Papers by Keyword: Green Manufacturing

Abstract: Friction Stir Processing (FSP) is an advanced solid-state surface modification technique used to enhance the microstructural and mechanical behavior of metallic materials, particularly aluminum alloys. Recently, High-Entropy Alloys (HEAs) have emerged as promising reinforcement materials due to their high strength, thermal stability, and corrosion resistance. Although multiple studies have explored FSP with conventional reinforcements, the integration of HEAs into the stir zone remains limited. This study examines the influence of tool geometry, processing parameters, and reinforcement strategies in FSP while evaluating the feasibility of incorporating HEAs into aluminum matrices. The role of finite element analysis (FEA) in predicting temperature distribution, material flow, and stress evolution is also discussed. The study identifies research gaps and emphasizes the need for experimental validation of HEA-reinforced FSP systems to develop high-performance aluminum-based surface composites.

Abstract: Recently, there is a significant increase in the number of people pursuing healthy living and expecting firms to adopt green manufacturing practices leading to improvement in the standard of living. The rapid deterioration of the environment has harmfully affected the socio-economic growth and development across the nations of the world. The severity of this effect is more pronounced among developing nations. The concern for a sustainable environment is thriving as one of the priorities for strategic firms, organization management, manufacturers, and product designers. The study present a critical review of the existing works of literature on green manufacturing,its evolution,definition and concept. The economic, environmental, social impacts from a global perspectives were discussed. The various challenges militating against its implementation and its possible drivers were examined. However, there are numerous opportunities and future research in the area of green manufacturing that are yet to be explored. Keywords: Green Manufacturing; Sustainable; Impact; Opportunities; Performance: Implementation

Abstract: With The emerging environmental concern of the public, as well as the implementation of governmental regulations, enabling the control of the environmental impact of production activities, companies are developing strategies to achieve more sustainable operations. In fact, over the last years, there has been growing pressure on organizations to manage their operations in a responsible manner to improve their environmental performance. Which has motivated companies to implement sustainable operations. In this context, Green Manufacturing can make a positive contribution to the environmental performance of organizations. Thus, the main objective of this paper is to identify Green Manufacturing and its impact on sustainable performance with some examples of companies that have integrated these sustainable practices in their process, and analyze their impact with a focus on the Moroccan industry. The survey includes 50 different automotive companies shows how they are carrying out green manufacturing and environmental practices.

Abstract: Increasing demands for reducing greenhouse gases drive the metal processing industries to a CO₂-neutral production. A thorough understanding of CO₂ emission sources from the stage of material acquisition up to the final component is thus necessary to improve the CO₂ footprint of sheet metal hot forming process chains. To emphasize on this, an exemplary hot forming process chain is assessed to identify the impact of each sub-process step on total CO₂ emissions and the savings potential of individual measures is evaluated. Moreover, a mathematical model is proposed that enables for the prediction of the product specific CO₂ emissions as early as in the product design stage. This model is tested to calculate the CO₂ emissions resulted during the production of an exemplary hot stamped sheet component. The results point out that the heating stage is responsible for the second highest percentage of CO₂ emissions in the process chain next to the material acquisition. Thus, as one of the most suitable measures, a concept to recover process heat from hot formed components to the cold initial blanks is proposed and evaluated analytically.

Abstract: Green manufacturing concept has become a cutting edge in the field of sustainable machining. The prime objective of the philosophy is to find a technique in machining or material removal processes that are environmentally friendly, with minimal wastage, energy efficient and optimal condition for the machining processes. This review paper discusses the significance of textured novel cutting tools, is one of the promising technologies and process. It discusses the Dry Machining process to capture green sustainable manufacturing practices. The study may answer of how it stands among other methods including minimum quantity lubrication and nano fluid lubricant. This paper also presents the importance of advanced manufacturing tools to match the sustainable future needs with an idea of proposed methodology to conduct a research on textured novel cutting tools for sustainable machining.

Abstract: To be economical, enterprises confronting present intense and phenomenal worldwide business situations must plan and provide the best products and services and move forward their manufacturing maneuvers by typically utilizing Lean manufacturing practice. It is involved with converting materials into valued products by utilizing raw material to enhance productively and to maximize the benefit of an organization and minimize the waste. Green manufacturing is a strategy that reduces waste and contamination by the nonstop approach. This study points to examine the lean and green manufacturing concept and its integration in operation management. Operations management is a collective endeavor to adjust costs incurred with income to realize the most elevated networking benefit conceivable [1]. In this way, procedures of lean logic can play an incredible role. The present paper is a case study approach in the qualitative analysis of selected SMEs.

Abstract: The equipment and technology characteristics of endless strip production line in Rizhao steel were analyzed and the achievements of endless strip production in Rizhao steel were illustrated with detailed productive data in 2017. The achievements of endless continuous casting process was introduced from the aspects of the mold level deviation, the casting speed and the tundish temperature. The achievements of endless continuous rolling process was described from the rolling length, the mechanical properties and the microstructure at different position along the width. The achievements of endless continuous casting and rolling process was discussed from the product qualification rate, the yield rate, the thin strip ratio, the accident rate and the energy consumption. The productive practice of endless strip production (ESP) shows that the longest number of continuous casting furnace reached to 15 heats (4500 tons), the longest rolling length in single casting period was 182 km, the qualified rate of products was up to 99.73%, the yield rate was up to 97.51% and the thin strip ratio had a maximum value of 40.57%. At the same time, its accident rate was below 2.02% and its energy consumption was less than 27.26 kgce·ton^-1. These achievements indicated that the ESP line in Rizhao steel had the advantages of low cost, good performance and green manufacturing, so the endless rolling technology will be rapidly promoted and the hot rolled thin products by ESP will further expand the market.

Abstract: Cutting fluid is commonly used during metal cutting process for cooling and lubrication. Fluid types are generally classified into mineral or fatty oils and water miscible oils. In Japan, the former is called water-insoluble coolants, and the latter is called water-soluble coolants. Water-insoluble coolants are specified as dangerous material by the Japanese law due to its flammability. Therefore, the water-insoluble coolants are not appropriate for unmanned operation of machine tools. Therefore, the usage rate of water-soluble coolants is increasing. Water soluble coolants are diluted with a water by several ten times. The waste management of the water-soluble coolant become important for environment-conscious green manufacturing. We have been developing a recycling system for water-soluble coolants. In the recycle system, water is extracted from the waste coolant and the water is then reutilized as a diluent of a new coolant. We have developed various types of chemical or bio-chemical water recovery methods for recycling systems. We found a commercially available amine-free water-soluble coolant is suitable for the recycling system. The processing time, processing cost, and the biochemical and chemical oxygen demand of the extracted water are improved by the amine-free water soluble coolant compared with a conventional amine-containing coolant. However, its corrosion inhibition performance was poor in general machining applications. Our cooperative company developed a prototype of a corrosion-inhibition-improved amine-free water-soluble cutting coolant. The prototype coolant showed a good stability and cooling and lubricating performances, and its recyclability was as good as that of conventional amine-free coolants. In this study, we focused on repeated recycling of the prototype coolant. We repeatedly applied the water recycling process to the recycled coolant. The recyclability of the prototype coolant was not affected by repeated recycling; however, process residues increased with the number of recycles, and a deterioration was noticed in the corrosion-inhibition performance of the coolant diluted with recycled water.

Abstract: Since entering 90’s, environmental strategy experienced a new turning point. The adjustment of worldwide industrial structure showing a new trend of green strategy, which is the trend of rational resource utilization, a small amount of waste production, none environmental pollution, and less pollution. Under the impact of green wave, the green manufacturing of industrial design gradually rise, becoming the target of the future development of industrial design. Putting the idea of sustainable development into the industrial design process. So that resources and energy can be used efficiently, and make the pollution to the minimum.

Abstract: The concern for environmental problems has been increasing rapidly in recent years. Water-soluble coolants are widely used in machining processes. To reduce management costs and the environmental load of water-soluble coolants, the authors studied a recycling system for water-soluble coolants. With this recycling system, water is extracted from a waste coolant by chemical or biochemical treatment; the recovered water is re-utilized as a diluent for a new coolant. Coolant recyclability depends on the coolant type. Most water-soluble coolants contain alkanolamines for corrosion inhibition and maintenance of putrefaction prevention. However, alkanolamines are difficult to eliminate from water-soluble coolants by chemical and physical waste treatment processes. Some amine-free, water-soluble coolants have been developed and are commercially available. The reduction of environmental load in the treatment of waste coolants is anticipated for amine-free coolants. We applied the recycling process to a commercially available amine-free, water-soluble coolant. The amine-free coolant showed good recyclability and lubricating performance. However, the corrosion inhibition performance of the coolant was inadequate for use in general machining. Recently, our cooperative company developed a prototype amine-free, water-soluble coolant with improved corrosion inhibition. In this study, we experimentally examined the recyclability and performance stability of this newly developed coolant. The experimental results showed that the new amine-free coolant has good corrosion inhibition equivalent to conventional amine-containing coolants. In addition, the recyclability, stability, and cooling and lubricating performance of the coolant are equal to conventional amine-free coolants. The amine-free, water-soluble coolant with improved corrosion inhibition has the advantage that it can be used in the recycling system for water-soluble coolants.