Innovations in Manufacturing for Sustainability (eBook)

Dr. Kapil Gupta is a Associate Professor in the Dept. of Mechanical and Industrial Engineering Technology at the University of Johannesburg. His field of interest are advanced machining processes, sustainable manufacturing, precision engineering and gear technology. 

Preface 6
Contents 8
1 Dry and Near-Dry Machining Techniques for Green Manufacturing 9
Abstract 9
1 Introduction 10
1.1 Introduction to Cutting Fluids 10
1.2 Characteristics of Cutting Fluids 10
1.3 Types and Application of Cutting Fluid 11
1.3.1 Oil-Based Cutting Fluids 11
1.3.2 Aqueous-Based Cutting Fluids 12
1.3.3 Synthetic and Semi-Synthetic Cutting Fluids 13
1.4 Ecological Problems of Conventional Cutting Fluids 13
1.5 Newly Developed Environmental Friendly Cutting Fluids 15
1.5.1 Vegetable-Based Cutting Fluids 15
1.5.2 Gas-Based Coolant Lubricants 16
1.5.3 Chemical Additive-Enhanced Cutting Fluids 17
1.5.4 Nanoparticle-Enhanced Cutting Fluids 17
2 Cooling and Lubricating Techniques 18
2.1 Conventional Methods 18
2.1.1 Traditional (Flood/Wet) Cooling Technique 19
2.1.2 High-Pressure Cooling Technique 19
2.1.3 Mist Cooling Technique 19
2.1.4 Internal Tool Cooling 20
2.2 Advanced Green Manufacturing 20
2.2.1 Dry Machining 20
2.2.2 Near-Dry Machining 22
Minimum Quantity Lubrication (MQL) 23
Nanofluid Additives in Green Manufacturing 24
2.2.3 Comparative Study Between Dry Machining and MQL 25
3 Case Studies on Machinability Using Different Coolant Conditions 27
4 Summary 31
References 32
2 Cryogenic Machining 36
Abstract 36
1 Introduction 36
2 Experimental Procedure for Cryogenic Machining 40
3 Methods of Cryogenic Cooling 42
3.1 Pre-cooling of Workpiece 42
3.2 Indirect Cooling 43
3.3 Jet Machining 43
3.4 Cooling Treatment by Cryogenic Material 44
3.5 Cryogenic Minimum Quantity Lubrication 45
4 Effect of Cryogenic Machining 46
4.1 Influence of Cryogenic Cooling on Tool Life and Wear 46
4.2 Influence of Cryogenic Cooling on Tool and Workpiece Temperature 47
4.3 Influence of Cryogenic Machining on Material Properties 48
4.4 Influence of Cryogenic Machining on Friction 49
4.5 Influence of Cryogenic Conditions on Cutting Forces 51
4.6 Influence of Cryogenic Machining on Surface Finish and Dimensional Precision 52
4.7 Effect of Cryogenic Temperature on Microstructural Change of Tool and Workpiece Material 53
5 Comparison Between CO2 and LIN Cryogenic Cooling 55
6 Conclusion 56
References 57
3 Sustainability Issues in Electric Discharge Machining 60
Abstract 60
1 Introduction 61
2 Dielectric Fluid in EDM 62
2.1 Dielectric Supply Methods 63
3 Sustainability of EDM Process 64
3.1 Impact of EDM Process on Environment, Health and Safety 64
3.2 Technological and Economic Concerns of EDM Process 66
3.3 Sustainable EDM 66
4 Green or Biodielectrics for EDM 67
4.1 Experimental Methodology 68
5 Performance Analysis of Biodielectric Fluids for EDM 69
5.1 Effects on Material Removal Rate (MRR) 70
5.2 Influence of Current on Surface Roughness and Surface Hardness 73
5.3 Influence of Pulse-ON Time on Surface Roughness and Surface Hardness 74
5.4 Metallurgical Structure Analysis 74
6 Conclusions and Future Directions 78
References 79
4 Energy-Efficient Casting Processes 83
Abstract 83
1 Introduction 83
2 Metal Casting Fundamentals 85
3 Energy Efficiency Through Management 86
3.1 Management Practices in Foundries 86
3.2 Lean Manufacturing Concepts in Foundries 87
3.3 Examples of Lean Implementation in Foundries 89
4 Energy Efficiency Through Technology 91
5 Examples of Energy-Efficient Casting Implementations 93
6 “Small Is Beautiful” Approach 95
6.1 Auditing Framework 96
6.2 Data Visualisation Tool 97
7 Foundries of the Future: A Short Conclusion 101
Acknowledgements 102
References 102
5 Research Framework of Sustainability in Additive Manufacturing: A Case of Fused Deposition Modeling 105
Abstract 105
1 Introduction 106
2 Life Cycle Perspective 108
3 Research Framework 111
4 Case Studies 114
4.1 Case I 115
4.2 Case II 119
4.3 Case III 121
5 Discussions and Conclusions 126
Acknowledgements 127
References 127
6 Sustainability in Welding and Processing 130
Abstract 130
1 Introduction 130
2 Fusion Arc Welding 133
2.1 Shielded Metal Arc Welding 134
2.2 Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW) and Plasma Arc Welding (PAW) 135
2.3 Submerge Arc Welding (SAW) 136
3 Solid-State Welding Processes 138
3.1 Magnetic Field-Based Welding 138
3.2 Ultrasonic Welding 140
3.3 Friction-Based Welding and Processing 141
3.3.1 Friction Welding 141
3.3.2 Friction Stir Welding 142
3.3.3 Friction Stir Spot Welding 143
3.3.4 Friction Bit Joining 144
3.3.5 Friction Stir Extrusion 144
3.3.6 Friction Stir Processing 144
4 Laser-Based Welding and Processing 145
5 Summary 145
References 148
7 Green Machining of Thin-Wall Titanium Alloy 151
Abstract 151
1 Introduction 152
2 Experimental Work 157
3 Results and Discussion 159
3.1 Computation of Thin-Wall Natural Frequency and Vibration Analysis 159
3.2 Surface Quality 161
4 Membrane Technology 164
4.1 Potential and Handling of Membrane Technology 164
4.2 PVDF Membrane for Mitigation of Wasted Cutting Fluids 166
4.3 Experimental Set-up of PVDF Membrane Technology 167
4.4 PVDF Membrane Experiments Results 168
5 Conclusions and Future Directions 169
References 170
8 Sustainability Assessment-Based Comparative Evaluation of Precision Miniature Gear Manufacturing Processes 173
Abstract 173
1 Introduction 174
1.1 Motivation 175
2 Materials and Methods 176
3 Results and Discussions 178
3.1 Sustainability Assessment 178
3.2 Calculations of Process Sustainability Index (PSI) 179
3.3 Process Performance/Machining Environment Sustainability Components 181
3.4 Product Performance Sustainability Components 182
4 Conclusions 184
References 185
Index 187