Papers by Keyword: Process Design

Abstract: “Gbogbonise” Polyherb (GP) is one of the traditional medicines used in Nigeria to cure various ailments as professed by Nigerian folks. However, no scientific work, including laboratory-proof-of-concept experiment, has been documented in the literature regarding total phenolic content of extract recovery from GP. Therefore, this study reports High-Performance-Liquid-Chromatography (HPLC) finger-profiling, process modelling, scale-up process simulation and manufacturing cost of phenolic extract production from GP. The poly-herbal extraction experiment and analyses were performed using Response Surface Methodology (RSM) at extraction time (2.79-4.21hours), extraction temperature (33.79-76.21°C), and solid-liquid ratio (0.007929- 0.018355 g/ml) with yield, Total Phenolic Content (TPC), Total Flavonoid Content (TFC) and Antioxidant Activity (AA) as dependent variables. RSM models compared with the developed Adaptive Neuro-Fuzzy Inference System (ANFIS) models in Matlab software. ASPEN software was used for process simulation and cost of manufacturing. RSM and ANFIS models for predicting the extraction responses showed coefficients of determination (R²) of 0.99152 (RSM) and 0.999 (ANFIS) for yield, 0.981766 (RSM) and 0.9999 (ANFIS) for TFC, 0.986031 (RSM) and 0.999 (ANFIS) for AA, 0.842463 (RSM) and 0.999 (ANFIS) for TPC. HPLC results showed presence of betulinic acid (0.028 µg/g.dw), gallic acid (0.034 µg/g.dw), caffeic acid (0.051 µg/g.dw), erulic (0.0826 µg/g.dw) and ellagic acid (0.064 µg/g.dw) in the extract. The scale-up simulation results gave batch size (3.99 kg/batch) and number of batches (1,751 batches) for the annual production target (7,000 kg); while 339.1 USD/kg was obtained as product cost of manufacturing. The technical-economic-parameters obtained from this study are precursors to poly-herbal extraction plant design construction.

Abstract: Progressive and transfer dies are used for forming of sheet metal parts in large quantities. For a given part, the design of progressive die sequence involves the selection of the number of forming stages as well as the determination of the punch and die dimensions at each stage. This design activity is largely experience-based and requires prototyping involving several trial and error operations. In some cases, empirical data and the experience based design procedure can be combined with Finite Element Method (FEM) based analysis to reduce time and cost. Often, when using FEM in progressive die design, friction and its effect upon temperatures is not adequately considered. However, at each forming station the plastic deformation and the tribological conditions influence the material flow as well as the temperatures and pressures at the tool/workpiece interface. The performance of the lubricant and coolant, used in progressive die forming, is affected significantly by interface pressure and temperatures. Therefore, a progressive process and die design methodology should include the consideration of metal flow as well as temperatures and pressures. Heat transfer coefficient, friction, plastic deformation, forming speed at each forming stage, time for part transfer from one stage to the next, and the ability of the used lubricant to cool the dies, have considerable effect upon a successful stamping. This paper describes a method for designing a progressive die sequence for forming axisymmetric sheet metal parts. The methodology for process sequence design combines experience based empirical data obtained through previous designs, design rules and numerical simulations including plastic deformation and friction. The initial experience-based design was refined using FEM and the thinning of the material in each successive drawing stage was calculated. The thermo-mechanical model was obtained using a constant friction coefficient along the tool/workpiece contact zone. Finally, the tool/workpiece interface temperature and the normal pressures were estimated in order that the lubricant can be selected based on these process conditions. The design predictions, made by using empirical data and FEM, were compared with experimental data.

Abstract: In this paper, the authors discuss process planning for the lateral extrusion of a pipe with a lost core. In this process, maximum longitudinal length of the bulged part is restricted by the balance of the extrusion speed of the material and the lost core. In the free bulging condition, longitudinal length is limited to the pipe radius, because the extrusion speed of the core is slower than that of the pipe material when the longitudinal length of the bulged part is longer. The authors designed a two-stage forming process using the transit shape of a truncated cone to solve this problem. The dimensions of the truncated cone were estimated through trial-and-error using a commercial FEM simulator and considering the stretch effect for wrinkles of the pipe by deformation and traveling of the lost core. Finally, the authors conducted experiments to confirm the design’s validity. As a result, a longer longitudinal length of the bulged part than the pipe radius was successfully obtained.

Abstract: The main goal of this paper is to show the new learning methodologies in techniques of forming process modelling in the context of Master in Industrial Engineering. In this context, Computer integrated manufacturing (CIM) has been established as a valuable tool for manufacturing process. The methodology developed in this work combines the process design, the usefulness workpiece and the computer aided (CAM).

Abstract: The article is devoted to the application of the method of performance evaluation of the production process design, using associative design. A number of approaches to estimation of efficiency of associative design, which are based on estimates of the design timing, the number of imposed changes at appropriate stages of the product life cycle.

Abstract: The incremental forming process of “friction-spinning” is suited to the manufacture of functionally graded workpieces made from tubes and sheets with the defined adjustment of material properties. The innovative feature of this new process is the use of process elements from both metal spinning and friction welding. As the workpieces are being processed, friction sub-processes are employed to achieve self-induced heat generation. Compared with conventional spinning processes, this in-process heat treatment permits the extension of existing forming limits and allows more complex geometries to be achieved, together with defined, favorable part properties. These properties, like strength, grain size or surface conditions, can be influenced by the set of specific temperature profiles that prevail during the manufacturing process in combination with the degree of deformation. The temperature profiles can be adjusted by selecting appropriate process and tool parameters in a defined manner. This paper presents the influence of the aforementioned parameters on the surface texture. The results presented start with the analysis of the surface texture development. Following this, the effects of the significant process parameters and tool geometries that give rise to the typical structure and hardness are explained.

Abstract: The Pulse Electrochemical Machining Process is an innovative, non-conventional process, based on the Electrochemical Machining process. Herein, pulsed current instead of constant current and a feed overlaid mechanical vibration of the tool electrode allows a higher precision and copying accuracy in contrast to the well-established ECM process. Yet, in this context the pulse-pause time and the length of the pulse on-time used in the process cause changes in the material removal while processing and therefore influences the processing result as well as cycle times and other industry relevant criteria. Understanding these pulse- and process specific changes is a key to the process design for industrial applications, since different sets and variations in parameters also change the final form and surface topography. This contribution shows, at the example of two materials 1.4301 and electrolytic copper, how a machining process can be designed and calculated based on material specific data. The way to acquire the necessary material data sets using industrial equipment, as well as the use and information which can be drawn from the data will be addressed.

Abstract: Due to its advantages including high quality of the forging parts and low production costs,hot closed-die forging (HCDF) play an essential role in the machine building industry. However, in recent decades, the pace of its development is gradually slowing down. In the hope of drawing up some new ideas about future development of the HCDF, this paper presents a brief overview of it. This study roughly prospects several potential research issues of the HCDF. Some new research fields such as precision forging, combined forging and numerical simulation have been shown. Challenges and possible response to them have been discussed.

Abstract: A process was designed for etherification of glycerol with isobutene based on latest results of kinetic and thermodynamic study. A continuous stirred tank reactor was employed to carry out the reaction. Fresh glycerol was used to extract mono-ethers (ME) of glycerol in the reaction product and then returned to the reactor. Residual glycerol and ME were recovered by water washing and distillation. Isobutene and isobutene dimers were separated from high-ethers in a side draw distillation column. The new process was optimized, and a product yield of 97 wt% was obtained.

Abstract: In the article we have carried on the design to promote frame and processing clamp. Formulate rules of mechanical processing technology fistly, mainly including:1. The production process and mechanical processing technology process.2. Formulate the original data to develop mechanical process. By analyzing the data, draw the processing technology of promote frame parts. Design the machining process, formulate the process route of machining. Finally, complete the design of fixture by Selection of locating datum, the cutting force and clamping force calculation, positioning error analysis.