Minimum Production Cost Research Articles

Process development and optimization of sustainable and integrated large scale ammonia production process using water electrolysis based green hydrogen: Investigating process, energy, economic & environmental perspectives

Ammonia is an important raw material for fertilizer production and significantly contributes globally to agricultural systems. The multi-objective optimization of a large-scale integrated ammonia production process using water electrolysis-based green hydrogen is carried out using the Hybrid Multi-Objective Differential Evolution-Distance Learning Scheme (Hybrid MODE-DLS) algorithm. Three optimization cases are solved with the objectives of ammonia production rate, total production cost, and total energy by considering nine decision variables, and multiple constraints. The maximum ammonia production (66.51 kmol/h) and minimum total production cost (105.07 $/yr × 105) are obtained in Case 1 whereas the minimum energy value (7863.45 kWh) is obtained in Case 2. The minimum heat credit value of 3057300.5 $/annum exists in Case 2 solutions whereas the maximum heat credit value of 7992076 $/annum is seen in Case 3. The ammonia production rate increased by 82.79% in Case 2 results compared to the base case results.

Exploiting the Ocean Thermal Energy Conversion (OTEC) technology for green hydrogen production and storage: Exergo-economic analysis

This study presents and analyses three plant configurations of the Ocean Thermal Energy Conversion (OTEC) technology. All the solutions are based on using the OTEC system to obtain hydrogen through an electrolyzer. The hydrogen is then compressed and stored. In the first and second layouts, a Rankine cycle with ammonia and a mixture of water and ethanol is utilised respectively; in the third layout, a Kalina cycle is considered. In each configuration, the OTEC cycle is coupled with a polymer electrolyte membrane (PEM) electrolyzer and the compression and storage system. The water entering the electrolyzer is pre-heated to 80 °C by a solar collector. Energy, exergy, and exergo-economic studies were conducted to evaluate the cost of producing, compressing, and storing hydrogen. A parametric analysis examining the main design constraints was performed based on the temperature range of the condenser, the mass flow ratio of hot and cold resource flows, and the mass fraction. The maximum value of the overall exergy efficiency calculated is equal to 93.5% for the Kalina cycle, and 0.524 €/kWh is the minimum cost of hydrogen production achieved. The results were compared with typical data from other hydrogen production systems.

Development of membrane distillation powered by engine exhaust for water desalination

To address water shortage in arid areas and make use of waste heat, an experimental investigation is presented for a novel system of air gap membrane distillation unit driven by an engine exhaust heat source for the development of an on-board car water desalination. The design of the gas-to-water heat exchanger is presented and optimized. The system’s performance, governed by the achieved feed water temperature and measured by the output vapor mass flux, is evaluated with time under varying operational parameters, including engine load, engine speed, and feed water flow rate, with the analysis of production cost for economic viability. Experimental results revealed that higher engine loads and speeds lead to rapid temperature increase of the feed water, enhancing the efficiency of the membrane distillation process and increasing the permeate flux. Notably, a maximum permeate flux of 45 kg/m2h was achieved after 40 min of operation. A minimum production cost of 3.2 $/m3 is estimated at an engine load of 35 N.m. With production costs ranging from 3.2 to 5.8 $/m3, the proposed system emerges as a highly competitive option when compared with other membrane distillation systems driven by waste heat in literature. This study underscores the potential of utilizing waste heat from car engines for cost-effective and sustainable water desalination, paving the way for further development and implementation of the system as a mobile desalination unit for different applications.

INTEGRATED FORECASTING AND AGGREGATE PLANNING FOR PRODUCTION OPTIMIZATION: A COMPARATIVE ANALYSIS OF OVERTIME AND SUBCONTRACTING CONTROLS

The current potential market demand with ever-changing situations and conditions must be managed properly to find out the potential market demand in the future. Rumah Warna Yogyakarta is one of the manufacturing industry players that has experienced fluctuations in market demand, even tending to decline from the end of 2021 to mid-2022. Data was obtained from the database and direct interviews with Rumah Warna in Yogyakarta from November 2021 to November 2022. This study aims to determine the prediction of product demand for Rumah Warna Yogyakarta in the next period, so that companies can carry out production planning strategies to minimize production cost. Product demand prediction is carried out using the Grey System method of the GM (1,1) model. Then proceed with the heuristic aggregate planning method that focuses on overtime control and subcontracting control. Based on the results of the analysis, the Grey System GM (1,1) method produces good prediction accuracy of 9.231%. The best aggregate planning method is the overtime control where Rumah Warna Yogyakarta can reduce costs by Rp 351,258,758 when compared to the subcontracting control method.

Eco-Design of Thermopressing through Induction of 100% Coriander-Based Fiberboards: Optimization of Molding Conditions.

The hot pressing process for 100% coriander-based fiberboards was optimized using an induction RocTool system, which offers rapid mold heating and cooling. The fiberboards were made using deoiled press cake as a protein binder and extrusion-refined straw as reinforcement. Doehlert's experimental design was used to evaluate the influence of pressure (10-50 MPa), molding time (60-300 s), and mold temperature (155-205 °C) on fiberboard properties, energy consumption, cost, and environmental impact. The results showed that the RocTool device allows for better temperature control during shaping throughout the mold, resulting in mechanical properties that are both more homogeneous across the entire surface of the panel and, more importantly, substantially improved. Using the isoresponse curves, the optimal hot pressing conditions were 35 MPa, 300 s, and 205 °C, corresponding to a 40.6 MPa flexural strength. However, it was observed that to achieve an MDF-like fiberboard with minimal production costs, much less restrictive molding conditions were sufficient, i.e., 32.5 MPa, 170 s, and 160 °C. The study revealed that maximum thermopressing conditions emitted 3.87 kg of CO2 eq., while conditions leading to the MDF-like board reduced emissions to 1.45 kg CO2 eq., resulting in a more environmentally friendly material.

A new iron recovery and dephosphorization approach from unroasted high‐phosphorus oolitic hematite ore via a facile chemical beneficiation process

AbstractDespite the abundance of scientific reports on the treatment of oolitic hematite, it still constitutes a global challenge. The distinctive oolitic structure within the ore is regarded as the primary factor causing the difficulty in the beneficiation of oolitic hematite ore. The objective of this study is to devise an effective approach to tackle the issue of beneficiation of oolitic hematite ore, thereby facilitating the utilization of oolitic hematite ore, which is widely abundant worldwide. Based on the Pourbaix diagram (Eh‐pH) of the Al‐Si‐H2O system, an alkaline leaching process for eliminating impurities from unroasted oolitic hematite using NaOH solution as the leaching agent was proposed. The optimal parameters were determined as a temperature of 250°C, a NaOH concentration of 16 mol/L, a liquid‐to‐solid ratio of 4 mL/g, and a reaction time of approximately 2 h. Around 54% of phosphorus (P), 21% of Al2O3, and 61% of SiO2 can be preliminarily removed from unroasted oolitic hematite ore. Through further dephosphorization with dilute sulfuric acid at room temperature, a high‐quality Fe concentrate with 63.3% Fe, 0.04% P, and a Fe recovery rate of 96% was obtained. The alkali can be readily regenerated by adding lime to the leaching solution, and the regenerated alkali has a leaching effect comparable to that of the fresh leaching solution. The recycling and utilization of alkaline leaching agents minimize production costs to the greatest extent possible. Mechanical studies have discovered that intact oolites undergo complete dissociation under alkaline leaching, enabling the leaching solution to permeate into the particles and thereby deeply eliminate impurities. The novel method has accomplished efficient processing of oolitic hematite and a reasonable control of production costs during processing, which is significant for expanding the reserves of iron ore resources.

Novel genomic and phenotypic traits of polyhydroxyalkanoate-producing bacterium ZZQ-149, the type strain of Halomonas qinghailakensis

BackgroundPolyhydroxyalkanoates (PHAs) are optimal potential materials for industrial and medical uses, characterized by exceptional sustainability, biodegradability, and biocompatibility. These are primarily from various bacteria and archaea. Bacterial strains with effective PHA formation capabilities and minimal production cost form the foundation for PHA production. Detailed genomic analysis of these PHA-generating bacteria is vital to understand their PHA production pathways and enhance their synthesis capability.ResultsZZQ-149, a halophilic, PHA-producing bacterium, was isolated from the sediment of China’s Qinghai Lake. Here, we decoded the full genome of ZZQ-149 using Single Molecule Real Time (SMRT) technology based on PacBio RS II platform, coupled with Illumina sequencing platforms. Physiological, chemotaxonomic traits, and phylogenetic analysis based on 16 S rRNA gene and single copy core genes of ninety-nine Halomonas type strains identified ZZQ-149 as the type strain of Halomonas qinghailakensis. Furthermore, a low average nucleotide identity (ANI, < 95%) delineated the genetic differences between ZZQ-149 and other Halomonas species. The ZZQ-149 genome, with a DNA G + C content of 52%, comprises a chromosome (3, 798, 069 bps) and a plasmid (6, 107 bps). The latter encodes the toxin-antitoxin system, BrnT/BrnA. Through comprehensive genome sequencing and analysis, we identified multiple PHA-synthesizing enzymes and an unprecedented combination of eight PHA-synthesizing pathways in ZZQ-149.ConclusionsBeing a halophilic, PHA-producing bacterium, ZZQ-149 exhibits potential as a high PHA producer for engineered bacteria via genome editing while ensuring low-cost PHA production through continuous, unsterilized fermentation.

The Mechanization Trend and Economic Prospects of Micro Irrigation in India

Agriculture plays a crucial role in the Indian economy, contributing nearly 16 percent to the total GDP, with farm mechanization serving as the backbone of agricultural GDP. This study analyzes the growth trend in agricultural mechanization in India by examining the shift from traditional human and animal-powered equipment to mechanically powered farm equipment like tractors and power tillers, which are vital for farm mechanization. Secondary data from 2004-2005 to 2021-2022 were used, and the compound annual growth rate (CAGR) and correlation analyses were performed to assess trends. The study found a 6.78 percent annual growth in tractor purchases, with a linear trend equation showing a 0.93 coefficient of determination (R²) at a 1 percent significance level, and a Pearson correlation coefficient of 0.76, indicating a strong correlation between tractor and power tiller purchasing trends. Precision farming, a type of farm management that uses information technology to optimize crop and soil health and productivity while minimizing production costs, is increasingly adopted due to advancements in mechanization. In India, precision farming techniques like drip and sprinkler micro-irrigation, covering 13,476,804 hectares with 46.90 percent under drip and 53.09 percent under sprinkler, have proven beneficial, especially in water-scarce areas. Precision farming is practiced mainly by medium to large progressive farmers, often experimentally or commercially, and offers profitable returns when applied to high-value crops such as fruits, vegetables, flowers, and medicinal plants.

Use of corncob and pineapple peel as associated substrates for biosurfactant production.

Biosurfactants are amphiphilic biomolecules with promising tensoative and emulsifying properties that find application in the most varied industrial sectors: environment, food, agriculture, petroleum, cosmetics, and hygiene. In the current work, a 23 full-factorial design was performed to evaluate the effect and interactions of pineapple peel and corncob as substrates for biosurfactant production by Bacillus subtilis LMA-ICF-PC 001. In a previous stage, an alkaline pretreatment was applied to corncob samples to extract the xylose-rich hydrolysate. The results indicated that pineapple peel extract and xylose-rich hydrolysate acted as partial glucose substitutes, minimizing production costs with exogenous substrates. Biosurfactant I (obtained at 8.11% pineapple peel extract, 8.11% xylose-rich hydrolysate from corncob, and 2.8109g/L glucose) exhibited a significant surface tension reduction (52.37%) and a promising bioremediation potential (87.36%). On the other hand, biosurfactant III (obtained at 8.11% pineapple peel extract, 31.89% xylose-rich hydrolysate from corncob, and 2.8109g/L glucose) exhibited the maximum emulsification index in engine oil (69.60%), the lowest critical micellar concentration (68mg/L), and the highest biosurfactant production (5.59g/L). These findings demonstrated that using pineapple peel extract and xylose-rich hydrolysate from corncob effectively supports biosurfactant synthesis by B. subtilis, reinforcing how agro-industrial wastes can substitute traditional carbon sources, contributing to cost reduction and environmental sustainability.

Modeling the Effects of Temperature in Enzymatic Biodiesel Synthesis of Jatropha Oil: An Optimal Control Approach.

Biodiesel, an alternative to diesel, is produced through the enzymatic transesterification of vegetable oil or animal fats. Enzymatic transesterification of oil is gaining more importance, as this method possesses no such disadvantages that are associated with the chemical process. Temperature is the most important factor in enzymatic transesterification for biodiesel synthesis. In this study, a mathematical model is developed to understand the effects of temperature on the enzymatic transesterification of Jatropha curcas oil. Reaction rates are expressed as a function of temperature using an appropriate function, and the effects of temperature on the overall enzymatic system are investigated using the mathematical model. A suitable temperature is determined using the mathematical model, keeping the other reaction conditions unchanged that gives maximum yield. Furthermore, an optimal control problem (OCP) is formulated to identify the temperature control strategy that maximizes the biodiesel yield while minimizing production costs. Simulated outcomes obtained from the mathematical model are analogized with the experimental results to make them acceptable. The optimal profile of temperature is determined from the developed OCP, which maximizes the biodiesel yield.

Modeling, parameter estimation and optimization of fluidized bed-based alternative ironmaking process for CO2 emission reduction

This study presents the development of a comprehensive process model for simulating and optimizing the FINEX process consists of the multi-stage fluidized beds, the melter-gasifier unit, and a gas recycling system. The model is developed using Pyomo, a Python-based open-source software package that provides extensive capabilities for formulating, solving, and analyzing optimization models. It incorporates heat and mass balance equations and captures a wide range of chemical reactions, including the reduction of iron ore by hydrogen and carbon monoxide, the calcination of carbonate materials, the water–gas shift reaction, and coal gasification and combustion. Unknown parameters in the model, such as heat loss in each reactor, the extent of the calcination reaction, and the outlet gas temperature from the melter-gasifier, were estimated to calibrate the model. These parameters were estimated by solving an optimization problem that minimizes the gap between the model and real plant data. The optimized model was employed to investigate various scenarios for minimizing CO2 emissions in the FINEX process. This included assessing the impact of HBI charging rates, iron ore quality, and the integration of a CCUS unit. For each scenario, an optimization problem was formulated to minimize production costs across a range of CO2 tax levels. The optimal solutions revealed the relationships between process economics and CO2 emissions for each variable.

Efektivitas Pencampuran Ekstrak Daun Kelor (Moringa Oleifera) yang Difermentasi Menggunakan Aspergillus Niger pada Pakan Buatan Terhadap Laju Pertumbuhan Ikan Nila (Oreochromis Niloticus)

Tilapia (Oreochromis niloticus) is a freshwater fish that is in great demand by the public because it has a thick meat texture and an affordable price. The problems faced in aquaculture activities are the high cost of feed and the length of cultivation time. Feed is a vital component in aquaculture activities, therefore feed efficiency is needed to minimize production costs. The addition of fermented moringa leaf extract in pellets is expected to accelerate the growth period. This study aims to determine the effect of the addition of fermented moringa leaf extract on tilapia growth rate. This study used a complete randomized design (CRD) method with 4 treatments, namely the addition of moringa leaf extract to pellets with concentrations of 0%, 25%, 30%, 35%. The treatment was carried out for 28 days. Parameters observed in this study were fish growth including fish length, fish weight, survival rate (SR), food conversion rate (FCR) and water quality in the form of temperature, pH and DO. The data were analyzed using anova and SPSS application. The results showed that the addition of fermented moringa leaf extract with concentrations of 0%, 25%, 30% and 35% in tilapia (Oreochromis niloticus) feed for 28 days had a significant effect on tilapia growth.

Equal Incremental Cost Method with Adjustable Gamma Control to Solve Generator Scheduling

Generator scheduling remains an intriguing issue within the energy industry. It relates to the optimization of production costs, where system operators must select the optimal combination of available resources to minimize production costs. This paper proposes an enhancement to the Equal Incremental Cost (EIC) Method using Adjustable Gamma Control (AGC) in generator scheduling. Iterations begin with an initial lambda value, then gradually increase with the application of the factor until power demand is met. A variable of 10% is used as an adjustment step in the optimization method. The proposed method is capable of achieving convergence with 100% accuracy, where the power generated by all generators precisely matches the load demand (2,650 MW), at a cost of USD 32,289.03. EIC-AGC ranks second-best after VLIM, albeit with the consequence of consuming 195 seconds. This method is expected to have a significant impact on designing highly accurate economic dispatch techniques. Thus, generator scheduling will lead to a reduction in operational costs compared to current practices.

Indigo (Indigo suffruticosa Mill.) seed germination to improve commercial viability

Indigo suffruticosa Mill., commonly known as Guatemalan indigo or anil indigo, is being investigated as a regenerative rotational crop that is used to produce natural plant-based dyes in the USA. The fashion and textile industry currently rely on harmful synthetic dyes to color fabric. To improve the viability of Indigo and to minimize production costs, methods to improve Indigo seed germination rates will benefit the quality, crop yields, and enable large scale field plantings.This study was initiated to develop a methodology of treating seeds to increase seed germination rates of Guatemalan Indigo and decrease fungal seed pathogens. All studies were conducted on the currently available commercial Indigo varieties. Sterilization and germination methods included: ethanol and bleach sterilization, mechanical scarification (coffee grinder, belt sander), gibberellic acid, dry heat, freezing, distilled water soaking, and boiling water. Each treatment was replicated four times for each of the various times and temperatures tested. The dry heat method at 80°C for 30 min resulted in the highest average germination rate of 83 %. Trials demonstrated that the dry heat method was the only treatment that resulted in higher germination rates than control treatment with an average of only 64 % germination. Dry heat at 90°C across all time intervals (30 min, 1 h, and 2 h) showed no results higher than 34 % germination. Pre-treating seed with 10 min soak in 10 % bleach resulted in complete control of surface pathogens with no decrease in seed germination. The boiling water method for 30 sec also lead to higher germination rates but may prove too difficult in larger volumes. Other methods of sterilization, gibberellic acid, freezing, mechanical scarification, and long-term soaking resulted in average germination percentages equal to or less than the control of no treatment. The dry heat method should be applied 2 h before planting. Applying a 10 min bleach sterilization step and dry heat treatment will greatly improve germination of Indigo and will allow for a commercially viable protocol to be created. This will allow natural indigo to compete with inexpensive synthetic dyes, enabling producers to direct seed indigo rather than costly transplant production.

Optimization of fermentation parameters to improve the biosynthesis of selenium nanoparticles by Bacillus licheniformis F1 and its comprehensive application

BackgroundSelenium nanoparticles (SeNPs) are increasingly gaining attention due to its characteristics of low toxicity, high activity, and stability. Additionally, Bacillus licheniformis, as a probiotic, has achieved remarkable research outcomes in diverse fields such as medicine, feed processing, and pesticides, attracting widespread attention. Consequently, evaluating the activity of probiotics and SeNPs is paramount. The utilization of probiotics to synthesize SeNPs, achieving large-scale industrialization, is a current hotspot in the field of SeNPs synthesis and is currently the most promising synthetic method. To minimize production costs and maximize yield of SeNPs, this study selected agricultural by-products that are nutrient-rich, cost-effective, and readily available as culture medium components. This approach not only fulfills industrial production requirements but also mitigates the impact on downstream processes.ResultsThe experimental findings revealed that SeNPs synthesized by B. licheniformis F1 exhibited a spherical morphology with diameters ranging from 110 to 170 nm and demonstrating high stability. Both the secondary metabolites of B. licheniformis F1 and the synthesized SeNPs possessed significant free radical scavenging ability. To provide a more robust foundation for acquiring large quantities of SeNPs via fermentation with B. licheniformis F1, key factors were identified through single-factor experiments and response surface methodology (RSM) include a 2% seed liquid inoculum, a temperature of 37 ℃, and agitation at 180 rpm. Additionally, critical factors during the optimization process were corn powder (11.18 g/L), soybean meal (10.34 g/L), and NaCl (10.68 g/L). Upon validating the optimized conditions and culture medium, B. licheniformis F1 can synthesize nearly 100.00% SeNPs from 5 mmol/L sodium selenite. Subsequently, pilot-scale verification in a 5 L fermentor using the optimized medium resulted in a shortened fermentation time, significantly reducing production costs.ConclusionIn this study, the efficient production of SeNPs by the probiotic B. licheniformis F1 was successfully achieved, leading to a significant reduction in fermentation costs. The exploration of the practical applications of this strain holds significant potential and provides valuable guidance for facilitating the industrial-scale implementation of microbial synthesis of SeNPs.

Development of Automatic Balancing Application forFashion Company Using Artificial Intelligence

Industrial companies aim to minimise production costs and improve product quality by analysing work organisation levels. Workshop scheduling and line balancing are essential in realising production plans, particularly in the fashion industry. Balancing systems must optimise precise criteria while sticking to constraints. Preserving balance needs precise parameters that align theoretical and practical production results. Manual methods overlook the balancing process, where managers rely on experience to prove balance and adjust parameters as needed. This article presents a creative automatic balancing application for fashion companies, leveraging artificial intelligence’s (AI) power. It focuses on utilising ant colony algorithms for optimal balancing. The results show the significance of these algorithms in attaining optimal balancing in production systems. The article highlights outstanding balancing results achieved through this approach, providing alignment with detailed criteria and constraints. The algorithm reliably distributes tasks among operators, improving overall productivity. Therefore, ant colony algorithms are perfect for manufacturers pursuing cost reduction, improved product quality and facilitated production processes. This article introduces an AI-based automatic balancing application for fashion companies. The ant colony algorithms achieve optimal balancing, improve inventory management and enhance productivity.

Performance, economic, and statistical analysis assessment for the hybrid solar dish concentrator with turbine, generator, and reverse osmosis desalination unit

The development of a thermodynamically modeled hybrid commercial solar dish with reverse osmosis is conducted in this study with a rated concentrate thermal and a receiver temperature of 853 °C. To simulate and assess the performance characteristics of the suggested TJ-SDC/RO hybrid system in the city of Tianjin-republic of China, a theoretical model was created and built with MATLAB application. A daily and yearly performance study of the TJ-SDC/RO system under investigation is accomplished. Furthermore, energy analysis viability is achieved in order to evaluate the TJ-SDC/RO system’s life cycle. According to the findings, the suggested TJ-SDC/RO system can produce enough desalinated water to meet daily changes in solar radiation. In June of Tianjin-China’s climate, the superior efficiency of the Rankine cycle was 33.92 %, while the SDC-RO system maximum cycle efficiency peaked at 24.95 % with minimum production costs per unit of electricity of 0.0902 $/kW.h and average water production costs yearly 7.09 $/m3. A mathematical model by Minitab commercial software of the nonlinear regression technique is used with an adjusted R2 of 0.99999485, which indicates the accuracy and reliability of the prediction correlation.

P2M systems based on proton-conducting solid oxide cells: Future prospects and costs of renewable methanol production

As consequence of the transition towards sustainable energy sources, the future production of liquid energy carriers (e.g. methanol) via H2 supply pathways utilizing water electrolyzers (power-to-liquid) will most likely be based on fluctuating grid electricity or islanded renewable inputs. As a result, these production processes are subject to fluctuating operating conditions and varying production capacities, ultimately leading to uncertainties with respect to their process economics and profitability. Therefore, the impact of different electricity supply-side scenarios (static grid and intermittent grid or renewable supply) on the production economics of power-to-liquid processes needs to be assessed thoroughly for the upcoming decades. Methanol is considered as an essential base chemical which is widely known for its versatility and broad potential use contexts in future chemical industries and energy storage applications. Methanol production pathways powered by renewable electricity sources, also known as power-to-methanol processes, are characterized by low specific life-cycle emissions and are therefore of paramount interest. One possible renewable process chain features proton-conducting high temperature electrolyzers combined with a direct hydrogenation of CO2. In this paper, a techno-economic forecast study of this process chain is presented and specific production costs of renewable methanol under different electricity supply scenarios are determined and discussed for the years 2030 and 2050. The studies showed that flexible grid-supported scenarios through direct spot-market participation and renewable scenarios based on wind onshore production enable the largest production cost reduction potential in the upcoming decades. Minimum production costs of 740 € t−1MeOH (2030) and 415 € t−1MeOH (2050) are determined for a flexible operation of the system with spot-market participation, benefitting from times of low or even negative electricity prices. Among the renewable production scenarios, islanded power-to-methanol systems coupled to wind onshore plants were identified as the most beneficial configuration with ascertained production costs as low as 820 € t−1MeOH and 353 € t−1MeOH by 2030 and 2050, respectively.

Design and Analysis of Jigs and Fixtures for Inspection Process

Abstract: In the realm of vehicle manufacturing, ensuring precise panel fitment is paramount for maintaining quality standards and customer satisfaction. This report delves into the significance of panel and fitment checking fixtures in the automotive industry. The study provides a thorough examination of the design, construction, and utilization of these fixtures, emphasizing their critical role in verifying the accuracy and alignment of vehicle panels during assembly. By employing advanced measurement techniques and precision engineering, these fixtures serve as indispensable tools for detecting deviations and inconsistenciesin panel fitment. Furthermore, the report explores the integration of innovative technologies such as 3D scanning and computer-aided design (CAD) in the development of these fixtures, enabling manufacturers to achieve higher levels of accuracy and efficiency in the quality control process. Through case studies and industry insights, the report showcases the practical application and effectiveness of panel and fitment checking fixtures across various stages of vehicle production. Additionally, it highlights the benefits of implementing standardized fixture designs and methodologies to streamline manufacturing processes and minimize production costs.

Experimental Investigation of Strain Rate Influence on Anisotropy of Uniaxial Tensile Mechanical Properties of CuFe2P Alloy Sheet.

Wire crimping, a process commonly used in the automotive industry, is a solderless method for establishing electrical and mechanical connections between wire strands and terminals. The complexity of predicting the final shape of a crimped terminal and the imperative to minimize production costs indicate the use of advanced numerical methods. Such an approach requires a reliable phenomenological elasto-plastic constitutive model in which material behavior during the forming process is described. Copper alloy sheets, known for their ductility and strength, are commonly selected as terminal materials. Generally, sheet metals exhibit significant anisotropy in mechanical properties, and this phenomenon has not been sufficiently investigated experimentally for copper alloy sheets. Furthermore, the wire crimping process is conducted at higher velocities; therefore, the influence of the strain rate on the terminal material behavior has to be known. In this paper, the influence of the strain rate on the anisotropic elasto-plastic behavior of the copper alloy sheet CuFe2P is experimentally investigated. Tensile tests with strain rates of 0.0002 s-1, 0.2 s-1, 1 s-1, and 5.65 s-1 were conducted on sheet specimens with orientations of 0°, 45°, and 90° to the rolling direction. The influence of the strain rate on the orientation dependences of the stress-strain curve, elastic modulus, tensile strength, elongation, and Lankford coefficient was determined. Furthermore, the breaking angle at fracture and the inelastic heat fraction were determined for each considered specimen orientation. The considered experimental data were obtained by capturing the loading process using infrared thermography and digital image correlation techniques.