Search results for: automobile manufacturing industries

Authors: P. Mukhopadhyay, N. C. Dey

Abstract:

Occupational health hazard is a very common term in every emerging country. Along with the unorganized sector, most organized sectors including government industries are suffering from this affliction. In addition to workload, the seasonal changes also have some impacts on working environment. With this focus in mind, one hundred male industrial workers, who are directly involved to the task of Periodic Overhauling (POH) in a fabricating workshop in the public domain are selected for this research work. They have been studied during work periods throughout different seasons in a year. For each and every season, the participants working heart rate (WHR) is measured and compared with the standards given by different national and internationally recognized agencies i.e., World Health Organization (WHO) and American Conference of Governmental Industrial Hygienists (ACGIH) etc. The different environmental parameters i.e. dry bulb temperature (DBT), wet bulb temperature (WBT), globe temperature (GT), natural wet bulb temperature (NWB), relative humidity (RH), wet bulb globe temperature (WBGT), air velocity (AV), effective temperature (ET) are recorded throughout the seasons to critically observe the effect of seasonal changes on the WHR of the workers. The effect of changes in environment to the WHR of the workers is very much surprising. It is found that the percentages of workers who belong to the ‘very heavy’ workload category are 83.33%, 66.66% and 16.66% in the summer, rainy and winter seasons, respectively. Ongoing undertaking of this type of job profile forces the worker towards occupational disorders causing absenteeism. This occurrence results in lower production rates, and on the other hand, costs due to medical claims also weaken the industry’s economic condition. In this circumstance, the authors are trying to focus on some remedial measures from the ergonomic angle by proposing a new work/ rest regimen and introducing engineering controls along with management controls which may help the worker, and consequently, the management also.

Keywords: Environmental changes, industrial worker, working heart rate, workload, occupational health hazard.

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Authors: M. Zeydan, G. Toğa

Abstract:

This study deals with a multi-criteria optimization problem which has been transformed into a single objective optimization problem using Response Surface Methodology (RSM), Artificial Neural Network (ANN) and Grey Relational Analyses (GRA) approach. Grey-RSM and Grey-ANN are hybrid techniques which can be used for solving multi-criteria optimization problem. There have been two main purposes of this research as follows. 1. To determine optimum and robust fiber dyeing process conditions by using RSM and ANN based on GRA, 2. To obtain the best suitable model by comparing models developed by different methodologies. The design variables for fiber dyeing process in textile are temperature, time, softener, anti-static, material quantity, pH, retarder, and dispergator. The quality characteristics to be evaluated are nominal color consistency of fiber, maximum strength of fiber, minimum color of dyeing solution. GRA-RSM with exact level value, GRA-RSM with interval level value and GRA-ANN models were compared based on GRA output value and MSE (Mean Square Error) performance measurement of outputs with each other. As a result, GRA-ANN with interval value model seems to be suitable reducing the variation of dyeing process for GRA output value of the model.

Keywords: Artificial Neural Network, Grey Relational Analysis, Optimization, Response Surface Methodology

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Authors: Mohsin T. Mohammed, Zahid A. Khan, Arshad N. Siddiquee

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The field of biomedical materials plays an imperative requisite and a critical role in manufacturing a variety of biological artificial replacements in a modern world. Recently, titanium (Ti) materials are being used as biomaterials because of their superior corrosion resistance and tremendous specific strength, free- allergic problems and the greatest biocompatibility compared to other competing biomaterials such as stainless steel, Co-Cr alloys, ceramics, polymers, and composite materials. However, regardless of these excellent performance properties, Implantable Ti materials have poor shear strength and wear resistance which limited their applications as biomaterials. Even though the wear properties of Ti alloys has revealed some improvements, the crucial effectiveness of biomedical Ti alloys as wear components requires a comprehensive deep understanding of the wear reasons, mechanisms, and techniques that can be used to improve wear behavior. This review examines current information on the effect of thermal and thermomechanical processing of implantable Ti materials on the long-term prosthetic requirement which related with wear behavior. This paper focuses mainly on the evolution, evaluation and development of effective microstructural features that can improve wear properties of bio grade Ti materials using thermal and thermomechanical treatments.

Keywords: Wear Resistance, Heat Treatment, Thermomechanical Processing, Biomedical Titanium Materials.

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Authors: Sung-Min Park, Chan Kwon Park, Chae-Bogk Kim

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The purpose of this study is to analyze the relationship between transaction fairness, social capital, supply chain integration and sustainability. Based on the previous studies, measurement items were determined by using SPSS 22 and exploratory factor analysis was performed, and again, using AMOS 21 for confirmatory factor analysis and path analysis was performed by using study items that satisfy reliability, validity, and appropriateness of measurement model. It has shown that transaction fairness has a (+) significant effect on social capital, social capital on supply chain integration, supply chain integration on economic sustainability and social sustainability, and has a (+), but not significant effect on environmental sustainability. It has shown that supply chain integration has been proven to play a role as a parameter between social capital and economic and social sustainability, but not as a parameter between environmental sustainability. Through this study, it is suggested that clearly examining the relationship between fairness of trade, social capital, supply chain integration and sustainability, maintaining fairness of the transaction make formation of social capital, and further integration of supply chain, and achieve sustainability of entire supply chain.

Keywords: Transaction fairness, social capital, supply chain integration, sustainability.

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Authors: Chia-Chen Wei, Pack Hsieh, Jeffrey Chen

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Surface Mount Technology (SMT) is widely used in the area of the electronic assembly in which the electronic components are mounted to the surface of the printed circuit board (PCB). Most of the defects in the SMT process are mainly related to the quality of solder paste printing. These defects lead to considerable manufacturing costs in the electronics assembly industry. Therefore, the solder paste inspection (SPI) machine for controlling and monitoring the amount of solder paste printing has become an important part of the production process. So far, the setting of the SPI threshold is based on statistical analysis and experts’ experiences to determine the appropriate threshold settings. Because the production data are not normal distribution and there are various variations in the production processes, defects related to solder paste printing still occur. In order to solve this problem, this paper proposes an online machine learning algorithm, called the automatic threshold adjustment (ATA) algorithm, and closed-loop architecture in the SMT process to determine the best threshold settings. Simulation experiments prove that our proposed threshold settings improve the accuracy from 99.85% to 100%.

Keywords: Big data analytics, Industry 4.0, SPI threshold setting, surface mount technology.

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Authors: Pupong Pongcharoen, Aphirak Khadwilard, Anothai Klakankhai

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The importance of supply chain and logistics management has been widely recognised. Effective management of the supply chain can reduce costs and lead times and improve responsiveness to changing customer demands. This paper proposes a multi-matrix real-coded Generic Algorithm (MRGA) based optimisation tool that minimises total costs associated within supply chain logistics. According to finite capacity constraints of all parties within the chain, Genetic Algorithm (GA) often produces infeasible chromosomes during initialisation and evolution processes. In the proposed algorithm, chromosome initialisation procedure, crossover and mutation operations that always guarantee feasible solutions were embedded. The proposed algorithm was tested using three sizes of benchmarking dataset of logistic chain network, which are typical of those faced by most global manufacturing companies. A half fractional factorial design was carried out to investigate the influence of alternative crossover and mutation operators by varying GA parameters. The analysis of experimental results suggested that the quality of solutions obtained is sensitive to the ways in which the genetic parameters and operators are set.

Keywords: Genetic Algorithm, Logistics, Optimisation, Supply Chain.

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Authors: H. Akhbari, M. Bidi, A. Bakhtiari, S. Eslami

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The present paper aims to the techno-economic feasibility of enhancing low-cost parabolic trough collectors in the light of developing the use of solar energy in under-developed regions where expensive high-tech solar devices cannot be afforded. Moreover, the collector is aimed to produce steam so that its performance is based on heat which can be discovered. In this regard, the manufacturing process and the detailed design models in Solidworks software are elaborated. Furthermore, the colletor’s material is chosen in a way to minimize the costs. Finally, to assess the performance of the built collector, it is installed in the site of Shahid Beheshti University, Tehran, and the values of the effective peripheral parameters, such as temperature, wind speed, and most importantly, solar irradiance, are recorded simultaneously in June. According to the results obtained, the manufactured collector with the aperture area of 2 m² (1×2 m) is capable of producing 350 ml.h^-1 steam. Also, the wind influence is comprehensively investigated in this paper. As a case in point, it was measured that as the wind speed maximized to 9.77 km/h, the amount of steam outlet is minimized to 580 ml.

Keywords: Direct steam production, design and fabrication parabolic trough collector, solar water heater, wind impact, experimental investigation.

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Authors: Guillaume Mullier, Jean François Chatelain

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Carbon Fiber Reinforced Plastics (CFRPs) are widely used for advanced applications, in particular in aerospace, automotive and wind energy industries. Once cured to near net shape, CFRP parts need several finishing operations such as trimming, milling or drilling in order to accommodate fastening hardware and meeting the final dimensions. The present research aims to study the effect of the cutting temperature in trimming on the mechanical strength of high performance CFRP laminates used for aeronautics applications. The cutting temperature is of great importance when dealing with trimming of CFRP. Temperatures higher than the glass-transition temperature (Tg) of the resin matrix are highly undesirable: they cause degradation of the matrix in the trimmed edges area, which can severely affect the mechanical performance of the entire component. In this study, a 9.50mm diameter CVD diamond coated carbide tool with six flutes was used to trim 24-plies CFRP laminates. A 300m/min cutting speed and 1140mm/min feed rate were used in the experiments. The tool was heated prior to trimming using a blowtorch, for temperatures ranging from 20°C to 300°C. The temperature at the cutting edge was measured using embedded KType thermocouples. Samples trimmed for different cutting temperatures, below and above Tg, were mechanically tested using three-points bending short-beam loading configurations. New cutting tools as well as worn cutting tools were utilized for the experiments. The experiments with the new tools could not prove any correlation between the length of cut, the cutting temperature and the mechanical performance. Thus mechanical strength was constant, regardless of the cutting temperature. However, for worn tools, producing a cutting temperature rising up to 450°C, thermal damage of the resin was observed. The mechanical tests showed a reduced mean resistance in short beam configuration, while the resistance in three point bending decreases with increase of the cutting temperature.

Keywords: Composites, Trimming, Thermal Damage, Surface Quality.

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Authors: Rungchat Chompu-Inwai, Akararit Charoenkasemsuk

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The use of electronic sensors in the electronics industry has become increasingly popular over the past few years, and it has become a high competition product. The frequency adjustment process is regarded as one of the most important process in the electronic sensor manufacturing process. Due to inaccuracies in the frequency adjustment process, up to 80% waste can be caused due to rework processes; therefore, this study aims to provide a preliminary understanding of the role of parameters used in the frequency adjustment process, and also make suggestions in order to further improve performance. Four parameters are considered in this study: air pressure, dispensing time, vacuum force, and the distance between the needle tip and the product. A full factorial design for experiment 2k was considered to determine those parameters that significantly affect the accuracy of the frequency adjustment process, where a deviation in the frequency after adjustment and the target frequency is expected to be 0 kHz. The experiment was conducted on two levels, using two replications and with five center-points added. In total, 37 experiments were carried out. The results reveal that air pressure and dispensing time significantly affect the frequency adjustment process. The mathematical relationship between these two parameters was formulated, and the optimal parameters for air pressure and dispensing time were found to be 0.45 MPa and 458 ms, respectively. The optimal parameters were examined by carrying out a confirmation experiment in which an average deviation of 0.082 kHz was achieved.

Keywords: Design of Experiment, Electronic Sensor, Frequency Adjustment, Parametric Analysis

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Authors: Chiang-Ho Cheng, An-Shik Yang, Hong-Yih Cheng, Ming-Yu Lai

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This paper presents the design and fabrication of a novel piezoelectric actuator for a gas micro pump with check valve having the advantages of miniature size, light weight and low power consumption. The micro pump is designed to have eight major components, namely a stainless steel upper cover layer, a piezoelectric actuator, a stainless steel diaphragm, a PDMS chamber layer, two stainless steel channel layers with two valve seats, a PDMS check valve layer with two cantilever-type check valves and an acrylic substrate. A prototype of the gas micro pump, with a size of 52 mm × 50 mm × 5.0 mm, is fabricated by precise manufacturing. This device is designed to pump gases with the capability of performing the self-priming and bubble-tolerant work mode by maximizing the stroke volume of the membrane as well as the compression ratio via minimization of the dead volume of the micro pump chamber and channel. By experiment apparatus setup, we can get the real-time values of the flow rate of micro pump and the displacement of the piezoelectric actuator, simultaneously. The gas micro pump obtained higher output performance under the sinusoidal waveform of 250 Vpp. The micro pump achieved the maximum pumping rates of 1185 ml/min and back pressure of 7.14 kPa at the corresponding frequency of 120 and 50 Hz.

Keywords: PDMS, Check valve, Micro pump, Piezoelectric.

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Authors: Amany A. Ragheb, Ghada Ragheb, Abd ElRahman A.

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Egypt has a countless heritage of mansions, castles, cities, towns, villages, industrial and manufacturing sites. This richness of heritage provides endless and matchless prospects for culture. Despite being famous worldwide, Egypt’s heritage still is in constant need of protection. Political conflicts and religious revolutions form a direct threat to buildings in various areas, historic, archaeological sites, and religious monuments. Egypt has witnessed two revolutions in less than 60 years; both had an impact on its architectural heritage. In this paper, the authors aim to review legal and policy framework to protect the cultural heritage and present the risk management strategy for cultural heritage in conflict. Through a review of selected international models of devastated architectural heritage in conflict zones and highlighting some of their changes, we can learn from the experiences of other countries to assist towards the development of a methodology to halt the plundering of architectural heritage. Finally, the paper makes an effort to enhance the formulation of a risk management strategy for protection and conservation of cultural heritage, through which to end the plundering of Egypt’s architectural legacy in the Egyptian community (revolutions, 1952 and 2011); and by presenting to its surrounding community the benefits derived from maintaining it.

Keywords: Cultural heritage, legal regulation, risk management, preservation.

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Authors: Mamoon Mousa Atout

Abstract:

The industries of construction are in continuous growth not only in Middle East rejoin but almost all over the world. For the last fifteen years, big expansion and increase of different types of projects has been observed. Many infrastructural projects have been developed, high rise buildings, big shopping malls, power sub-stations, roads, bridges, schools, universities and developing many of new cities with full and complete facilities. The growth and enlargement of the mentioned developed projects has been accomplished through many international and local contracting organizations. Senior management of these organizations depend on their qualified and experienced team whom are aware of the implications of project management, construction management, engineering management and resource management during tendering till final completion of the project. This research aims to find out why reasons of principles of construction engineering and management are necessary for contracting firms and their managers. Principles of construction management help contracting organizations to accomplish and deliver projects without delay. This can be maintained by establishing guidelines’ details for updating the adopted system of construction management that they have through qualified and experienced project managers. The research focuses on benefits of other essential skills of projects planning, monitoring and control. Defining roles and responsibilities of contractor project managers during tendering and execution is a part of the investigated factors that will be analyzed. Other skills like optimizing and utilizing the obtainable project resources to deliver the project within time, cost and quality will be also investigated to find out how these factors are affecting the performance of contracting firms, projects managers and projects. The conclusion of the research will help senior management team and the contractors project managers about the benefits of implications and benefits construction management system and its effect upon the performance and knowledge of contract values that they have, and the optimal profit margin of the firm it.

Keywords: Construction management, contracting firms, project managers, planning processes, roles and responsibilities.

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Authors: Stephen C. W. Kong

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The use of 3D computer-aided design (CAD) models to support construction project planning has been increasing in the previous year. 3D CAD models reveal more planning ideas by visually showing the construction site environment in different stages of the construction process. Using 3D CAD models together with scheduling software to prepare construction plan can identify errors in process sequence and spatial arrangement, which is vital to the success of a construction project. A number of 4D (3D plus time) CAD tools has been developed and utilized in different construction projects due to the awareness of their importance. Virtual prototyping extends the idea of 4D CAD by integrating more features for simulating real construction process. Virtual prototyping originates from the manufacturing industry where production of products such as cars and airplanes are virtually simulated in computer before they are built in the factory. Virtual prototyping integrates 3D CAD, simulation engine, analysis tools (like structural analysis and collision detection), and knowledgebase to streamline the whole product design and production process. In this paper, we present the application of a virtual prototyping software which has been used in a few construction projects in Hong Kong to support construction project planning. Specifically, the paper presents an implementation of virtual prototyping in a residential building project in Hong Kong. The applicability, difficulties and benefits of construction virtual prototyping are examined based on this project.

Keywords: construction project planning, prefabrication, simulation, virtual prototyping.

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Authors: Jung-Lo Park, Sung-Sik Kim, Sun-Young Choi, Ju-Hyung Kim, Jae-Jun Kim

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Sub-prime mortgage crisis which began in the US is regarded as the most economic crisis since the Great Depression in the early 20th century. Especially, hidden problems on efficient operation of a business were disclosed at a time and many financial institutions went bankrupt and filed for court receivership. The collapses of physical market lead to bankruptcy of manufacturing and construction businesses. This study is to analyze dynamic efficiency of construction businesses during the five years at the turn of the global financial crisis. By discovering the trend and stability of efficiency of a construction business, this study-s objective is to improve management efficiency of a construction business in the ever-changing construction market. Variables were selected by analyzing corporate information on top 20 construction businesses in Korea and analyzed for static efficiency in 2008 and dynamic efficiency between 2006 and 2010. Unlike other studies, this study succeeded in deducing efficiency trend and stability of a construction business for five years by using the DEA/Window model. Using the analysis result, efficient and inefficient companies could be figured out. In addition, relative efficiency among DMU was measured by comparing the relationship between input and output variables of construction businesses. This study can be used as a literature to improve management efficiency for companies with low efficiency based on efficiency analysis of construction businesses.

Keywords: Construction Company, DEA, DEA/Window, Efficiency Analysis

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Authors: Mohammed Tahir, Jonas Lagergren

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Vancron 40, a nitrided powder metallurgical tool Steel, is used in cold work applications where the predominant failure mechanisms are adhesive wear or galling. Typical applications of Vancron 40 are among others fine blanking, cold extrusion, deep drawing and cold work rolls for cluster mills. Vancron 40 positive results for cold work rolls for cluster mills and as a tool for some severe metal forming process makes it competitive compared to other type of work rolls that require higher precision, among others in cold rolling of thin stainless steel, which required high surface finish quality. In this project, three roll materials for cold rolling of stainless steel strip was examined, Vancron 40, Narva 12B (a high-carbon, high-chromium tool steel alloyed with tungsten) and Supra 3 (a Chromium-molybdenum tungsten-vanadium alloyed high speed steel). The purpose of this project was to study the depth profiles of the ironed stainless steel strips, emergence of galling and to study the lubrication performance used by steel industries. Laboratory experiments were conducted to examine scratch of the strip, galling and surface roughness of the roll materials under severe tribological conditions. The critical sliding length for onset of galling was estimated for stainless steel with four different lubricants. Laboratory experiments result of performance evaluation of resistance capability of rolls toward adhesive wear under severe conditions for low and high reductions. Vancron 40 in combination with cold rolling lubricant gave good surface quality, prevents galling of metal surfaces and good bearing capacity.

Keywords: Adhesive wear, Cold rolling, Lubricant, Stainless steel, Surface finish, Vancron 40.

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Authors: Sue-Yi Chen, Wei-Chun Hsu, Jon-Yiew Gan

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Si-based double-junction tandem solar cells have become a popular research topic because of the advantages of low manufacturing cost and high energy conversion efficiency. However, there is no set of calculations to select the appropriate top cell materials. Therefore, this paper will propose a simple but practical selection method. First of all, we calculate the S-Q limit and explain the reasons for developing tandem solar cells. Secondly, we calculate the theoretical energy conversion efficiency of the double-junction tandem solar cells while combining the commercial monocrystalline Si and materials' practical efficiency to consider the actual situation. Finally, we conservatively conclude that if considering 75% performance of the theoretical energy conversion efficiency of the top cell, the suitable bandgap energy range will fall between 1.38 eV to 2.5 eV. Besides, we also briefly describe some improvements of several proper materials, CZTS, CdSe, Cu2O, ZnTe, and CdS, hoping that future research can select and manufacture high-efficiency Si-based tandem solar cells based on this paper successfully. Most importantly, our calculation method is not limited to silicon solely. If other materials’ performances match or surpass silicon's ability in the future, researchers can also apply this set of deduction processes.

Keywords: High-efficiency solar cells, material selection, Si-based double-junction solar cells, tandem solar cells, photovoltaics.

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Authors: P. D. Pastuszak

Abstract:

The present work is devoted to thermographic studies of curved composite panels (unidirectional GFRP) with subsurface defects. Various artificial defects, created by inserting PTFE stripe between individual layers of a laminate during manufacturing stage are studied. The analysis is conducted both with the use finite element method and experiments. To simulate transient heat transfer in 3D model with embedded various defect sizes, the ANSYS package is used. Pulsed Thermography combined with optical excitation source provides good results for flat surfaces. Composite structures are mostly used in complex components, e.g., pipes, corners and stiffeners. Local decrease of mechanical properties in these regions can have significant influence on strength decrease of the entire structure. Application of active procedures of thermography to defect detection and evaluation in this type of elements seems to be more appropriate that other NDT techniques. Nevertheless, there are various uncertainties connected with correct interpretation of acquired data. In this paper, important factors concerning Infrared Thermography measurements of curved surfaces in the form of cylindrical panels are considered. In addition, temperature effects on the surface resulting from complex geometry and embedded and real defect are also presented.

Keywords: Active thermography, finite element analysis, composite, curved structures, defects.

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Authors: Anto Antony Samy, Atefeh Golbang, Edward Archer, Alistair McIlhagger

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Fused Deposition Modelling (FDM) is one of the additive manufacturing techniques that has become highly attractive in the industrial and academic sectors. However, parts fabricated through FDM are highly susceptible to geometrical defects such as warpage, shrinkage, and delamination that can severely affect their function. Among the thermoplastic polymer feedstock for FDM, semi-crystalline polymers are highly prone to part distortion due to polymer crystallization. In this study, the influence of FDM processing conditions such as chamber temperature and print bed temperature on the induced thermal residual stress and resulting warpage are investigated using 3D transient thermal model for a semi-crystalline polymer. The thermo-mechanical properties and the viscoelasticity of the polymer, as well as the crystallization physics which considers the crystallinity of the polymer, are coupled with the evolving temperature gradient of the print model. From the results it was observed that increasing the chamber temperature from 25 °C to 75 °C leads to a decrease of 3.3% residual stress and increase of 0.4% warpage, while decreasing bed temperature from 100 °C to 60 °C resulted in 27% increase in residual stress and a significant rise of 137% in warpage. The simulated warpage data are validated by comparing it with the measured warpage values of the samples using 3D scanning.

Keywords: Finite Element Analysis, FEA, Fused Deposition Modelling, residual stress, warpage.

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Authors: Shilpesh R. Rajpurohit, Harshit K. Dave

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Fused deposition modeling (FDM) gains popularity in recent times, due to its capability to create prototype as well as functional end use product directly from CAD file. Parts fabricated using FDM process have mechanical properties comparable with those of injection-molded parts. However, performance of the FDM part is severally affected by the poor mechanical properties of the part due to nature of layered structure of printed part. Mechanical properties of the part can be improved by proper selection of process variables. In the present study, a comparative study between unidirectional and bidirectional raster angle has been carried out at a combination of different layer height and raster width. Unidirectional raster angle varied at five different levels, and bidirectional raster angle has been varied at three different levels. Fabrication of tensile specimen and tensile testing of specimen has been conducted according to ASTM D638 standard. From the results, it can be observed that higher tensile strength has been obtained at 0° raster angle followed by 45°/45° raster angle, while lower tensile strength has been obtained at 90° raster angle. Analysis of fractured surface revealed that failure takes place along with raster deposition direction for unidirectional and zigzag failure can be observed for bidirectional raster angle.

Keywords: Additive manufacturing, fused deposition modeling, raster angle, tensile strength.

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Authors: Ahmed A. D. Sarhan, M. Sayuti, M. Hamdi

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Nowadays, the demand for high product quality focuses extensive attention to the quality of machined surface. The (CNC) milling machine facilities provides a wide variety of parameters set-up, making the machining process on the glass excellent in manufacturing complicated special products compared to other machining processes. However, the application of grinding process on the CNC milling machine could be an ideal solution to improve the product quality, but adopting the right machining parameters is required. In glass milling operation, several machining parameters are considered to be significant in affecting surface roughness. These parameters include the lubrication pressure, spindle speed, feed rate and depth of cut. In this research work, a fuzzy logic model is offered to predict the surface roughness of a machined surface in glass milling operation using CBN grinding tool. Four membership functions are allocated to be connected with each input of the model. The predicted results achieved via fuzzy logic model are compared to the experimental result. The result demonstrated settlement between the fuzzy model and experimental results with the 93.103% accuracy.

Keywords: CNC-machine, Glass milling, Grinding, Surface roughness, Cutting force, Fuzzy logic model.

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Authors: Oscar E. Ruiz, S. Arroyave, J. F. Cardona

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In the context of computer numerical control (CNC) and computer aided manufacturing (CAM), the capabilities of programming languages such as symbolic and intuitive programming, program portability and geometrical portfolio have special importance. They allow to save time and to avoid errors during part programming and permit code re-usage. Our updated literature review indicates that the current state of art presents voids in parametric programming, program portability and programming flexibility. In response to this situation, this article presents a compiler implementation for EGCL (Extended G-code Language), a new, enriched CNC programming language which allows the use of descriptive variable names, geometrical functions and flow-control statements (if-then-else, while). Our compiler produces low-level generic, elementary ISO-compliant Gcode, thus allowing for flexibility in the choice of the executing CNC machine and in portability. Our results show that readable variable names and flow control statements allow a simplified and intuitive part programming and permit re-usage of the programs. Future work includes allowing the programmer to define own functions in terms of EGCL, in contrast to the current status of having them as library built-in functions.

Keywords: CNC Programming, Compiler, G-code Language, Numerically Controlled Machine-Tools.

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Authors: Shigeyuki Haruyama, Aidil Khaidir Bin Muhamad, Tadayuki Kyoutani, Dai-Heng Chen, Ken Kaminishi

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The product development process has undergone many changes concomitant with world progress in order to produce products that meet customer needs quickly and inexpensively. Analysis-Led Design (ALD) is one of the latest methods in the product development process. It focuses more on up-front engineering, a product quality optimization process that starts early in the conceptual design stage. Product development and manufacturing through ALD utilizes digital tools extensively for design, analysis and product optimization. This study uses computer-aided design (CAD) and finite element method (FEM) simulation to examine the modes of deformation of tubular members under axial loading. A multiple-combination impact absorption tubular member, referred to as a compress–expand member, is proposed as a substitute for the conventional thin-walled cylindrical tube to be used as a vehicle’s crash box. The study of deformation modes is crucial for evaluating the geometrical dimension limits by which a member can absorb energy efficiently.

Keywords: Analysis-led design, axial collapse, tubular member, finite element method, thin-walled cylindrical tube, compress-expand member, deformation modes.

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Authors: Guenther Schuh, Christina Koenig, Nico Schoen, Markus Wellensiek

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Identification and selection of appropriate product and manufacturing technologies are key factors for competitiveness and market success of technology-based companies. Therefore, many companies perform technology intelligence (TI) activities to ensure the identification of evolving technologies at the right time. Technology monitoring is one of the three base activities of TI, besides scanning and scouting. As the technological progress is accelerating, more and more technologies are being developed. Against the background of limited resources it is therefore necessary to focus TI activities. In this paper we propose a concept for defining appropriate search fields for technology monitoring. This limitation of search space leads to more concentrated monitoring activities. The concept will be introduced and demonstrated through an anonymized case study conducted within an industry project at the Fraunhofer Institute for Production Technology IPT. The described concept provides a customized monitoring approach, which is suitable for use in technology-oriented companies. It is shown in this paper that the definition of search fields and search tasks are suitable methods to define topics of interest and thus to align monitoring activities. Current as well as planned product, production and material technologies and existing skills, capabilities and resources form the basis for derivation of relevant search areas. To further improve the concept of technology monitoring the proposed concept should be extended during future research e.g. by the definition of relevant monitoring parameters.

Keywords: Monitoring radar, search field, technology intelligence, technology monitoring.

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Authors: Gupta Amit, Kumar Ramesh, Tewari P. C.

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Globalization is putting enormous pressure on the business organizations specially manufacturing one to rethink the supply chain in innovative manners. Inventory consumes major portion of total sale revenue. Effective and efficient inventory management plays a vital role for the successful functioning of any organization. Selection of inventory policy is one of the important purchasing activities. This paper focuses on selection and ranking of alternative inventory policies. A deterministic quantitative model based on Distance Based Approach (DBA) method has been developed for evaluation and ranking of inventory policies. We have employed this concept first time for this type of the selection problem. Four inventory policies economic order quantity (EOQ), just in time (JIT), vendor managed inventory (VMI) and monthly policy are considered. Improper selection could affect a company’s competitiveness in terms of the productivity of its facilities and quality of its products. The ranking of inventory policies is a multi-criteria problem. There is a need to first identify the selection criteria and then processes the information with reference to relative importance of attributes for comparison. Criteria values for each inventory policy can be obtained either analytically or by using a simulation technique or they are linguistic subjective judgments defined by fuzzy sets, like, for example, the values of criteria. A methodology is developed and applied to rank the inventory policies.

Keywords: Inventory Policy, Ranking, DBA, Selection criteria.

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Authors: Mochammad Dewo, Sumarsono Sudarto

Abstract:

The Exponential Triple Smoothing Algorithm approach nowadays, which is used to anticipate the export value of Indonesia's two major commodities, coal and palm oil, has a Mean Percentage Absolute Error (MAPE) value of 30-50%, which may be considered as a "reasonable" forecasting mistake. Forecasting errors of more than 30% shall have a domino effect on industrial output, as extra production adds to raw material, manufacturing and storage expenses. Whereas, reaching an "excellent" classification with an error value of less than 10% will provide new investors and exporters with confidence in the commercial development of related sectors. Industrial growth will bring out a positive impact on economic development. It can be applied for other commodities if the forecast error is less than 10%. The purpose of this project is to create a forecasting technique that can produce precise forecasting results with an error of less than 10%. This research analyzes forecasting methods such as ARIMA (Autoregressive Integrated Moving Average), ANN (Artificial Neural Network) and LSTM (Long-Short Term Memory). By providing a MAPE of 1%, this study reveals that ANN is the most successful strategy for forecasting coal and palm oil commodities in Indonesia.

Keywords: ANN, Artificial Neural Network, ARIMA, Autoregressive Integrated Moving Average, export value, forecast, LSTM, Long Short Term Memory.

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Authors: Seungkyum Kim, Yongtae Park

Abstract:

Recently, business environment and customer needs have become rapidly changing, hence it is very difficult to fulfill sophisticated customer needs by product or service innovation only. In practice, to cope with this problem, various manufacturing companies have developed services to combine with their products. Along with this, many academic studies on PSS (Product Service System) which is the integrated system of products and services have been conducted from the viewpoint of manufacturers. On the other hand, service providers are also attempting to develop service-supporting products to increase their service competitiveness and provide differentiated value. However, there is a lack of research based on the service-centric point of view. Accordingly, this paper proposes a concept generation method for service-supporting product development from the service-centric point of view. This method is designed to be executed in five consecutive steps: situation analysis, problem definition, problem resolution, solution evaluation, and concept generation. In the proposed approach, some tools of TRIZ (Theory of Solving Inventive Problem) such as ISQ (Innovative Situation Questionnaire) and 40 inventive principles are employed in order to define problems of the current services and solve them by generating service-supporting product concepts. This research contributes to the development of service-supporting products and service-centric PSSs.

Keywords: TRIZ, PSS (Product Service System), service-supporting product, concept generation

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Authors: R. F. B. Gonçalves, E. N. Iwama, J. A. F. F. Rocco, K. Iha

Abstract:

Propellants based on Hydroxyl Terminated Polybutadiene/Ammonium Perchlorate (HTPB/AP) are the most commonly used in most of the rocket engines used by the Brazilian Armed Forces. This work aimed at the possibility of extending its useful life (currently in 10 years) by performing kinetic-chemical analyzes of its energetic material via Differential Scanning Calorimetry (DSC) and also performing computer simulation of aging process using the software Large-scale Atomic/Molecular Massively Parallel Simulator (LAMMPS). Thermal analysis via DSC was performed in triplicates and in three heating ratios (5 ºC, 10 ºC, and 15 ºC) of rocket motor with 11 years shelf-life, using the Arrhenius equation to obtain its activation energy, using Ozawa and Kissinger kinetic methods, allowing comparison with manufacturing period data (standard motor). In addition, the kinetic parameters of internal pressure of the combustion chamber in 08 rocket engines with 11 years of shelf-life were also acquired, for comparison purposes with the engine start-up data.

Keywords: Shelf-life, thermal analysis, Ozawa method, Kissinger method, LAMMPS software, thrust.

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Authors: Avita K. Marihal, K.S. Jagadeesh, Sarita Sinha

Abstract:

Pentachlorophenol (PCP) is a polychlorinated aromatic compound that is widespread in industrial effluents and is considered to be a serious pollutant. Among the variety of industrial effluents encountered, effluents from tanning industry are very important and have a serious pollution potential. PCP is also formed unintentionally in effluents of paper and pulp industries. It is highly persistent in soils and is lethal to a wide variety of beneficial microorganisms and insects, human beings and animals. The natural processes that breakdown toxic chemicals in the environment have become the focus of much attention to develop safe and environmentfriendly deactivation technologies. Microbes and plants are among the most important biological agents that remove and degrade waste materials to enable their recycling in the environment. The present investigation was carried out with the aim of developing a microbial system for bioremediation of PCP polluted soils. A number of plant species were evaluated for their ability to tolerate different concentrations of pentachlorophenol (PCP) in the soil. The experiment was conducted for 30 days under pot culture conditions. The toxic effect of PCP on plants was studied by monitoring seed germination, plant growth and biomass. As the concentration of PCP was increased to 50 ppm, the inhibition of seed germination, plant growth and biomass was also increased. Although PCP had a negative effect on all plant species tested, maize and groundnut showed the maximum tolerance to PCP. Other tolerating crops included wheat, safflower, sunflower, and soybean. From the rhizosphere soil of the tolerant seedlings, as many as twenty seven PCP tolerant bacteria were isolated. From soybean, 8; sunflower, 3; safflower 8; maize 2; groundnut and wheat, 3 each isolates were made. They were screened for their PCP degradation potentials. HPLC analyses of PCP degradation revealed that the isolate MAZ-2 degraded PCP completely. The isolate MAZ-1 was the next best isolate with 90 per cent PCP degradation. These strains hold promise to be used in the bioremediation of PCP polluted soils.

Keywords: Biodegradation, pentachlorophenol, rhizobacteria.

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Authors: Hussain Ali Bekhet, Nor Salwati Othman

Abstract:

Malaysia has achieved remarkable economic growth since 1957, moving toward modernization from a predominantly agriculture base to manufacturing and—now—modern services. The development policies (i.e., New Economic Policy [1970–1990], the National Development Policy [1990–2000], and Vision 2020) have been recognized as the most important drivers of this transformation. The transformation of the economic structure has moved along with rapid gross domestic product (GDP) growth, urbanization growth, and greater demand for energy from mainly fossil fuel resources, which in turn, increase CO2 emissions. Malaysia faced a great challenge to bring down the CO2 emissions without compromising economic development. Solid policies and a strategy to reduce dependencies on fossil fuel resources and reduce CO2 emissions are needed in order to achieve sustainable development. This study provides an overview of the Malaysian economic, energy, and environmental situation, and explores the existing policies and strategies related to energy and the environment. The significance is to grasp a clear picture on what types of policies and strategies Malaysia has in hand. In the future, this examination should be extended by drawing a comparison with other developed countries and highlighting several options for sustainable development.

Keywords: Energy policies, energy efficiency, renewable energy, green building, Malaysia, sustainable development.

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Authors: B. Varaprasad, C. Srinivasa Rao

Abstract:

In the manufacturing sector, hard turning has emerged as vital machining process for cutting hardened steels. Besides many advantages of hard turning operation, one has to implement to achieve close tolerances in terms of surface finish, high product quality, reduced machining time, low operating cost and environmentally friendly characteristics. In the present study, three-dimensional CAE (Computer Aided Engineering) based simulation of  hard turning by using commercial software DEFORM 3D has been compared to experimental results of  stresses, temperatures and tool forces in machining of AISI D3 steel using mixed Ceramic inserts (CC6050). In the present analysis, orthogonal cutting models are proposed, considering several processing parameters such as cutting speed, feed, and depth of cut. An exhaustive friction modeling at the tool-work interfaces is carried out. Work material flow around the cutting edge is carefully modeled with adaptive re-meshing simulation capability. In process simulations, feed rate and cutting speed are constant (i.e.,. 0.075 mm/rev and 155 m/min), and analysis is focused on stresses, forces, and temperatures during machining. Close agreement is observed between CAE simulation and experimental values.

Keywords: Hard-turning, computer-aided engineering, computational machining, finite element method.

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