Abstract: Earing defect in drawing process is highly undesirable not only because it adds on an additional trimming operation but also because the uneven material flow demands extra care. The objective of this work is to study the earing problem in the Deep Drawing of circular cup and to optimize the blank shape to reduce the earing. A finite element model is developed for 3-D numerical simulation of cup forming process in ABAQUS. Extra-deep-drawing (EDD) steel sheet has been used for simulation. Properties and tool design parameters were used as input for simulation. Earing was observed in the simulated cup and it was measured at various angles with respect to rolling direction. To reduce the earing defect initial blank shape was modified with the help of anisotropy coefficient. Modified blanks showed notable reduction in earing.
Abstract: Due to increasing environmental awareness jute fibers are more often used in fiber reinforced composites. In the Sheet Molding Compound (SMC) process, the mold cavity is filled via material flow allowing more complex component design. But, the difficulty of using jute fibers in this process is the decreased capacity of fiber movement in the mold. A comparative flow study with jute nonwoven reinforced SMC was conducted examining the influence of the fiber volume content, the grammage of the jute nonwoven textile and a mechanical modification of the nonwoven textile on the flowability. The nonwoven textile reinforcement was selected to support homogeneous fiber distribution. Trials were performed using two SMC paste formulations differing only in filler type. Platy-shaped kaolin with a mean particle size of 0.8 μm and ashlar calcium carbonate with a mean particle size of 2.7 μm were selected as fillers. Ensuring comparability of the two SMC paste formulations the filler content was determined to reach equal initial viscosity for both systems. The calcium carbonate filled paste was set as reference. The flow study was conducted using a jute nonwoven textile with 300 g/m² as reference. The manufactured SMC sheets were stacked and centrally placed in a square mold. The mold coverage was varied between 25 and 90% keeping the weight of the stack for comparison constant. Comparing the influence of the two fillers kaolin yielded better results regarding a homogeneous fiber distribution. A mold coverage of about 68% was already sufficient to homogeneously fill the mold cavity whereas for calcium carbonate filled system about 79% mold coverage was necessary. The flow study revealed a strong influence of the fiber volume content on the flowability. A fiber volume content of 12 vol.-% and 25 vol.-% were compared for both SMC formulations. The lower fiber volume content strongly supported fiber transport whereas 25 vol.-% showed insignificant influence. The results indicate a limiting fiber volume content for the flowability. The influence of the nonwoven textile grammage was determined using nonwoven jute material with 500 g/m² and a fiber volume content of 20 vol.-%. The 500 g/m² reinforcement material showed inferior results with regard to fiber movement. A mold coverage of about 90 % was required to prevent the destruction of the nonwoven structure. Below this mold coverage the 500 g/m² nonwoven material was ripped and torn apart. Low mold coverages led to damage of the textile reinforcement. Due to the ripped nonwoven structure the textile was modified with cuts in order to facilitate fiber movement in the mold. Parallel cuts of about 20 mm length and 20 mm distance to each other were applied to the textile and stacked with varying orientations prior to molding. Stacks with unidirectional orientated cuts over stacks with cuts in various directions e.g. (0°, 45°, 90°, -45°) were investigated. The mechanical modification supported tearing of the textile without achieving benefit for the flowability.
Abstract: This work investigates upsetting of the tri-metallic cylindrical billets both experimentally and analytically with a reduction ratio 30%. Steel, brass, and copper are used for the outer and outmost rings and aluminum for the inner core. Two different models have been designed to show material flow and the cavity took place over the two interfaces during forming after this reduction ratio. Each model has an outmost ring material as steel. Model 1 has an outer ring between the outmost ring and the solid core material as copper and Model 2 has a material as brass. Solid core is aluminum for each model. Billets were upset in press machine by using parallel flat dies. Upsetting load was recorded and compared for models and single billets. To extend the tests and compare with experimental procedure to a wider range of inner core and outer ring geometries, finite element model was performed. ABAQUS software was used for the simulations. The aim is to show how contact between outmost ring, outer ring and the inner core are carried on throughout the upsetting process. Results have shown that, with changing in height, between outmost ring, outer ring and inner core, the Model 1 and Model 2 had very good interaction, and the contact surfaces of models had various interface behaviour. It is also observed that tri-metallic materials have lower weight but better mechanical properties than single materials. This can give an idea for using and producing these new materials for different purposes.
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.
Abstract: Decision making for sustainable manufacturing design and management requires critical considerations due to the complexity and partly conflicting issues of economic, social and environmental factors. Although there are tools capable of assessing the combination of one or two of the sustainability factors, the frameworks have not adequately integrated all the three factors. Case study and review of existing simulation applications also shows the approach lacks integration of the sustainability factors. In this paper we discussed the development of a simulation based framework for support of a holistic assessment of sustainable manufacturing design and management. To achieve this, a strategic approach is introduced to investigate the strengths and weaknesses of the existing decision supporting tools. Investigation reveals that Discrete Event Simulation (DES) can serve as a rock base for other Life Cycle Analysis frameworks. Simio-DES application optimizes systems for both economic and competitive advantage, Granta CES EduPack and SimaPro collate data for Material Flow Analysis and environmental Life Cycle Assessment, while social and stakeholders’ analysis is supported by Analytical Hierarchy Process, a Multi-Criteria Decision Analysis method. Such a common and integrated framework creates a platform for companies to build a computer simulation model of a real system and assess the impact of alternative solutions before implementing a chosen solution.
Abstract: Nowadays, manufactures are encountered with production of different version of products due to quality, cost and time constraints. On the other hand, Additive Manufacturing (AM) as a production method based on CAD model disrupts the design and manufacturing cycle with new parameters. To consider these issues, the researchers utilized Design For Manufacturing (DFM) approach for AM but until now there is no integrated approach for design and manufacturing of product through the AM. So, this paper aims to provide a general methodology for managing the different production issues, as well as, support the interoperability with AM process and different Product Life Cycle Management tools. The problem is that the models of System Engineering which is used for managing complex systems cannot support the product evolution and its impact on the product life cycle. Therefore, it seems necessary to provide a general methodology for managing the product’s diversities which is created by using AM. This methodology must consider manufacture and assembly during product design as early as possible in the design stage. The latest approach of DFM, as a methodology to analyze the system comprehensively, integrates manufacturing constraints in the numerical model in upstream. So, DFM for AM is used to import the characteristics of AM into the design and manufacturing process of a hybrid product to manage the criteria coming from AM. Also, the research presents an integrated design method in order to take into account the knowledge of layers manufacturing technologies. For this purpose, the interface model based on the skin and skeleton concepts is provided, the usage and manufacturing skins are used to show the functional surface of the product. Also, the material flow and link between the skins are demonstrated by usage and manufacturing skeletons. Therefore, this integrated approach is a helpful methodology for designer and manufacturer in different decisions like material and process selection as well as, evaluation of product manufacturability.
Abstract: Revenue leakages are one of the major challenges
manufacturers face in production processes, as most of the input
materials that should emanate as products from the lines are lost as
waste. Rather than generating income from material input which is
meant to end-up as products, losses are further incurred as costs in
order to manage waste generated. In addition, due to the lack of a
clear view of the flow of resources on the lines from input to output
stage, acquiring information on the true cost of waste generated have
become a challenge. This has therefore given birth to the
conceptualization and implementation of waste minimization
strategies by several manufacturing industries. This paper reviews the
principles and applications of three environmental management
accounting tools namely Activity-based Costing (ABC), Life-Cycle
Assessment (LCA) and Material Flow Cost Accounting (MFCA) in
the manufacturing industry and their effectiveness in curbing revenue
leakages. The paper unveils the strengths and limitations of each of
the tools; beaming a searchlight on the tool that could allow for
optimal resource utilization, transparency in production process as
well as improved cost efficiency. Findings from this review reveal
that MFCA may offer superior advantages with regards to the
provision of more detailed information (both in physical and
monetary terms) on the flow of material inputs throughout the
production process compared to the other environmental accounting
tools. This paper therefore makes a case for the adoption of MFCA as
a viable technique for the identification and reduction of waste in
production processes, and also for effective decision making by
production managers, financial advisors and other relevant
stakeholders.
Abstract: To understand the friction stir welding process, it is
very important to know the nature of the material flow in and around
the tool. The process is a combination of both thermal as well as
mechanical work i.e. it is a coupled thermo-mechanical process.
Numerical simulations are very much essential in order to obtain a
complete knowledge of the process as well as the physics underlying
it. In the present work a model based approach is adopted in order to
study material flow. A thermo-mechanical based CFD model is
developed using a Finite Element package, Comsol Multiphysics.
The fluid flow analysis is done. The model simultaneously predicts
shear strain fields, shear strain rates and shear stress over the entire
workpiece for the given conditions. The flow fields generated by the
streamline plot give an idea of the material flow. The variation of
dynamic viscosity, velocity field and shear strain fields with various
welding parameters is studied. Finally the result obtained from the
above mentioned conditions is discussed elaborately and concluded.
Abstract: Ultra-light overhead conveyor systems are rope-based conveying systems with individually driven vehicles. The vehicles can move automatically on the rope and this can be realized by energy and signals. The ultra-light overhead conveyor systems always must be integrated with a logistical process by finding a best way for a cheaper material flow in order to guarantee precise and fast workflows. This paper analyzes the process of an ultra-light overhead conveyor system using necessary assumptions. The analysis consists of three scenarios. These scenarios are based on raising the vehicle speeds with equal increments at each case. The correlation between the vehicle speed and system throughput is investigated. A discrete-event simulation model of an ultra-light overhead conveyor system is constructed using DOSIMIS-3 software to implement three scenarios. According to simulation results; the optimal scenario, hence the optimal vehicle speed, is found out among three scenarios. This simulation model demonstrates the effect of increased speed on the system throughput.
Abstract: In the highly competitive and rapidly changing global
marketplace, independent organizations and enterprises often come
together and form a temporary alignment of virtual enterprise in a
supply chain to better provide products or service. As firms adopt the
systems approach implicit in supply chain management, they must
manage the quality from both internal process control and external
control of supplier quality and customer requirements. How to
incorporate quality management of upstream and downstream supply
chain partners into their own quality management system has recently
received a great deal of attention from both academic and practice.
This paper investigate the collaborative feature and the entities-
relationship in a supply chain, and presents an ontology of
collaborative supply chain from an approach of aligning
service-oriented framework with service-dominant logic. This
perspective facilitates the segregation of material flow management
from manufacturing capability management, which provides a
foundation for the coordination and integration of the business process
to measure, analyze, and continually improve the quality of products,
services, and process. Further, this approach characterizes the different
interests of supply chain partners, providing an innovative approach to
analyze the collaborative features of supply chain. Furthermore, this
ontology is the foundation to develop quality management system
which internalizes the quality management in upstream and
downstream supply chain partners and manages the quality in supply
chain systematically.
Abstract: Overhead conveyor systems are in use in many installations around the world, meeting the widest range of applications possible. Overhead conveyor systems are particularly preferred in automotive industry but also at post offices. Overhead conveyor systems must always be integrated with a logistical process by finding the best way for a cheaper material flow in order to guarantee precise and fast workflows. With their help, any transport can take place without wasting ground and space, without excessive company capacity, lost or damaged products, erroneous delivery, endless travels and without wasting time. Ultra-light overhead conveyor systems are rope-based conveying systems with individually driven vehicles. The vehicles can move automatically on the rope and this can be realized by energy and signals. Crossings are realized by switches. Ultra-light overhead conveyor systems provide optimal material flow, which produces profit and saves time. This article introduces two new ultra-light overhead conveyor designs in logistics and explains their components. According to the explanation of the components, scenarios are created by means of their technical characteristics. The scenarios are visualized with the help of CAD software. After that, assumptions are made for application area. According to these assumptions scenarios are visualized. These scenarios help logistics companies achieve lower development costs as well as quicker market maturity.
Abstract: This paper reports a new application of material accounting techniques to characterise and quantify material stocks and flows at the “neighbourhood" scale. The study area is the main campus of the University of New South Wales in Sydney, Australia. The system boundary is defined by the urban structural unit (USU), a typological construct devised to facilitate assessment of the metabolism of urban systems. A streamlined material flow analysis (MFA) was applied to quantify the stocks and flows of key construction materials within the campus USU over time, drawing on empirical data from a major campus development project. The results are reviewed to assess the efficacy of the method in supporting urban environmental evaluation and design practice, for example to facilitate estimation of significant impacts such as greenhouse gas emissions. It is concluded that linking a service (in this case, teaching students) enabled by a given product (university buildings) to the amount of materials used in creating that product offers a potential way to reduce the environmental impact of that service, through more efficient use of materials.
Abstract: Flexible manufacturing system is a system that is able to respond to changed conditions. In general, this flexibility is divided into two key categories and several subcategories. The first category is the so called machine flexibility which enables to make various products by the given machinery. The second category is routing flexibility enabling to execute the same operation by various machines. Flexible manufacturing systems usually consist of three main parts: CNC machine tools, transport system and control system. A higher level of flexible manufacturing systems is represented by the so called intelligent manufacturing systems.
Abstract: The eco-efficient use of “waste" makes sense from
economic, social, and environmental perspectives. By efficiency diverting “waste" products back into useful and/or profitable inputs,
industries and entire societies can reap the benefits of improved financial profit, decreased environmental degradation, and overall
well-being of humanity.
In this project, several material flows at
Company Limited were investigated. Principles of "industrial ecology" were applied to improve the management of waste rubbers that are used in the jewelry manufacturing process. complete this project, a brief engineering analysis stream, and investigated eco-efficient principles for more efficient
handling of the materials and wastes were conducted, and the result were used to propose implementation strategies.
Abstract: Injection forging is a Nett-shape manufacturing
process in which one or two punches move axially causing a radial
flow into a die cavity in a form which is prescribed by the exitgeometry,
such as pulley, flanges, gears and splines on a shaft. This
paper presents an experimental and numerical study of the injection
forging of splines in terms of load requirement and material flow.
Three dimensional finite element analyses are used to investigate the
effect of some important parameters in this process. The experiment
has been carried out using solid commercial lead billets with two
different billet diameters and four different dies.
Abstract: In modern telecommunications industry, demand &
supply chain management (DSCM) needs reliable design and
versatile tools to control the material flow. The objective for efficient
DSCM is reducing inventory, lead times and related costs in order to
assure reliable and on-time deliveries from manufacturing units
towards customers. In this paper the multi-rate expert system based
methodology for developing simulation tools that would enable
optimal DSCM for multi region, high volume and high complexity
manufacturing environment was proposed.
Abstract: The recycling of concrete, bricks and masonry rubble
as concrete aggregates is an important way to contribute to a
sustainable material flow. However, there are still various
uncertainties limiting the widespread use of Recycled Concrete
Aggregates (RCA). The fluctuations in the composition of grade
recycled aggregates and their influence on the properties of fresh and
hardened concrete are of particular concern regarding the use of
RCA. Most of problems occurring while using recycled concrete
aggregates as aggregates are due to higher porosity and hence higher
water absorption, lower mechanical strengths, residual impurities on
the surface of the RCA forming weaker bond between cement paste
and aggregate. So, the reuse of RCA is still limited. Efficient
polymer based treatment is proposed in order to reuse RCA easier.
The silicon-based polymer treatments of RCA were carried out and
were compared. This kind of treatment can improve the properties of
RCA such as the rate of water absorption on treated RCA is
significantly reduced.
Abstract: Current trends in manufacturing are characterized by
production broadening, innovation cycle shortening, and the products
having a new shape, material and functions. The production strategy
focused on time needed change from the traditional functional
production structure to flexible manufacturing cells and lines.
Production by automated manufacturing system (AMS) is one of the
most important manufacturing philosophies in the last years. The
main goals of the project we are involved in lies on building a
laboratory in which will be located a flexible manufacturing system
consisting of at least two production machines with NC control
(milling machines, lathe). These machines will be linked to a
transport system and they will be served by industrial robots. Within
this flexible manufacturing system a station for the quality control
consisting of a camera system and rack warehouse will be also
located. The design, analysis and improvement of this manufacturing
system, specially with a special focus on the communication among
devices constitute the main aims of this paper. The key determining
factors for the manufacturing system design are: the product, the
production volume, the used machines, the disposable manpower, the
disposable infrastructure and the legislative frame for the specific
cases.
Abstract: This paper offers a case study, in which
methodological aspects of cell design for transformation the
production process are applied. The cell redesign in this work is
tightly focused to reach optimization of material flows under real
manufacturing conditions. Accordingly, more individual techniques
were aggregated into compact methodical procedure with aim to built
one-piece flow production. Case study was concentrated on relatively
typical situation of transformation from batch production to cellular
manufacturing.
Abstract: In this study, the precision heading process of
spur gears has been investigated by means of numerical
analysis. The effect of some parameters such as teeth number
and module on the forming force and material flow were
presented. The simulation works were performed rigid-plastic
finite element method using DEFORM 3D software. In order
to validate the estimated numerical results, they were
compared with those obtained experimentally during heading
of spur gear using lead as a model material. Results showed
that the optimum number of gear teeth is between 10 to 20,
that is because of being the specific pressure in its minimum
value.