Key Engineering Materials Vol. 502

Abstract: Energy sources, in the form of coal, oil, natural gas, solar or nuclear power, are global commodities, and as demand is projected to rise in the coming decades, so will costs. As such, an understanding of the energy needs of manufacturing processes and the ability to reduce the energy and carbon footprints are essential for sustainability reasons. This paper examines the global sources of energy, since the source used has a large effect on the cost and environmental impact of energy. Energy source effects are quantified in a number of measures. The theoretical approaches used to obtain a carbon footprint are explained and their shortcomining identified. Models of energy needs by manufacturing process are then examined, along with models incorporating the use of ancillary equipment such as pumps, filters, blowers, lighting, etc. Finally, the successful application of tribological principles to influence energy consumption is discussed.

Abstract: Productivity is an important factor in any industrial production. Based on several concepts and philosophies such as Kaizen and others, it is possible to realize an increase of productivity. Since it is of great interest to know and to evaluate the improvement, a suitable method that allows not only analyzing the improvement of cost but also of time is of interest. Based on the value stream map (VSM) and the profile of cost and time (PCT) the author has developed the PECOTA method, a graphical method of analysis. The concept of investment in time and cost by PECOTA allows first-time analysis and evaluation of a change in a manufacturing process in an easy and fast way. The method includes also the possibility to define the limit of lean manufacturing with the current processes.

Abstract: A research paper should generate new questions and is cyclical in nature, where answers to research questions of today will be the base for the research questions of tomorrow [. To facilitate this work, we propose a holistic approach to information search, in addition to an overview and orderly search process to determine the state of the art, it helps the investigator under any circumstances, to find new lines of work or tendencies in any subject under analysis.

Abstract: This paper presents a design system that enables the composition of parts using manufacturing features. Features are selected from feature libraries. Upon insertion, the system ensures that the feature does not contradict the design-for-manufacture rules. This helps eliminating costly manufacturing problems. The system is developed as an extension to a commercial CAD/CAM system Pro/Engineer.

Abstract: Currently, when the most suitable material manufacturing process is chosen, not only technical or economical aspects have to be considered, otherwise, it has to emphasize its sustainability. In this document, an easy method to compare mass reduction processes and mass conservation processes, with an application to compare drawing process and machining process, is shown. The comparative comparison makes possible to justify that plastic deformation processes usually have more advantages.

Abstract: In this paper, it is proposed an integrated management model applied to R&D&I and manufacturing processes for an organization. The model intends to integrate the environmental, risk prevention and ethical aspects as well as research, development and innovation projects management in the general quality management structure proposed by ISO 9001:2008. Specifically, it tries to fulfill the standards ISO 9001, ISO 14001, OSHAS 18001, SGE 21 and UNE 166002. The global structure is based on the continuous improvement Plan-Do-Check-Act cycle. The main advantages of this integrated management system are detailed, specifically the optimization of the documentation which results in the reduction of costs of implementation and maintenance.

Abstract: Reverse engineering (RE) tries to model and manufacture an object from measurements one of a reference object. Modern optical measurement systems and computer aided engineering software have improved reverse engineering procedures. We detail the main RE steps from 3D digitalization by Digital Image Correlation to manufacturing. The previous description is complemented with an application example, which portrays the performance of RE. The differences between original and manufactured objects are less than 2 mm (close to the tool radius).

Abstract: The development of new forming processes primarily aims for increasing the process robustness and shortening the process chain. With the development of the novel Sheet-Bulk Metal Forming, cause-effect relationships are to be parameterized optimally and the economic efficiency of the manufacturing process is to be improved. The extensive and comprehensive development tasks often lead to an intransparent development status. Hence, operational and strategic decisions - particularly in the early development stages - are often made on the basis of subjective criteria and a high information uncertainty. This often results in wrong decisions as well as subsequent cost-intensive modifications in the design of expensive forming tools and forming machines. Based on a designed maturity method relevant indicators for the early maturity assessment and thus cost-reduced improvement of the development status of new forming processes are defined in this paper. The maturity here reflects the phase dependent development status. By providing a uniform basis of maturity indicators a comparable evaluation of the development status becomes enabled. The validity of the maturity assessment is enhanced by considering the information uncertainty by use of Fuzzy Logic. An exemplary maturity determination is performed within the development of the Sheet-Bulk Metal Forming.

Abstract: The work presented in this paper consists of the development of a decision making support system, based on a real problem, with the purpose of optimizing the operation of an automobile assembly line with a four closedloop network configuration. This layout system reflects one of the most common configurations of automobile assembly and preassembly lines formed by conveyors. The impact of the speed variation of the intermediate buffers formed by conveyors on the first three closed-loops and of the proportion of four-door car bodies on the number of cars produced / hour has been thoroughly investigated.

Abstract: SEBS (styrene-ethylene/butylene-styrene) is a hydrogenated SBS used as a compatibilizer of other thermoplastic or as a blend to improve the properties (mainly impact). There is very little information about SEBSs research, independent of other materials. This study focuses on a blend from the providers SEBS extreme hardness (50% Shore-A 5 and 50% Shore-A 90) in order to analyze the miscibility of mixed materials from the storage of 2 references only. It has been used the thermoplastic elastomer Megol TA® SEBS, whose characteristics make it special due to the wide range of hardness and transparency, and can be obtained blend for industrial applications where nowadays liquid silicone rubber is used. Next step is rheological characterization of the blend, analyzing the viscosity for subsequent mathematical modeling. Finally, in order to reproduce the rheological behavior of materials during the injection process, Autodesk Moldflow Inside 2010 CAE (Computer Aided Engineering) tool has been used with Cross-WLF model parameters, and compared with tests injected.