Sustainable Manufacturing Processes

Front Cover
SUSTAINABLE MANUFACTURING PROCESSES
SUSTAINABLE MANUFACTURING PROCESSES
Dedication
Copyright
Contents
Contributors
About the editors
Foreword
Preface
Acknowledgment
1 - Introduction to sustainable manufacturing processes
1.1 Definition and importance
1.2 Manufacturing processes and sustainability implementation
1.2.1 Sustainable reusage of spent foundry sand
1.2.2 Sustainable fabrication of automotive components by metal forming route
1.2.3 Fusion and solid-state welding and sustainability
1.2.4 Sustainable machining
1.2.5 Sustainability of additive manufacturing
1.3 Sustainability assessment
1.4 Computer-aided analyses and sustainable manufacturing
1.5 Industry 4.0 and sustainable manufacturing
1.6 Education for sustainability development
1.7 Summary
References
2 - Sustainability in foundry and metal casting industry
2.1 Introduction
2.2 What are foundry and metal casting processes?
2.3 Environmental issues in foundry and metal casting
2.4 Sustainability indicators for the foundry and metal casting industry
2.5 Concepts, technologies, management practices, and systems for sustainability assessment in the foundry and metal casting
2.5.1 Sustainability concepts
2.5.2 Sustainable technologies
2.5.3 Sustainable management practices
2.5.4 Sustainability assessment tools
2.6 IoT and Industry 4.0 in the foundry and metal casting
2.7 Summary
2.8 Disclosure
References
3 - Sustainable manufacturing: material forming and joining
3.1 Need for sustainable material forming
3.2 Extrusion and forging
3.3 Rolling and wire drawing
3.4 Sheet stamping
3.5 Flexible tooling
3.6 Green lubrication
3.7 Laser-based manufacturing
3.8 Need for sustainable joining processes
3.9 Sustainable fusion and solid-state welding processes
3.9.1 Fusion welding
3.9.2 Solid-state welding
3.10 Mechanical joining
3.11 Adhesive bonding
3.12 Hybrid joining
3.13 Inclusive manufacturing
3.14 Summary
References
4 - Sustainable manufacturing strategies in machining
4.1 Need for sustainable machining
4.2 Sustainable characteristics in machining
4.3 Sustainable machining techniques
4.3.1 Dry machining
4.3.2 Minimum quantity lubrication machining
4.3.3 Cryogenic machining
4.3.4 Surface texturing of tools
4.4 Role of sustainable machining techniques in conventional machining processes
4.4.1 Cryogenic cooling
4.4.1.1 Cryogenic turning operation
4.4.1.2 Cryogenic drilling operation
4.4.1.3 Cryogenic milling operation
4.4.1.4 Cryogenic grinding, boring, and broaching operations
4.4.2 MQL machining
4.4.2.1 MQL turning operation
4.4.2.2 MQL drilling operation
4.4.2.3 MQL milling operation
4.4.2.4 MQL grinding operation
4.4.3 Machining with surface textured tools
4.4.3.1 Texture tools in turning operation
4.4.3.2 Texture tools in drilling operation
4.4.3.3 Texture tools in milling and grinding operations
4.5 Sustainable nonconventional machining processes
4.6 Summary of recent developments, challenges, and future prospects
References
Further reading
5 - Materials development for sustainable manufacturing
5.1 Introduction
5.2 Need for development of materials
5.3 Classification of materials development
5.4 Microstructural modification of traditional materials
5.4.1 Severe plastic deformation
5.4.2 Equal channel angular extrusion
5.4.3 High-pressure torsion
5.4.4 Accumulative roll bonding
5.4.5 Special rolling techniques
5.4.6 Cryorolling
5.4.7 Asymmetric rolling
5.5 Optimization of material processing conditions
5.6 Material workability and microstructural control during deformation processes
5.7 Material processing maps
5.8 Role of activation energy
5.9 Role of stability
5.10 Increasing productivity of aluminum extrusion industry case study
5.11 Effects of prior processing history on workpiece behavior case study
5.12 Processing windows for different forms of Al-2024 materials case study
5.13 Stainless steel forging microstructure and property control case study
5.14 Summary
References
6 - Sustainable product development process
6.1 Innovation and product development
6.2 Product innovation strategy
6.3 Product life cycle
6.4 Product development process
6.5 Stage gate processes
6.6 NPD organization
6.7 Decision making process
6.8 Program release and launch
6.9 Proactive feedback mechanism and lessons learnt
6.10 Design processes, tools, and design for sustainability
6.11 Sustainability in remanufacturing
6.12 End of life design
6.13 Future outlook and direction
References
7 - A case study on sustainable manufacture of Ti–6Al–4V ultralightweight structurally porous metallic materials by ...
7.1 Introduction
7.1.1 Modeling of SPM by the finite element method
7.2 ANTARES interface
7.2.1 Material behavior modeling
7.2.2 Microstructure comparisons
7.2.3 Rolled specimens
7.3 Dynamic material model processing map
7.3.1 DMM processing map
7.4 Summary
Further reading
8 - Waste energy harvesting in sustainable manufacturing
8.1 Introduction
8.1.1 Energy harvesting technologies
8.1.2 Waste energy harvesting in sustainable manufacturing
8.2 Piezoelectric technology in sustainable manufacturing
8.2.1 Piezoelectric effects
8.2.2 Piezoelectric energy harvesting
8.2.3 Piezoelectric technology in sustainable manufacturing
8.3 Thermoelectric technology in sustainable manufacturing
8.3.1 Thermoelectric effects
8.3.2 Thermoelectric energy harvesting
8.3.3 Thermal energy harvesting in sustainable manufacturing
8.4 Other energy harvesting technologies in sustainable manufacturing
8.4.1 Pyroelectric technology in sustainable manufacturing
8.4.2 Electromagnetic energy harvesting
8.4.3 Electrostatic energy harvesting
8.4.4 Thermomagnetic energy harvesting
8.4.5 Triboelectric energy harvesting
8.4.6 Sensors and IIoT in sustainable manufacturing
8.5 Conclusion
References
9 - Sustainability performance evaluation in manufacturing: theoretical and practical perspectives
9.1 Literature and state of art
9.2 Methodology
9.3 Case study
9.3.1 Determination of the suitable linguistic scale for evaluating the performance rating and weights of the assessment model
9.3.2 Approximation of the expert's data of rating and weights
9.3.3 Evaluation of the performance rating for criteria and enabler
9.3.4 Determination of the overall grey performance index
9.3.5 Determination of GPII
9.3.6 Estimation of grey possibility degree and attribute ranking
9.4 Results
9.5 Summary and recommendations
References
10 - Additive manufacturing including laser-based manufacturing
10.1 Introduction and basic principles
10.1.1 What is additive manufacturing?
10.1.2 The generic AM process
10.1.3 Advantages and challenges of AM
10.1.4 AM technologies
10.2 Vat photopolymerization process (SLA)
10.3 Powder bed fusion process (PBF)
10.4 Extrusion-based process (FDM or FFF)
10.5 Jetting-based process (material jetting (MJ) and binder jetting (BJ))
10.6 Sheet lamination process (SL)
10.7 Directed energy deposition process (DED)
10.8 Hybrid manufacturing
10.9 Post-treatment processes
10.9.1 Support material removal
10.9.2 Surface finishing
10.9.3 Property enhancements
10.9.4 Machining
10.10 Sustainability issues in AM
10.10.1 Sustainability assessment of AM components
10.10.2 Energy demand and environment impact of AM
10.10.3 Recycling/reusing of AM components
10.10.4 Reusing metal powder leftovers
10.10.5 Recycling plastic waste
10.11 Summary and future outlook
References
11 - Computer integrated sustainable manufacturing
11.1 Introduction to computer integrated manufacturing
11.2 CAD/CAM/CAE in sustainable manufacturing
11.2.1 Computer-aided design
11.3 CAE in sustainable manufacturing
11.3.1 Introduction
11.3.2 Finite element method
11.3.2.1 Introduction to FEM
11.3.2.2 Case study
11.3.2.2.1 Tool and die design
11.3.2.2.2 Results and validation
11.3.2.2.3 Validations of results
11.3.2.2.4 Conclusions
11.3.3 Computational fluid dynamics
11.3.4 Multibody dynamics
11.3.5 Multiphysics and multidiscipline CAE analysis
11.3.6 Summary
References
Index
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M
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O
P
R
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V
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Z
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