Sustainable Manufacturing Processes

Sustainable Manufacturing Processes provides best practice advice on sustainable manufacturing methods, with examples from industry as well as important supporting theory. In the current manufacturing industry, processes and materials are developed with close reference to sustainability issues, and with an outward look to optimum production efficiency and reduced environmental impact. Important topics like the use of renewable energy, reducing material waste and recycling, reduction in energy and water consumption, and reduction in emissions are all discussed, along with broad coverage of deformation and joining technologies, computational techniques and digital engineering. In addition, a wide range of traditional and innovative manufacturing technologies are covered, including friction stir welding, micro forming, additive manufacturing, extrusion, and hot forming. 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 A B C D E F G H I J K L M N O P R S T U V W Z Back Cover Sustainable Manufacturing Processes provides best practice advice on sustainable manufacturing methods, with examples from industry as well as important supporting theory. In the current manufacturing industry, processes and materials are developed with close reference to sustainability issues, with an outward look to optimum production efficiency and reduced environmental impact. Important topics such as the use of renewable energy, reduction of material waste and recycling, reduction in energy and water consumption, and reduction in emissions are all discussed, along with broad coverage of deformation and joining technologies, computational techniques, and computer-aided engineering. In addition, a wide range of traditional and innovative manufacturing technologies are covered, including friction stir welding, incremental forming, abrasive water jet machining, laser beam machining, sustainable foundry, porous material fabrication by powder metallurgy, laser and additive manufacturing, and thermoelectric and thermomagnetic energy harvesting. Features practical case studies from industry experts Explains methods for reducing waste in additive manufacturing Provides a detailed examination on how sustainability is measured in manufacturing "Sustainable Manufacturing Processes provides best practice advice on sustainable manufacturing methods, with examples from industry as well as important supporting theory. In the current manufacturing industry, processes and materials are developed with close reference to sustainability issues, with an outward look to optimum production efficiency and reduced environmental impact. Important topics such as the use of renewable energy, reduction of material waste and recycling, reduction in energy and water consumption, and reduction in emissions are all discussed, along with broad coverage of deformation and joining technologies, computational techniques, and computer-aided engineering. In addition, a wide range of traditional and innovative manufacturing technologies are covered, including friction stir welding, incremental forming, abrasive water jet machining, laser beam machining, sustainable foundry, porous material fabrication by powder metallurgy, laser and additive manufacturing, and thermoelectric and thermomagnetic energy harvesting."-- Page 4 of cover