessment of these effects needs a detailed analysis of spillovers according to the source of knowledge with respect to formal and informal patent citations made in European and internal search, the horizontal and vertical mechanisms by which knowledge spillovers take place, and the technological characteristics of innovative firms that able them to absorb external knowledge and integrate it in their existing innovation process. We use Organisation for Economic Co-operation and Development (OECD) data and find evidence that knowledge spillovers occur only from horizontal and backward linkages. The importance of these effects depends on the type of citation, in which the references to non-patent literature (informal citations made in European and international searches) have a greater impact. In addition, only firms with high technological capacities benefit from knowledge spillovers from formal and informal citations. Low-technology firms fail to catch up and efficiently learn external knowledge from patent citations.

Keywords: Innovation performance, patent citation, absorptive capacity, knowledge spillover mechanisms.

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Authors: M. Suutari

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In this content analysis research note the aim was to explore to how sustainability and especially environmental issues are conveyed into environmental items in annual reports and disclosures. As The Global Reporting Initiative (GRI) is a globally wide multistakeholder process, the enterprises using voluntarily GRI framework are considered to be aware of sustainability and environmental concerns. The findings were that although these enterprises included in an environmentally sensitive industry sector and had special capabilities to consider environmental issues there were few GRIreporting enterprises presented substantially detailed environmental items in audited financial statements. There were only slight differences between publishing years 2008 and 2009 - the beginning years of economic turmoil. The environmental issues seemed not to be considered substantial enough for financial reporting as a basis for concerning investment or voting decisions.

Keywords: Environmental, reporting, financial, GRI.

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Authors: Meftah O. Bashir, Fatma A. Karkory

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Rapid prototyping is a new group of manufacturing processes, which allows fabrication of physical of any complexity using a layer by layer deposition technique directly from a computer system. The rapid prototyping process greatly reduces the time and cost necessary to bring a new product to market. The prototypes made by these systems are used in a range of industrial application including design evaluation, verification, testing, and as patterns for casting processes. These processes employ a variety of materials and mechanisms to build up the layers to build the part. The present work was to build a FDM prototyping machine that could control the X-Y motion and material deposition, to generate two-dimensional and three-dimensional complex shapes. This study focused on the deposition of wax material. This work was to find out the properties of the wax materials used in this work in order to enable better control of the FDM process. This study will look at the integration of a computer controlled electro-mechanical system with the traditional FDM additive prototyping process. The characteristics of the wax were also analysed in order to optimise the model production process. These included wax phase change temperature, wax viscosity and wax droplet shape during processing.

Keywords: Rapid prototyping, wax, manufacturing processes, additive prototyping.

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Authors: Brigita Altenbaher

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The friction between two metal surfaces results in a high frequency noise (squealing) which also occurs during the braking of wagons with rail brakes in the process of shunting at a marshalling yard with a hump. At that point the noise level may exceed 130dB, which is extremely unpleasant for workers and inhabitants. In our research we developed a new composite material which does not change braking properties, is capable of taking extremely high pressure loads, reduces noise and is environmentally friendly. The noise reduction results had been very good and had shown a decrease of the high frequency noise almost completely (by 99%) at its source. With our technology we had also reduced general noise by more than 30dBA.

Keywords: Composite heavily fluid compound, hump yard, noise reduction, rail brakes.

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Authors: Natália B. Pompermayer, Mariana B. Porto, Elizabeth F. Souza

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Nanophotocatalysts such as titanium (TiO2), zinc (ZnO), and iron (Fe2O3) oxides can be used in organic pollutants oxidation, and in many other applications. But among the challenges for technological application (scale-up) of the nanotechnology scientific developments two aspects are still little explored: research on environmental risk of the nanomaterials preparation methods, and the study of nanomaterials properties and/or performance variability. The environmental analysis was performed for six different methods of ZnO nanoparticles synthesis, and showed that it is possible to identify the more environmentally compatible process even at laboratory scale research. The obtained ZnO nanoparticles were tested as photocatalysts, and increased the degradation rate of the Rhodamine B dye up to 30 times.

Keywords: Environmental impact analysis, inorganic nanoparticles, photocatalysts.

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Authors: Salam K. Al-Nasri, SM Holmes

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Composite of Celatom-ZeoliteY (Cel-ZY) was used to remove cobalt ion from an aqueous solution using batch mode. ZeoliteY has successfully superimposed on Celatom FW-14 surface using hydrothermal treatment .The product was synthesized as a novel of hierarchical porous material. It was observed from the results that Cel-ZY has higher ability to remove cobalt ions than the pure ZeoliteY powder (PZY) synthesized under the same conditions. Several parameters were studied in this project to investigate the effect of removal cobalt ion such as pH and initial cobalt concentration. It was clearly observed that the uptake of cobalt ions was affected with increase these parameters. The results proved that the product can be used effectively to remove Co2+ ions from wastewater as an environmentally friendly alternative.

Keywords: Adsorption, Celatom-Zeolite, Cobalt ions, Isotherm models.

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Authors: Youngji Yoo, Cheong-Sool Park, Jun Seok Kim, Young-Hak Lee, Sung-Shick Kim, Jun-Geol Baek

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In the semiconductor manufacturing process, large amounts of data are collected from various sensors of multiple facilities. The collected data from sensors have several different characteristics due to variables such as types of products, former processes and recipes. In general, Statistical Quality Control (SQC) methods assume the normality of the data to detect out-of-control states of processes. Although the collected data have different characteristics, using the data as inputs of SQC will increase variations of data, require wide control limits, and decrease performance to detect outof- control. Therefore, it is necessary to separate similar data groups from mixed data for more accurate process control. In the paper, we propose a regression tree using split algorithm based on Pearson distribution to handle non-normal distribution in parametric method. The regression tree finds similar properties of data from different variables. The experiments using real semiconductor manufacturing process data show improved performance in fault detecting ability.

Keywords: Semiconductor, non-normal mixed process data, clustering, Statistical Quality Control (SQC), regression tree, Pearson distribution system.

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Authors: Gabi N. Nehme

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The reduction of phosphorus and sulfur in engine oil are the main topics of this paper. Very reproducible boundary lubrication tests were conducted as part of Design of Experiment software (DOE) to study the behavior of fluorinated catalyst iron fluoride (FeF3), and polutetrafluoroethylene or Teflon (PTFE) in developing environmentally friendly (reduced P and S) anti-wear additives for future engine oil formulations. Multi-component Chevron fully formulated oil (GF3) and Chevron plain oil were used with the addition of PTFE and catalyst to characterize and analyze their performance. Lower phosphorus blends were the goal of the model solution. Experiments indicated that new sub-micron FeF3 catalyst played an important role in preventing breakdown of the tribofilm.

Keywords: Wear, SEM, EDS, friction, lubricants.

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Authors: Nasser M. Amaitik, Nabil A. Alfagi

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The world-s largest Pre-stressed Concrete Cylinder Pipe (PCCP) water supply project had a series of pipe failures which occurred between 1999 and 2001. This has led the Man-Made River Authority (MMRA), the authority in charge of the implementation and operation of the project, to setup a rehabilitation plan for the conveyance system while maintaining the uninterrupted flow of water to consumers. At the same time, MMRA recognized the need for a long term management tool that would facilitate repair and maintenance decisions and enable taking the appropriate preventive measures through continuous monitoring and estimation of the remaining life of each pipe. This management tool is known as the Pipe Risk Management System (PRMS) and now in operation at MMRA. Both the rehabilitation plan and the PRMS require the availability of complete and accurate pipe construction and manufacturing data This paper describes a systematic approach of data collection, analysis, evaluation and correction for the construction and manufacturing data files of phase I pipes which are the platform for the PRMS database and any other related decision support system.

Keywords: Asbuilt, History, IMD, MMRA, PDBMS & PRMS

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Authors: Shilpesh R. Rajpurohit, Harshit K. Dave

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Additive manufacturing gains the popularity in recent times, due to its capability to create prototype as well functional as end use product directly from CAD data without any specific requirement of tooling. Fused deposition modeling (FDM) is one of the widely used additive manufacturing techniques that are used to create functional end use part of polymer that is comparable with the injection-molded parts. FDM printed part has an application in various fields such as automobile, aerospace, medical, electronic, etc. However, application of FDM part is greatly affected by poor mechanical properties. Proper selection of the process parameter could enhance the mechanical performance of the printed part. In the present study, experimental investigation has been carried out to study the behavior of the mechanical performance of the printed part with respect to process variables. Three process variables viz. raster angle, raster width and layer height have been varied to understand its effect on tensile strength. Further, effect of process variables on fractured surface has been also investigated.

Keywords: 3D printing, fused deposition modeling, layer height, raster angle, raster width, tensile strength.

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Authors: Kjersti Engan, Thor Ole Gulsrud, Karl Fredrik Fretheim, Barbro Furebotten Iversen, Liv Eriksen

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Clusters of microcalcifications in mammograms are an important sign of breast cancer. This paper presents a complete Computer Aided Detection (CAD) scheme for automatic detection of clustered microcalcifications in digital mammograms. The proposed system, MammoScan μCaD, consists of three main steps. Firstly all potential microcalcifications are detected using a a method for feature extraction, VarMet, and adaptive thresholding. This will also give a number of false detections. The goal of the second step, Classifier level 1, is to remove everything but microcalcifications. The last step, Classifier level 2, uses learned dictionaries and sparse representations as a texture classification technique to distinguish single, benign microcalcifications from clustered microcalcifications, in addition to remove some remaining false detections. The system is trained and tested on true digital data from Stavanger University Hospital, and the results are evaluated by radiologists. The overall results are promising, with a sensitivity > 90 % and a low false detection rate (approx 1 unwanted pr. image, or 0.3 false pr. image).

Keywords: mammogram, microcalcifications, detection, CAD, MammoScan μCaD, VarMet, dictionary learning, texture, FTCM, classification, adaptive thresholding

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Authors: Isabel Duarte de Almeida, João Vilas-Boas, Luís Miguel Ferreira

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Environmental concerns about the scarcity of marine resources are critical driving forces for firms aiming to prepare their supply chains for sustainability. Building on previous work, this paper highlights the implementation of good practices geared towards sustainable operations in the seafood department, which were pursued in an exploratory retailer case. Outcomes of the adopted environmentally and socially acceptable fish retailing strategies, ranged from traceability, to self-certification and eco-labelling. The consequences for business were, as follows: stronger collaboration and trust across the chain of custody, improvement of sponsors’ image and of consumers’ loyalty and, progress in the Greenpeace retailers’ evaluation ranking.

Keywords: Sustainability in sea food, Supply Chain Traceability, Social Responsibility.

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Authors: D. Gåsvaer, L. Stålberg, A. Fundin, M. Jackson, P. Johansson

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Exploration and exploitation capabilities are both important within Operations as means for improvement when managed separately, and for establishing dynamic improvement capabilities when combined in balance. However, it is unclear what exploration and exploitation capabilities imply in improvement and development work within an Operations context. So, in order to better understand how to develop exploration and exploitation capabilities within Operations, the main characteristics of these constructs needs to be identified and further understood. Thus, the objective of this research is to increase the understanding about exploitation and exploration characteristics, to concretize what they translates to within the context of improvement and development work in an Operations unit, and to identify practical challenges. A literature review and a case study are presented. In the literature review, different interpretations of exploration and exploitation are portrayed, key characteristics have been identified, and a deepened understanding of exploration and exploitation characteristics is described. The case in the study is an Operations unit, and the aim is to explore to what extent and in what ways exploration and exploitation activities are part of the improvement structures and processes. The contribution includes an identification of key characteristics of exploitation and exploration, as well as an interpretation of the constructs. Further, some practical challenges are identified. For instance, exploration activities tend to be given low priority, both in daily work as in the manufacturing strategy. Also, the overall understanding about the concepts of exploitation and exploration (or any similar aspect of dynamic improvement capabilities) is very low.

Keywords: Exploitation, Exploration, Improvement, Lean production, Manufacturing.

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Authors: Trevor Kroeger, Hayden Williams, Edward Holzinger, David Coleman, Brian Haberman

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The network connectivity of medical devices is increasing at a rapid rate. Many medical devices, such as vital sign monitors, share information via wireless or wired connections. However, these connectivity options suffer from a variety of well-known limitations. Wireless connectivity, especially in the unlicensed radio frequency bands, can be disrupted. Such disruption could be due to benign reasons, such as a crowded spectrum, or to malicious intent. While wired connections are less susceptible to interference, they inhibit the mobility of the medical devices, which could be critical in a variety of scenarios. This work explores the application of Light Fidelity (Li-Fi) communication to enhance the security, performance, and mobility of medical devices in connected healthcare scenarios. A simple bridge for connected devices serves as an avenue to connect traditional medical devices to the Li-Fi network. This bridge was utilized to conduct bandwidth tests on a small Li-Fi network installed into a Mock-ICU setting with a backend enterprise network similar to that of a hospital. Mobile and stationary tests were conducted to replicate various different situations that might occur within a hospital setting. Results show that in room Li-Fi connectivity provides reasonable bandwidth and latency within a hospital like setting.

Keywords: Hospital, light fidelity, Li-Fi, medical devices, security.

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Authors: Gulshan Sachdeva, Vaibhav Jain

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In present paper, the performance of various alternative refrigerants is compared to find the substitute of R22, the widely used hydrochlorofluorocarbon refrigerant in developing countries. These include the environmentally friendly hydrofluorocarbon (HFC) refrigerants such as R134A, R410A, R407C and M20. In the present study, a steady state thermodynamic model (includes both first and second law analysis) which simulates the working of an actual vapor-compression system is developed. The model predicts the performance of system with alternative refrigerants. Considering the recent trends of replacement of ozone depleting refrigerants and improvement in system efficiency, R407C is found to be potential candidate to replace R22 refrigerant in the present study.

Keywords: Refrigeration, compression system, performance study, modeling, R407C.

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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.

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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: Casting, cylinder liners, journal bearing, robot.

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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: Zahra Ghiabaklou

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This paper presents the climatic range calculations for comfort evaporative cooling for Tehran. In this study the minimum climatic conditions required to achieve an appropriate comfort zone will be presented. Physiologically uncomfortable conditions in arid climates are mainly caused by the extreme heat and dryness. Direct evaporative cooling adds moisture to the air stream until the air stream is close to saturation. The dry bulb temperature is reduced, while the wet bulb temperature stays the same. Evaporative cooling is economical, effective, environmentally friendly, and healthy. Comfort cooling by direct evaporative cooling (passive or fan forced) in the 35. 41 N (such as Tehran) latitude requires design wet-bulb temperature not over 25.4 C. Evaporative cooling outside this limit cannot achieve the required 26.7 ET, and is recommended for relief cooling only.

Keywords: Evaporative cooling, Comfort temperature, Climaticdesign, Comfort cooling

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Authors: Brigita Altenbaher

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In recent years there has been a continuous increase of axle loads, tonnage, train speed and train length which has increased both the productivity in the rail sector and the risk of rail breaks and derailments. On the other hand, the environmental requirements (e.g. noise reduction) for railway operations will become tighter in the future. In our research we developed a new composite material which does not change braking properties, is capable of taking extremely high pressure loads, reduces noise and is environmentally friendly. Part of our research was also the development of technology which will be able to apply this material to the rail. The result of our research was the system which reduces the wear out significantly and almost completely eliminates the squealing noise at the same time, and by using only one special material.

Keywords: Active protection, composite material, lubrication, noise reduction, reduction at source, railway.

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Authors: N. Ahmed, A.J. Day, J.L. Victory L. Zeall, B. Young

Abstract:

The manufacture of large-scale precision aerospace components using CNC requires a highly effective maintenance strategy to ensure that the required accuracy can be achieved over many hours of production. This paper reviews a strategy for a maintenance management system based on Failure Mode Avoidance, which uses advanced techniques and technologies to underpin a predictive maintenance strategy. It is shown how condition monitoring (CM) is important to predict potential failures in high precision machining facilities and achieve intelligent and integrated maintenance management. There are two distinct ways in which CM can be applied. One is to monitor key process parameters and observe trends which may indicate a gradual deterioration of accuracy in the product. The other is the use of CM techniques to monitor high status machine parameters enables trends to be observed which can be corrected before machine failure and downtime occurs. It is concluded that the key to developing a flexible and intelligent maintenance framework in any precision manufacturing operation is the ability to evaluate reliably and routinely machine tool condition using condition monitoring techniques within a framework of Failure Mode Avoidance.

Keywords: Maintenance, Condition Monitoring, CNC, Machining, Accuracy, Capability, Key Process Parameters, Critical Parameters

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