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Sustainable Manufacturing Processes and Machine Tool Technology

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A special issue of Sustainability (ISSN 2071-1050). This special issue belongs to the section "Sustainable Engineering and Science".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 23405

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Special Issue Editors

Prof. Dr. John D. Kechagias

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Guest Editor

Department of FWSD (Design & Manufacturing Lab), School of Technology, University of Thessaly, 41500 Gaiopolis, Greece
Interests: manufacturing; materials; processes; smart 3D printing
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Panagiotis Kyratsis

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Guest Editor

Department of Product and Systems Design Engineering, University of Western Macedonia, 50100 Kila Kozani, Greece
Interests: computational design; CAD/CAM/CAE; digital manufacturing; product design; FEA; industry 4.0; prototyping; reverse engineering
Special Issues, Collections and Topics in MDPI journals

Dr. Angelos P. Markopoulos

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Guest Editor

Section of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, 15780 Athens, Greece
Interests: manufacturing technology; machining processes; non-conventional machining; modeling and simulation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Sustainable manufacturing processes (SMP) and machine tool technology issues are extremely interesting topics nowadays that combine high performance with environmental conscious design and manufacturing. A number of issues from the design process, the machining processes to the manufacturing mechanisms are involved and the researchers are able to explore different aspects of SMPs and simulation tools. Conventional and non-conventional manufacturing can be used together under the sustainability umbrella. Simulation based optimisation can offer considerable benefits towards an environmentally friendly way of life.

Computer Aided Manufacturing has gone far beyond than just creating CNC codes. Optimisation tools for machining trajectories for peculiar geometries, simulation tools based on a variety of principles and linear/nonlinear finite element methodologies applied, lead to more sustainable design and manufacturing results.

This Special Issue provides an opportunity for researchers to present recent advances and technologies in the aforementioned fields and indicate the future trends for sustainability in manufacturing and tooling technologies.

Suitable topics for this Special Issue include, but are not limited to:

Machinability
Conventional and Non-conventional manufacturing processes
Manufacturing processes simulations
Simulations for sustainability
CNC Trajectory optimisation
Quality engineering
CAD/CAM/CAE
Precision machining
Circular economy
Sustainable Industry 4.0,
Autonomous and collaborative robots
Cloud manufacturing
Manufacturing and design optimisation
Soft computing (neural networks, deep learning etc)
Additive manufacturing
Sustainable design and manufacturing
Automotive and Aerospace applications

Prof. Dr. John D. Kechagias
Prof. Dr. Panagiotis Kyratsis
Prof. Dr. Angelos P. Markopoulos
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Sustainability is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

CNC machine tools, manufacturing technology, quality engineering, CAD/CAM/CAE, manufacturing and machining, product and packaging design, reverse engineering and prototyping, micromachining
nonconventional processes in macro
micro- and nanoscale
modeling

Published Papers (6 papers)

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Research

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18 pages, 3607 KiB

Open AccessArticle

Experimental Study on the Sustainability Assessment of AWJ Machining of Ti-6Al-4V Using Glass Beads Abrasive Particles

by Nikolaos E. Karkalos, Panagiotis Karmiris-Obratański, Rafał Kudelski and Angelos P. Markopoulos

Sustainability 2021, 13(16), 8917; https://0-doi-org.brum.beds.ac.uk/10.3390/su13168917 - 09 Aug 2021

Cited by 10 | Viewed by 2091

Abstract

Abrasive Waterjet Machining (AWJM) is considered a viable alternative to conventional machining processes, due to its capability of rendering even complex features on parts with high productivity. However, it is currently also important for manufacturing processes to comply with the various aspects of sustainability, by putting emphasis on the environmental dimension apart from the economic. Although AWJM generally is considered an inherently environmentally friendly process, it is required that thorough experimental studies be carried out to evaluate the sustainability of AWJM under various conditions. In the present work, AWJM experiments under various conditions were conducted on a Ti-6Al-4V workpiece in order to determine the optimal conditions leading to a high degree of sustainability in this process based on several indicators. The experiments were carried out using glass beads, which act as an eco-friendly abrasive. After the basic outcome of the experiment was analyzed to determine the correlations between process parameters and depth of penetration, kerf width, and kerf taper angle, sustainability analysis with the aid of Grey Relational Analysis (GRA) was conducted. The optimum solution provided a sufficiently high score regarding both the economic and environmental dimensions of sustainability. Full article

(This article belongs to the Special Issue Sustainable Manufacturing Processes and Machine Tool Technology)

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25 pages, 7959 KiB

Open AccessArticle

Performance Investigation of the Effects of Nano-Additive-Lubricants with Cutting Parameters on Material Removal Rate of AL8112 Alloy for Advanced Manufacturing Application

by Imhade Princess Okokpujie and Lagouge Kwanda Tartibu

Sustainability 2021, 13(15), 8406; https://0-doi-org.brum.beds.ac.uk/10.3390/su13158406 - 28 Jul 2021

Cited by 10 | Viewed by 1730

Abstract

The implementation of nano-additives in machining fluid is significant for manufacturers to attain a sustainable manufacturing process. The material removal rate (MRR) is a significant process of transforming solid raw materials into specific shapes and sizes. This process has many challenges due to friction, vibration, chip discontinuity when machining aluminum alloy, which has led to poor accuracy and affected the fatigue life of the developed material. It is worth noting that aluminum 8112 alloy is currently being applied in most engineering applications due to its lightweight-to-strength ratio compared to some other metals. This research aims to compare the effects of copra oil-based-titanium dioxide (TiO₂)- and Multi-walled Carbon Nanotubes (MWCNTs)-nano-lubricant with cutting parameter interactions by conducting a study on MRR for advanced machining of aluminum 8112 alloys. The biodegradable nano-additive-lubricants were developed using two-step preparation techniques. The study employed a quadratic rotatable central composite design (QRCCD) to carry out the interaction study of the five machining parameters in the three lubrication environments on MRR. The results show that the copra-based-TiO₂ nano-lubricant increases the MRR by 7.5% and 16% than the MWCNTs and copra-oil-lubrication machining environments, respectively. In conclusion, the eco-friendly nano-additive-lubricant TiO₂-Copra oil-based should be applied to manufacture machine parts for high entropy applications for sustainable production systems. Full article

(This article belongs to the Special Issue Sustainable Manufacturing Processes and Machine Tool Technology)

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11 pages, 3267 KiB

Open AccessArticle

Unlocking Sustainability Potentials in Heat Treatment Processes

by Stefan Scharf, Niklas Bergedieck, Eric Riedel, Hans Richter and Norbert Stein

Sustainability 2020, 12(16), 6457; https://0-doi-org.brum.beds.ac.uk/10.3390/su12166457 - 11 Aug 2020

Cited by 3 | Viewed by 2470

Abstract

Energy consumption, greenhouse gas emissions, environmental impact levels, and the availability of materials as well as their sustainable usage are all topics of high current interest. The energy intensive processes of casting production such as heat treatment are particularly affected by the pursuit of sustainability. It has been estimated that up to 20% of the total energy demand in a non-ferrous foundry is required to provide the heat energy necessary during heat treatment processes. This paper addresses the application-oriented development of a sustainable configuration of the heat treatment process at the example of the aluminium-casting alloy A356 (AlSi7Mg0.3). Based on calculations of the physically necessary operating modes and under investigation of previous parameter recommendations, experimental studies were carried out to investigate the effects of various heat treatment parameters on the ultimate mechanical properties of the alloy. Since the achievable mechanical properties of the finished casting are decisive, the static and dynamic casting properties resulting from the heat treatment with optimized process parameters were compared with those of conventional process control. Significant optimization potential is shown for reducing the treatment time and thus lowering the energy consumption. Full article

(This article belongs to the Special Issue Sustainable Manufacturing Processes and Machine Tool Technology)

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15 pages, 5837 KiB

Open AccessArticle

Sustainable Additive Manufacturing: Mechanical Response of Acrylonitrile-Butadiene-Styrene over Multiple Recycling Processes

by Nectarios Vidakis, Markos Petousis, Athena Maniadi, Emmanuel Koudoumas, Achilles Vairis and John Kechagias

Sustainability 2020, 12(9), 3568; https://0-doi-org.brum.beds.ac.uk/10.3390/su12093568 - 27 Apr 2020

Cited by 70 | Viewed by 7392

Abstract

Sustainability in additive manufacturing refers mainly to the recycling rate of polymers and composites used in fused filament fabrication (FFF), which nowadays are rapidly increasing in volume and value. Recycling of such materials is mostly a thermomechanical process that modifies their overall mechanical behavior. The present research work focuses on the acrylonitrile-butadiene-styrene (ABS) polymer, which is the second most popular material used in FFF-3D printing. In order to investigate the effect of the recycling courses on the mechanical response of the ABS polymer, an experimental simulation of the recycling process that isolates the thermomechanical treatment from other parameters (i.e., contamination, ageing, etc.) has been performed. To quantify the effect of repeated recycling processes on the mechanic response of the ABS polymer, a wide variety of mechanical tests were conducted on FFF-printed specimens. Regarding this, standard tensile, compression, flexion, impact and micro-hardness tests were performed per recycle repetition. The findings prove that the mechanical response of the recycled ABS polymer is generally improved over the recycling repetitions for a certain number of repetitions. An optimum overall mechanical behavior is found between the third and the fifth repetition, indicating a significant positive impact of the ABS polymer recycling, besides the environmental one. Full article

(This article belongs to the Special Issue Sustainable Manufacturing Processes and Machine Tool Technology)

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16 pages, 2482 KiB

Open AccessArticle

Decision Support Simulation Method for Process Improvement of Electronic Product Testing Systems

by Péter Tamás, Sándor Tollár, Béla Illés, Tamás Bányai, Ágota Bányai Tóth and Róbert Skapinyecz

Sustainability 2020, 12(7), 3063; https://0-doi-org.brum.beds.ac.uk/10.3390/su12073063 - 10 Apr 2020

Cited by 3 | Viewed by 2584

Abstract

Spread of the Jidoka concept can be phrased as a trend at the production of electronic products. In most of the cases, with the application of this concept, the development of testing procedures (for quality assurance purposes) of the finished products can be avoided. In those cases, when the production process of the appropriate quality product cannot be implemented safely for the establishment of the product testing process (following the production process), changing the number of variety products, change of requirements concerning the electronic products (e.g., instructions related to energy consumption, noise level) and the variation of the required testing capacity make the modification of the established testing process necessary. The implementation of related plans often leads to problems (e.g., not the appropriate storage area, material flow process or material handling equipment having been chosen). The method of process configuration affects the sustainability, since the poorly established process can lead to additional usage of non-renewable natural resources and unjustified environmental impact. For one of the tools of Industry 4.0, we developed such a state-of-the-art testing method with the use of simulation modelling by which the change of testing process can be effectively examined and evaluated, thus we can prevent the unnecessary planning failures. The application of the developed method is also shown through a case study. Full article

(This article belongs to the Special Issue Sustainable Manufacturing Processes and Machine Tool Technology)

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Review

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22 pages, 5504 KiB

Open AccessReview

Sustainable Manufacturing Technologies: A Systematic Review of Latest Trends and Themes

by Ali Bastas

Sustainability 2021, 13(8), 4271; https://0-doi-org.brum.beds.ac.uk/10.3390/su13084271 - 12 Apr 2021

Cited by 23 | Viewed by 5687

Abstract

Meeting current needs while not sacrificing the future ability to do so as a key sustainability concept is becoming more challenging than ever, with the increasing population rate, energy poverty, global warming, and surging demand for products and services. Manufacturing is in a prime position to address this challenge, with its significant economic contribution to the global GDP and its high influence over the environment and humanity. Sustainable manufacturing technologies research is growing to support our journey towards sustainable development. This article undertook the systematic review of state-of-the-art sustainable manufacturing technologies literature, evidencing the latest themes and trends in this important research avenue. Descriptive and thematic analyses were performed, synthesising the latest advancements in the field. Sustainable manufacturing processes, especially sustainable machining, was established as a key theme, including research endeavours of elimination of lubricants. Various manufacturing systems and process sustainability assessment technologies were noted. Sustainability indicators addressed were critically evaluated. As an outcome, a conceptual framework of sustainable manufacturing technology research was constructed to structure the knowledge acquired and to provoke future thinking. Finally, challenges and future directions were provided for both industrial and academic reader base, stimulating growth in this fruitful research stream. Full article

(This article belongs to the Special Issue Sustainable Manufacturing Processes and Machine Tool Technology)

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