A computer-aided sustainable modelling and optimization analysis of cnc milling and turning processes
- Authors: Singh, Karmjit , Sultan, Ibrahim
- Date: 2018
- Type: Text , Journal article
- Relation: Journal of Manufacturing and Materials Processing Vol. 2, no. 4 (2018), p.
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- Description: The sustainability of a manufacturing process can be measured by three main factors which impact both ecological and financial constraints. These factors are the energy required to achieve a specific job, the material utilized for the job, and the time taken to complete that job. These factors have to be quantified and analysed so that a proper manufacturing system can be designed to optimize process sustainability. For this purpose, a computer package, which utilizes life cycle inventory models has been presented for CNC (Computer Numerical Control) milling and turning processes. Based on utilization of resources and production stages, the job completion time for the turning and milling processes can be divided into process (i.e., machining), idle and basic times. As parameters are different for evaluating the process times, i.e., depth and width of cut in case of milling, initial and final diameters for turning, two different case studies are presented, one for each process. The effect of material selection on the sustainability factors has been studied for different processes. Our simulations show that highly dense and hard materials take more time in finishing the job due to low cutting speed and feed rates as compared to soft materials. In addition, face milling takes longer and consumes more power as compared to peripheral milling due to more retraction time caused by over travel distance and lower vertical transverse speeds than the horizontal transverse speed used in a peripheral retraction process. © 2018 by the authors. Licensee MDPI, Basel, Switzerland.
A computer-aided unit process sustainable modelling for manufacturing processes : Case for extrusion process
- Authors: Singh, Karmjit , Sultan, Ibrahim
- Date: 2019
- Type: Text , Journal article
- Relation: Production and Manufacturing Research-an Open Access Journal Vol. 7, no. 1 (2019), p. 143-160
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- Description: Sustainable manufacturing assessment is meant to ensure that products are manufactured such that negative environmental impacts are reduced by conserving energy and managing the use of natural resources as well as ensuring economical soundness for the process. The main objective of this work is to introduce sustainable development methodology/models for manufacturing processes. For this purpose, the paper utilizes background data, develops a computer model and presents detailed case studies. This paper will identify and adopt key performance indicators (KPIs) and utilize these to assess the sustainability of extrusion process and their designs. Different manufacturing parameters such as material types, product specifications and manufacturing tools are considered in the process of measuring sustainability. The proposed computer model is verified with data obtain from actual aluminium extrusion plants.
A framework for sustainability performance assessment for manufacturing processes
- Authors: Singh, Karmjit
- Date: 2019
- Type: Text , Thesis , PhD
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- Description: Sustainable manufacturing methods make it possible to develop products in ways which minimize negative environmental impacts, conserve energy and save natural resources whilst being economically sound. The concepts of sustainability in manufacturing being are still fairly broad, in scope, and need to be more focused and firmly established at the process, machine or factory levels. This project proposes a structure for manufacturing with a main objective to develop a sustainability framework which encompasses various production processes. Structured information models for the seamless flow of information across the design and manufacturing domains, for selected manufacturing processes, are defined. The thesis work identifies key performance indicators (KPIs) for the assessment of manufacturing sustainability and performs analysis of selected unit manufacturing processes and their sub-processes with the aim of proposing a methodology for determining science-based measurements of the manufacturing processes affecting these KPIs. The theoretical foundations established are then used to develop a model that could evaluate sustainability of selected manufacturing processes and their respective process plans providing a basis for inter-process comparison and selection of the most sustainable process plan. The proposed framework is presented in form of a manufacturing planning computer-based package which is designed to to consider different influencing factors such as product information, part geometry, material related physical and processing properties and the manufacturing equipment operating data. The thesis presents a number of case studies which have been published in international journals. The case studies present estimates of the manufacturing sustainability KPIs for a number of production methods. These estimates have been verified with available shop floor data. The work in the thesis makes it possible to establish manufacturing industry equipped to deal the challenges of the future when sustainability will be the major factor up on which the quality of success will be determined.
- Description: Doctor of Philosophy
Framework for sustainability performance assessment for manufacturing processes- A Review
- Authors: Singh, Karmjit , Sultan, Ibrahim
- Date: 2017
- Type: Text , Conference proceedings
- Relation: IOP Conference Series: Earth and Environmental Science, Volume 73; International Conference on Sustainable Energy Engineering 12–14 June 2017; Perth, Australia Vol. 73
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- Description: Manufacturing industries are facing tough competition due to increasing raw material cost and depleting natural resources. There is great pressure on the industry to produce environmental friendly products using environmental friendly processes. To address these issues modern manufacturing industries are focusing on sustainable manufacturing. To develop more sustainable societies, industries need to better understand how to respond to environmental, economic and social challenges. This paper proposed some framework and tools that accelerate the transition towards a sustainable system. The developed framework will be beneficial for sustainability assessment comparing different plans alongside material properties, ultimately helping the manufacturing industries to reduce the carbon emissions and material waste, besides improving energy efficiency. It is expected that this would be highly beneficial for determination of environmental impact of a process at early design stages. Therefore, it would greatly help the manufacturing industries for selection of process plan based on sustainable indices. Overall objective of this paper would have good impact on reducing air emissions and protecting environment. We expect this work to contribute to the development of a standard reference methodology to help further sustainability in the manufacturing sector.
Information and computational modeling for sustainability evaluation and improvement of manufacturing processes
- Authors: Singh, Karmjit , Sultan, Ibrahim
- Date: 2020
- Type: Text , Book chapter
- Relation: Additive and Subtractive Manufacturing: Emergent Technologies. Chapter 8 p. 271-288
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- Description: Over the last few decades, manufacturing industries are working toward sustainable manufacturing due to the high cost of raw material and depletion of natural resources. There is also a great concern for manufacturing companies to produce products by considering three aspects of sustainability, that is, economic, environmental, and social. This pressure has motivated modern manufacturing industries to, commit to, adopt the ethos and methods of sustainable manufacturing. An outcome is manifested by the current undertakings of many research projects that are designed to propose automated systems for determination of CO2 emissions, solid waste, and energy consumption of various manufacturing plants. An effort for developing a generic model for different manufacturing processes, graphic user interface system, is presented in this chapter. The chapter presents detailed discussions of the proposed models for two different manufacturing processes. Sustainability analysis case studies, based on the models developed, are presented for die-casting, injection molding, and turning processes. It will be shown that the developed models are effective for sustainability assessment process and have the potential of helping the manufacturing companies. Moreover, the work presented is highly beneficial in determining the sustainability assessment of a manufacturing process at the beginning of product design. An overarching motive of this chapter is to reduce emissions from energy production into atmosphere and alleviate impact on the environment. © 2019 Walter de Gruyter GmbH, Berlin/Boston.
Modelling and evaluation of KPIs for the assessment of sustainable manufacturing : An extrusion process case study
- Authors: Singh, Karmjit , Sultan, Ibrahim
- Date: 2018
- Type: Text , Conference paper
- Relation: 7th International Conference of Materials Processing and Characterization, ICMPC 2017; Hyderabad, India; 17th-19th March 2017; published in Materials Today: Proceedings Vol. 5, p. 3825-3834
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- Description: Manufacturing industries today are focusing on controlling negative environmental impacts, reducing cost, conserving energy and natural resources while producing new products through various methods and tools of Sustainable manufacturing assessment. This paper proposes science-based guidelines for modeling and evaluation of key performance indicators (KPIs) in an aluminium extrusion process. The proposed methodology consists of the following main components: 1) identification of key performance indicators 2) classification of manufacturing processes on the basis of KPIs 3) evaluation of key performance indicators. We discuss in detail the steps of the proposed indicators for aluminium extrusion process. The proposed indicators also contribute towards the development of standard reference methodology to help further sustainability in the manufacturing industries. In this paper we propose science-based guidelines, which can be used to determine key performance indicators, namely energy consumption, solid waste and carbon emissions of an aluminium extrusion process. The proposed methodology has been verified with actual shop floor data obtained from the industry.
Parameters optimization for sustainable machining by using Taguchi method
- Authors: Singh, Karmjit , Sultan, Ibrahim
- Date: 2019
- Type: Text , Journal article
- Relation: Materials today : proceedings Vol. 18, no. (2019), p. 4217-4226
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- Description: Sustainability has crucial importance in the field of machining processes where great amount of energy is being consumed. The environmental performance of machining operations can significantly be improved by reducing energy consumption. This paper outlines optimization of the machining parameters for CNC turning by using a Taguchi method. The objective of this study is to investigate sustainability issues pertinent to turning process in machining industry. Parameters such as emission rate and energy consumption are considered as sustainability factors. Analysis of Variance (ANOVA) is applied to test the data. The results of the study help to understand the effect of the cutting parameters on energy consumption and emission rate. The process is optimized from power consumption, time and energy point of view. Extended form of the model could be useful to predict the environmental impact of other manufacturing processes which will bring environmental concern.
Sustainable manufacturing modelling : a case for milling process
- Authors: Singh, Karmjit , Sultan, Ibrahim
- Date: 2019
- Type: Text , Journal article
- Relation: International Journal of Materials, Mechanics and Manufacturing Vol. 7, no. 1 (2019), p. 46-50
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- Description: In manufacturing industries, metal machining is very important process due to the competitiveness. Every manufacturer needs quick, effective and optimized processes. The experience of the operator plays a major role, but even for a skilled operator it is very difficult to attain the optimum values each time. Sustainability Analysis has attracted growing interests from industry, as an optimum cost estimation system analysis method, and energy consumption progress has been achieved. In this work, scrap production as well as production lead time have to be reduced and machining cost per kg of material is target. To reduce the cost, energy consumption and material wastage impact of the milling process worldwide many aspects of the process are investigated. In the present work, a system has been proposed, which can be used to determine various components of Sustainability analysis of milling process.