Search results for: Equipment manufacturing

Authors: Albana Hasimi, Edlira Tako, Partizan Malkaj, Elvin Çomo, Blerina Papajani, Mirela Ndrita, Ledjan Malaj

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Many endeavors have been exerted during the last years for developing new artificial polymeric membranes, which fulfill the demanded conditions for biomedical uses. One of the most tested polymers is Poly(vinyl alcohol) [PVA]. Our teams are based on the possibility of using PVA for personal protective equipment against COVID-19. In personal protective equipment, we explore the possibility of modifying the properties of the polymer by adding Montmorillonite [MMT]. Heat-treatment above the glass transition temperature is used to improve mechanical properties mainly by increasing the crystallinity of the polymer, which acts as a physical network. Temperature-Modulated Differential Scanning Calorimetry (TMDSC) measurements indicated that the presence of 0.5% MMT in PVA causes a higher Tg value and shaped peak of crystallinity. Decomposition is observed at two of the melting points of the crystals during heating 25-240 oC and overlap of the recrystallization ridges during cooling 240-25 oC. This is indicative of the presence of two types (quality or structure) of polymer crystals. On the other hand, some indication of improvement of the quality of the crystals by heat-treatment is given by the distinct non-reversing contribution to melting. Data on sorption and transport of water in PVA films: PVA pure and PVA/MMT matrix, modified by thermal treatment are presented. The membranes become more rigid as a result of the heat treatment and because of this the water uptake is significantly lower in membranes. That is indicated by analysis of the resulting water uptake kinetics. The presence of 0.5% w/w of MMT has no significant impact on the properties of PVA membranes. Water uptake kinetics deviate from Fick’s law due to slow relaxation of glassy polymer matrix for all types of membranes.

Keywords: Crystallinity, montmorillonite, nanocomposite, poly(vinyl alcohol).

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Authors: Emad S. Abouel Nasr, Abdulaziz M. El-Tamimi, Mustufa H. Abidi, Abdulrahman M. Al-Ahmari

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Virtual Assembly (VA) is one of the key technologies in advanced manufacturing field. It is a promising application of virtual reality in design and manufacturing field. It has drawn much interest from industries and research institutes in the last two decades. This paper describes a process for integrating an interactive Virtual Reality-based assembly simulation of a digital mockup with the CAD/CAM infrastructure. The necessary hardware and software preconditions for the process are explained so that it can easily be adopted by non VR experts. The article outlines how assembly simulation can improve the CAD/CAM procedures and structures; how CAD model preparations have to be carried out and which virtual environment requirements have to be fulfilled. The issue of data transfer is also explained in the paper. The other challenges and requirements like anti-aliasing and collision detection have also been explained. Finally, a VA simulation has been carried out for a ball valve assembly and a car door assembly with the help of Vizard virtual reality toolkit in a semi-immersive environment and their performance analysis has been done on different workstations to evaluate the importance of graphical processing unit (GPU) in the field of VA.

Keywords: Collision Detection, Graphical Processing Unit (GPU), Virtual Reality (VR), Virtual Assembly (VA).

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Authors: Matthew Dickinson

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A core/trunk exoskeleton design has been produced that is aimed to assist the raise to stand motion. A 3D model was produced to examine the use of additive manufacturing as a core method for producing structural components for the exoskeleton presented. The two materials that were modelled for this simulation work were Polylatic acid (PLA) and polyethylene terephthalate with carbon (PET-C), and the central spinal cord of the design being Nitrile rubber. The aim of this study was to examine the use of 3D printed materials as the main skeletal structure to support the core of a human when moving raising from a resting position. The objective in this work was to identify if the 3D printable materials could be offered as an equivalent alternative to conventional more expensive materials, thus allow for greater access for production for home maintenance. A maximum load of lift force was calculated, and this was incrementally reduced to study the effects on the material. The results showed a total number of 8 simulations were run to study the core in conditions with no muscular support through to 90% of operational support. The study presents work in the form of a core/trunk exoskeleton that presents 3D printing as a possible alternative to conventional manufacturing.

Keywords: 3D printing, Exo-Skeleton, PLA, PETC.

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Authors: Batin Latif Aylak, Bernd Noche

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Nowadays there are lots of applications of power and free conveyors in logistics. They are the most frequently used conveyor systems worldwide. Overhead conveyor technologies like power and free systems are used in the most intra-logistics applications in trade and industry. The automotive, food, beverage and textile industry as well as aeronautic catering or engineering are among the applications. Power and free systems employ different manufacturing intervals in manufacturing as well as in production as temporary store and buffer. Depending on the application area, power and free conveyors are equipped with target controls enabling complex distribution-and sorting tasks. This article introduces a new power and free conveyor design in intra-logistics and explains its components. According to the explanation of the components, a model is created by means of their technical characteristics. Through the CAD software, the model is visualized. After that, the static analysis is evaluated. This analysis helps the calculation of the mandatory state of structures under force action. This powerful model helps companies achieve lower development costs as well as quicker market maturity.

Keywords: Intra-logistics, material flow, power and free conveyor.

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Authors: Faisal Bin Alam

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Most of the manufacturing entities cause negative footprint to nature that demand due attention. Textile industries have one of the longest supply chains and bear the liability of significant environmental impact to our planet. Issues of environmental safety, scarcity of energy and resources, and demand for eco-friendly products have driven research to search for safe and suitable alternatives in apparel processing. Consumer awareness, increased pressure from fashion brands and actions from local legislative authorities have somewhat been able to improve the practices. Objective of this paper is to reveal the best selection of raw materials and methods of production, taking environmental sustainability into account. Methodology used in this study is exploratory in nature based on personal experience, field visits in the factories of Bangladesh and secondary sources. Findings are limited to exploring better alternatives to conventional operations of a Readymade Garment manufacturing, from fibre selection to final product delivery, therefore showing some ways of achieving greener environment in the supply chain of a clothing industry.

Keywords: Textile and apparel, environment, sustainability, supply chain, production, clothing.

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Authors: Josef Wolfartsberger, Michael Heiml, Georg Schwarz, Sabrina Egger

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Growing individualization and higher numbers of variants in industrial assembly products raise the complexity of manufacturing processes. Technical assistance systems considering both procedural and human factors allow for an increase in product quality and a decrease in required learning times by supporting workers with precise working instructions. Due to varying needs of workers, the presentation of working instructions leads to several challenges. This paper presents an approach for a multi-modal visualization application to support assembly work of complex parts. Our approach is integrated within an interconnected assistance system network and supports the presentation of cloud-streamed textual instructions, images, videos, 3D animations and audio files along with multi-modal user interaction, customizable UI, multi-platform support (e.g. tablet-PC, TV screen, smartphone or Augmented Reality devices), automated text translation and speech synthesis. The worker benefits from more accessible and up-to-date instructions presented in an easy-to-read way.

Keywords: Assembly, assistive technologies, augmented reality, manufacturing, visualization.

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Authors: J. K. Visser, H. T. Malan

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A need exists to identify the sources of risks associated with the process automation systems within petrochemical companies or similar energy related industries. These companies use many different process automation technologies in its value chain. A crucial part of the process automation system is the information technology component featuring in the supervisory control layer. The ever-changing technology within the process automation layers and the rate at which it advances pose a risk to safe and predictable automation system performance. The age of the automation equipment also provides challenges to the operations and maintenance managers of the plant due to obsolescence and unavailability of spare parts. The main objective of this research was to determine the risk sources associated with the equipment that is part of the process automation systems. A secondary objective was to establish whether technology managers and technicians were aware of the risks and share the same viewpoint on the importance of the risks associated with automation systems. A conceptual model for risk sources of automation systems was formulated from models and frameworks in literature. This model comprised six categories of risk which forms the basis for identifying specific risks. This model was used to develop a questionnaire that was sent to 172 instrument technicians and technology managers in the company to obtain primary data. 75 completed and useful responses were received. These responses were analyzed statistically to determine the highest risk sources and to determine whether there was difference in opinion between technology managers and technicians. The most important risks that were revealed in this study are: 1) the lack of skilled technicians, 2) integration capability of third-party system software, 3) reliability of the process automation hardware, 4) excessive costs pertaining to performing maintenance and migrations on process automation systems, and 5) requirements of having third-party communication interfacing compatibility as well as real-time communication networks.

Keywords: Distributed control system, identification of risks, information technology, process automation system.

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Authors: M. Othman, N. Bhuiyan, G. J. Gouw

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In today-s competitive market, most companies develop manufacturing systems that can help in cost reduction and maximum quality. Human issues are an important part of manufacturing systems, yet most companies ignore their effects on production performance. This paper aims to developing an integrated workforce planning system that incorporates the human being. Therefore, a multi-objective mixed integer nonlinear programming model is developed to determine the amount of hiring, firing, training, overtime for each worker type. This paper considers a workforce planning model including human aspects such as skills, training, workers- personalities, capacity, motivation, and learning rates. This model helps to minimize the hiring, firing, training and overtime costs, and maximize the workers- performance. The results indicate that the workers- differences should be considered in workforce scheduling to generate realistic plans with minimum costs. This paper also investigates the effects of human learning rates on the performance of the production systems.

Keywords: Human Factors, Learning Curves, Workers' Differences, Workforce Scheduling

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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: 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: 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: 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: Achim Kampker, Heiner H. Heimes, Mathias Ordung, Christoph Lienemann, Ansgar Hollah, Nemanja Sarovic

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Electric cars with their fast innovation cycles and their disruptive character offer a high degree of freedom regarding innovative design for remanufacturing. Remanufacturing increases not only the resource but also the economic efficiency by a prolonged product life time. The reduced power train wear of electric cars combined with high manufacturing costs for batteries allow new business models and even second life applications. Modular and intermountable designed battery packs enable the replacement of defective or outdated battery cells, allow additional cost savings and a prolongation of life time. This paper discusses opportunities for future remanufacturing value chains of electric cars and their battery components and how to address their potentials with elaborate designs. Based on a brief overview of implemented remanufacturing structures in different industries, opportunities of transferability are evaluated. In addition to an analysis of current and upcoming challenges, promising perspectives for a sustainable electric car circular economy enabled by design for remanufacturing are deduced. Two mathematical models describe the feasibility of pursuing a circular economy of lithium ion batteries and evaluate remanufacturing in terms of sustainability and economic efficiency. Taking into consideration not only labor and material cost but also capital costs for equipment and factory facilities to support the remanufacturing process, cost benefit analysis prognosticate that a remanufacturing battery can be produced more cost-efficiently. The ecological benefits were calculated on a broad database from different research projects which focus on the recycling, the second use and the assembly of lithium ion batteries. The results of this calculations show a significant improvement by remanufacturing in all relevant factors especially in the consumption of resources and greenhouse warming potential. Exemplarily suitable design guidelines for future remanufacturing lithium ion batteries, which consider modularity, interfaces and disassembly, are used to illustrate the findings. For one guideline, potential cost improvements were calculated and upcoming challenges are pointed out.

Keywords: Circular economy, electric mobility, lithium ion batteries, remanufacturing.

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

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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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Authors: Rakesh Prajapati, Purvik Patel, Avadhoot Rajurkar

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

Keywords: Toolpath, part program, optimization, pocket.

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Authors: Pankaj Chandna, Surinder Deswal, Arunesh Chandra, SK Sharma

Abstract:

Noise has adverse effect on human health and comfort. Noise not only cause hearing impairment, but it also acts as a causal factor for stress and raising systolic pressure. Additionally it can be a causal factor in work accidents, both by marking hazards and warning signals and by impeding concentration. Industry workers also suffer psychological and physical stress as well as hearing loss due to industrial noise. This paper proposes an approach to enable engineers to point out quantitatively the noisiest source for modification, while multiple machines are operating simultaneously. The model with the point source and spherical radiation in a free field was adopted to formulate the problem. The procedure works very well in ideal cases (point source and free field). However, most of the industrial noise problems are complicated by the fact that the noise is confined in a room. Reflections from the walls, floor, ceiling, and equipment in a room create a reverberant sound field that alters the sound wave characteristics from those for the free field. So the model was validated for relatively low absorption room at NIT Kurukshetra Central Workshop. The results of validation pointed out that the estimated sound power of noise sources under simultaneous conditions were on lower side, within the error limits 3.56 - 6.35 %. Thus suggesting the use of this methodology for practical implementation in industry. To demonstrate the application of the above analytical procedure for estimating the sound power of noise sources under simultaneous operating conditions, a manufacturing facility (Railway Workshop at Yamunanagar, India) having five sound sources (machines) on its workshop floor is considered in this study. The findings of the case study had identified the two most effective candidates (noise sources) for noise control in the Railway Workshop Yamunanagar, India. The study suggests that the modification in the design and/or replacement of these two identified noisiest sources (machine) would be necessary so as to achieve an effective reduction in noise levels. Further, the estimated data allows engineers to better understand the noise situations of the workplace and to revise the map when changes occur in noise level due to a workplace re-layout.

Keywords: Industrial noise, sound power level, multiple noise sources, sources contribution.

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Authors: Yujie Zhao, Jiantao Weng

Abstract:

In the past decade, with the rapid development of China's economy, the purchasing power and physical demand of residents have been improved, which results in the vast emergence of public buildings like large shopping malls. However, the architects usually focus on the internal functions and streamlines of these buildings, ignoring the impact of the environment on the subjective feelings of building users. Only in Zhejiang province, the infiltration of cold air in winter frequently occurs at the entrance of sizeable commercial complex buildings that have been in operation, which will affect the environmental comfort of the building lobby and internal public spaces. At present, to reduce these adverse effects, it is usually adopted to add active equipment, such as setting air curtains to block air exchange or adding heating air conditioners. From the perspective of energy consumption, the infiltration of cold air into the entrance will increase the heat consumption of indoor heating equipment, which will indirectly cause considerable economic losses during the whole winter heating stage. Therefore, it is of considerable significance to explore the suitable entrance forms for improving the environmental comfort of commercial buildings and saving energy. In this paper, a commercial complex with apparent cold air infiltration problem in Hangzhou is selected as the research object to establish a model. The environmental parameters of the building entrance, including temperature, wind speed, and infiltration air volume, are obtained by Computational Fluid Dynamics (CFD) simulation, from which the heat consumption caused by the natural air infiltration in the winter and its potential economic loss is estimated as the objective metric. This study finally obtains the optimization direction of the building entrance form of the commercial complex by comparing the simulation results of other local commercial complex projects with different entrance forms. The conclusions will guide the entrance design of the same type of commercial complex in this area.

Keywords: Air infiltration, commercial complex, heat consumption, CFD simulation.

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Authors: Tuğrul Varol, Halil Barış Özel

Abstract:

In this study which has been conducted in Akçasu Forest Range District of Devrek Forest Directorate; 3 methods (weed control with labourer power, cover removal with Hitachi F20 Excavator, and weed control with agricultural equipment mounted on a Ferguson 240S agriculture tractor) were utilized in weed control efforts in regeneration of degraded oriental beech forests have been compared. In this respect, 3 methods have been compared by determining certain work hours and standard durations of unit areas (1 hectare). For this purpose, evaluating the tasks made with human and machine force from the aspects of duration, productivity and costs, it has been aimed to determine the most productive method in accordance with the actual ecological conditions of research field. Within the scope of the study, the time studies have been conducted for 3 methods used in weed control efforts. While carrying out those studies, the performed implementations have been evaluated by dividing them into business stages. Also, the actual data have been used while calculating the cost accounts. In those calculations, the latest formulas and equations which are also used in developed countries have been utilized. The variance of analysis (ANOVA) was used in order to determine whether there is any statistically significant difference among obtained results, and the Duncan test was used for grouping if there is significant difference. According to the measurements and findings carried out within the scope of this study, it has been found during living cover removal efforts in regeneration efforts in demolished oriental beech forests that the removal of weed layer in 1 hectare of field has taken 920 hours with labourer force, 15.1 hours with excavator and 60 hours with an equipment mounted on a tractor. On the other hand, it has been determined that the cost of removal of living cover in unit area (1 hectare) was 3220.00 TL for labourer power, 1250 TL for excavator and 1825 TL for equipment mounted on a tractor. According to the obtained results, it has been found that the utilization of excavator in weed control effort in regeneration of degraded oriental beech regions under actual ecological conditions of research field has been found to be more productive from both of aspects of duration and costs. These determinations carried out should be repeated in weed control efforts in degraded forest fields with different ecological conditions, it is compulsory for finding the most efficient weed control method. These findings will light the way of technical staff of forestry directorate in determination of the most effective and economic weed control method. Thus, the more actual data will be used while preparing the weed control budgets, and there will be significant contributions to national economy. Also the results of this and similar studies are very important for developing the policies for our forestry in short and long term.

Keywords: Artificial regeneration, weed control, oriental beech, productivity, mechanization, man power, cost analysis.

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Authors: Maja Sajdak

Abstract:

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

Keywords: Agile company, acuity, entrepreneurship, flexibility, research model, strategic leadership.

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