Production Engineering Research Articles

Hybrid PBF-LB/M of Pure Copper for Hairpin Winding Heads of Electric Traction Drives

In the automotive sector, the so-called hairpin technology currently dominates the copper winding of stators in traction drives. In addition to the advantages of higher power density and deterministic production process steps, the winding technology also entails complexities and disadvantages. The production of hairpin stators requires high investments for production machines and their highly complex tools for manufacturing the windings. In addition, it is a major challenge to integrate variant flexibility in these production lines. Producing different product variants of a hairpin stator is only possible with additional costs for tools of the individual lines. In contrast, additive manufacturing technologies enable tool-free production of complex 3D geometries.In the field of PBF-LB/M, the processability of pure copper for electrical applications has been intensively researched and improved in recent years. Therefore, the approach of printing complex winding heads of a hairpin winding directly on conventional copper conductors using PBF-LB/M process is researched in this study. Challenges regarding alignment in the hybrid process as well as redesign using design automation methods considering restrictions and boundary conditions are faced and investigated. By integrating additive manufacturing in hairpin stator production and developing an innovative production process chain, process steps, machines and tools can thus be substituted. By exploiting design potentials of additive manufacturing, winding head heights can additionally be reduced, thus reducing losses in the e‑machine and saving quantities of copper material. The approach is validated using a hairpin stator from the automotive sector. The same conventionally produced hairpin stator is used as a benchmark to evaluate the results achieved by the hybrid stator in a production engineering context.

КОНЦЕПЦИЯ МЕТОДОЛОГИИ ПРОГНОЗИРОВАНИЯ ВОСТРЕБОВАННОГО ПОТРЕБИТЕЛЯМИ КАЧЕСТВА ПРОДУКЦИИ МАШИНОСТРОЕНИЯ ПРИ ВЫХОДЕ КОМПАНИИ-ПРОИЗВОДИТЕЛЯ НА НОВЫЕ КОНКУРЕНТНЫЕ РЫНКИ

The article presents the results of developing the concept of a methodology for predicting the quality of mechanical engineering products demanded by consumers when a manufacturing company enters new competitive markets, using the example of automotive production.

СТРУКТУРНО-ФУНКЦІОНАЛЬНЕ МОДЕЛЮВАННЯ МАРКЕТИНГОВОЇ ПОЛІТИКИ ЗАБЕЗПЕЧЕННЯ ЕКОНОМІЧНОЇ БЕЗПЕКИ МАШИНОБУДУВАННЯ

The article analyzes modern scientific approaches to ensuring the economic security of machine-building enterprises based on the marketing concept of mutual relations. It is established that the appropriate marketing policy in industrial markets is focused on the study of the interaction of companies with business consumers, competitors and other interested parties. It was emphasized that due to the balancing of interests between consumers and producers of products, the appropriate level of economic security of enterprises in the machine-building market is achieved, which allows business entities to form stable relations on a mutually beneficial basis and plan their activities in the long term. It is emphasized that in the context of ensuring the economic security of machine-building enterprises, the marketing policy of mutual relations allows reducing the marketing risks of economic security at the expense of the company achieving competitive advantages by establishing, maintaining and developing long-term relationships with partners in the process of improving production, promotion and sales of products in order to create the value that wants to get a buyer. A conceptual model of the marketing policy of the relationship between the supplier and the consumer in the context of ensuring the economic safety of mechanical engineering has been formed. It is proposed to include elements of the marketing complex in the marketing policy of relations: management of product quality, price / costs, distribution, promotion and quality of service. It has been proven that this approach contributes to the balancing of interests between sellers and buyers of engineering products in the process of ensuring economic security. The complex of works related to the planning and implementation of the marketing policy of mutual relations is proposed to be solved with the help of a process approach based on structural-functional modeling tools, which allows you to streamline the course of action and quickly adjust all aspects of the marketing policy within the framework of a long-term business partnership.

Управление качеством процессов производства продукции машиностроения в сети

Statement of the problem (relevance of the work): the article outlines the main advantages of using the network to improve the quality of the production processes of engineering products, which is especially important in the context of the formation of technological sovereignty. The purpose of the work: the purpose of the article is to systematize and analyze the models of product quality management in the engineering industry and develop, on their basis, an intersectoral model of a quality management system in a network. Methods used: the article uses general scientific methods of cognition, namely, the method of description, generalization, critical analysis, visualization. As a theoretical basis for the study, theories of process and network management in the industrial complex are used. Novelty: generalization and systematization of theoretical approaches to quality management in mechanical engineering made it possible to design an intersectoral model of a quality management system in a network, the use of which will make it possible to create and strengthen technological sovereignty. Result: as a result of a study on the analysis of quality management models of the production process, their distinctive characteristics are determined in relation to the network, the core of which is a machine-building enterprise, which made it possible to develop an intersectoral model of a quality management system, the use of which allows obtaining such network effects as the achievement of integrated production support at all stages of the life cycle; reducing transaction costs, increasing the flexibility of the design and production of new science-intensive and high-tech products, which makes it possible to increase the level of technological sovereignty of the industry by strengthening cooperation ties. Practical significance: the conclusions and results contained in the article can be used in the development of strategies for the formation and strengthening of technological sovereignty both in the machine-building industry and in the industrial complex as a whole.

Organizational Ohm's Law in PracticeMeasuring Engineering Productivity

Organizational Ohm's Law in PracticeMeasuring Engineering Productivity

ПРЕДПОСЫЛКИ УСТОЙЧИВОСТИ И ЭФФЕКТИВНОСТИ РАЗВИТИЯ МАШИНОСТРОЕНИЯ В УСЛОВИЯХ САНКЦИОННОГО ДАВЛЕНИЯ

The article examines in detail the impact of sanctions pressure from Western countries on the state of the domestic industry as a whole and its separate branch - mechanical engineering. The purpose of the study was to analyze the current state of mechanical engineering in Russia in order to identify existing problems, determine optimal directions and formulate proposals for achieving sustainable economic development of the Russian Federation. The objectives of the study were: analysis of the current state of mechanical engineering; identification of problems of the efficiency of mechanical engineering development; determination of directions of development of the mechanical engineering industry in the Russian Federation; development of measures for import substitution in the mechanical engineering complex. The study used the methods of scientific knowledge: analysis and synthesis, monographic, methods of statistical and economic analysis, graphical method, system-structural and formal-logical methods. The information base was the data of Rosstat, the Industrial Development Fund and the Institute for Statistical Research and Economics of Knowledge, presented on the official website and scientific materials of domestic and foreign researchers. We identified the optimal directions for the development of the mechanical engineering industry of the Russian Federation: overcoming the technological gap and increasing demand for machinery and equipment manufactured in the Russian Federation; Innovation-oriented integration into import substitution processes; Creation of modern and progressive technologies in mechanical engineering; Digitalization of business processes and implementation of the Industry 4.0 production management technology; Establishment of cooperation with domestic and friendly foreign enterprises; Increasing the efficiency and competitiveness of mechanical engineering enterprises, etc. The following measures are proposed for import substitution in the mechanical engineering complex: Purchase of components in friendly countries; Cooperation with manufacturing enterprises; Preferential lending by industrial development institutes; Creation by executive authorities of a unified information and industrial system to solve logistics problems; Placement of production segments of the mechanical engineering industry; Stabilization of the domestic product market and Development of cooperative interaction between industries. It is recommended to focus mechanical engineering production on the implementation of priority projects, development projects, projects for the digitalization of industry and SPIC, financed by the FRP, which will allow bringing the enterprise to a modern level and improving the state of the industry as a whole. The directions of future research will be the mechanisms of technological development of the domestic mechanical engineering. The conducted research and its results can be applied by researchers and students in economic fields interested in the state of mechanical engineering in Russia.

МІСЦЕ ІНЖИНІРИНГУ В ЖИТТЄВОМУ ЦИКЛІ ПРОМИСЛОВИХ ВИРОБІВ

In undertaking the exploration, the authors endeavored to disseminate to the readership a developed comprehension of the essence of engineering as a distinct form of economic endeavor and its positioning within the lifecycle of generating consumer value. Emphasis is placed on shipbuilding artifacts, considering their pivotal role in both the global and, by extension, national economies increasingly enmeshed within the international economic milieu. It is discerned that the upsurge in demand for Engineering services is attributable to the steep ascension in fleet size, notably within its most robust segment - the commercial sector. The doubling of the fleet size for transporting various types of cargo over the past twenty years has been confirmed by visualized statistics. This phenomenon is not merely a result of a surge in maritime freight transportation, which has increased by nearly three hundred percent over the analyzed period. Simultaneously, there is a growing interest among shipowners in extending the operational lifespan of vessels. In this context, they place hopes on vessel repair, modernization, and conversion. Furthermore, even the disposal of these complex engineering structures, in accordance with the requirements of the International Maritime Organization and the standards of the European Union and participating countries, should occur without causing harm to the personnel of specialized shipyards and the environment. It has been demonstrated that solving this problem is also impossible without engineering support. A model has been provided, defining the role of Engineering in the life cycle of industrial products (using shipbuilding as an example). It confirmed the working hypothesis regarding the parallel-sequential organization of relationships between Engineering and other stages of the life cycle of mechanical engineering products. Attention is focused on the fact that addressing the challenges that arise at each stage is facilitated by digital twins of physical objects. The "lives" of both are completely synchronized, as events occurring during the real-time operation of the offline object and their consequences are automatically reflected in the virtual "twin". This conclusion is of particular significance in the context of applying the concept and corresponding tools of Product Lifecycle Management in practice.

Short-term Fluctuations and Fluctuations in the Development Dynamics of Fixed Assets of Industry

Management and Production Engineering Review (MPER) is a peer-refereed, international, multidisciplinary journal covering a broad spectrum of topics in production engineering and management. Production engineering is a currently developing stream of science encompassing planning, design, implementation and management of production systems. Orientation towards human resources factor differentiates production engineering from other technical disciplines. The journal aims to advance the theoretical and applied knowledge of this rapidly evolving field, with a special focus on production management, organisation of production processes, management of production knowledge, computer integrated management of production flow, enterprise effectiveness, maintainability and sustainable manufacturing, productivity and organisation, modelling and simulation, decision making systems, project management, innovation management and technology transfer, quality engineering and safety at work. Management and Production Engineering Review is published under the auspices of the Polish Academy of Sciences Committee on Production Engineering and Polish Association for Production Management. The main purpose of Management and Production Engineering Review is to publish the results of cutting-edge research advancing the concepts, theories and implementation of novel solutions in modern manufacturing. Papers presenting original research results related to production engineering and management education are also welcomed. We welcome original papers written in English. The Journal also publishes technical briefs, discussions of previously published papers, book reviews, and editorials. Letters to the Editor-in-Chief are highly encouraged.

The Water–Energy–Carbon Coupling Coordination Level in China

The water–energy–carbon (WEC) nexus is a complex, systematic relationship whose influential factors can be interdependent, as well as interactive. Although many action has been taken to achieve the goal of global carbon emission reductions, the disparity and unbalanced among water–energy–carbon systems hundles urban comprehensive development which can not be ignored. Therefore, investigating the water–energy–carbon (WEC) nexus become critical for the global. This study explores the relationship between water utilization, energy consumption, and carbon emissions systematically and take China, one of the largest global carbon emission countries in the world with high energy consumption and unevenly distributed water resources, as an example to investigate coupling coordination model. We selected 2004–2021 data from China’s 30 provinces as our research material, explored them using the entropy weight method, and attempted to study the coupling coordination level of the WEC nexus. Multiple linear regression (MLR) was used to identify the possible influential factors in the WEC nexus. In addition, Spatial correlation of the water-energy-carbon coupling coordination level in 31 provinces and cities has also been researched by Spatial Durbin Model(SDM). The results show that (1) in general, the level of WEC coupling coordination in China is increasing, and the spatial differences between different provinces are large; (2) the lowest level of WEC coupling coordination is mainly distributed in the central region, and the highest level is found in the southwestern region; and (3) water production and hydraulic engineering investment are important factors affecting the coupling coordination of the WEC nexus.

Integration of Technological Preparation of Production into Automated Design Systems

The concept of the development of an integrated system for the design of technological processes for the manufacture of mechanical engineering products is considered. The research relates to the field of automation of technological preparation of production in the development of the technological process of manufacturing a product (part, assembly unit). An algorithm for automated analysis of a three-dimensional product model (CAD model) made by the KIT system (KIT-computer information technology) is proposed to identify and formalize significant product parameters. As a discrete element of the part, a structural element is considered as the basis for choosing the manufacturing technology of the product as a whole. The general functional structure of the system being developed is described, which is necessary for the formation of the product manufacturing route taking into account the production process data structured in the product database. The practical result of the system when introduced into production is a reduction in the cycle of technological preparation for the release of a new product. The system allows you to design route-operational TP for all technological conversions of the enterprise. It is possible to design technologies for a group of parts. There are no restrictions on the size of the TP. The volume of the Database of Technological Design (BDTP) to date is more than 7000 technological processes, including existing production and discontinued products. The number of jobs on the enterprise network for the system is more than 150, the degree of coverage of the technological design system in the main production is 100 %.

Biotechnological Advancements in Streptokinase Production

This article offers a deep analysis of activating streptokinase which looks into the biotechnological challenges and future perspectives. One of the main problems associated with streptokinase is its short half-life, complex production process, and immunogenicity which hinders patients from getting a successful reperfusion. Yet, the development of biotechnology methods that would not face these drawbacks, such as the strategy of recombinant streptokinase production and enzyme engineering theories, is a promise. This paper aims to provide an overview of biotechnological breakthroughs in the production of streptokinase with a focus on discovering long-lasting formulations exhibiting less immunogenicity and in addition the economic viability and scalability of biotechnological production processes. This article also gives the comping image of known purification methods like chromatography, ultrafiltration, and I-A chromatography for the separation and purification of streptokinase. In addition, the author presents the advantage of such suitable production technologies as cell-free production systems and E. Coli system optimization, such as recombinant streptokinase synthesis in Yeast systems. Biotechnology is turning out to be a new area, having a future boom due to the rising innovation and demand that are associated with the prospects revealed by the market trends.

ABOUT THE APPLICATION OF MR MATERIAL FOR NOISE REDUCTION OF MECHANICAL ENGINEERING PRODUCTS

ABOUT THE APPLICATION OF MR MATERIAL FOR NOISE REDUCTION OF MECHANICAL ENGINEERING PRODUCTS

Substrate surface processing in gas vacuum arc discharge

Problem. Preparation of the surface before the deposition of vacuum arc coatings is of great importance, as it affects not only the adhesive properties of the obtained coatings, but also the physical and mechanical properties of the substrate surface layer. The processes of ions interaction with the substrate surface during its ionic cleaning, before the deposition of coatings, have been relatively little studied and are almost not described in the literature. Goal. In this work, some of their features are considered in relation to the surface preparation of materials before the deposition of vacuum arc coatings. Methodology. The nature of the plasma interaction with the substrate material is determined by the ions energy and their flow density, other things being equal. The energy of the ions treating the substrate consists of their initial energy and the energy acquired in the Debye layer adjacent to the substrate when a negative potential is applied to it. The value of the potential at which the processes of condensation or sputtering are balanced is determined mainly by the nature of the vaporized material. When the value of the substrate potential increases, the deposited particles and its material are sputtered. At the same time, atoms on the substrate that are weakly connected to it, various impurities are removed, substrate temperature increases, especially in its surface layers. Results. The work investigates the influence of various metals and gases used to clean the surface of substrates made of cubic boron nitride PcBN and steels on the surface morphology. It was established that the use of gases (argon, nitrogen) for cleaning the surface of dielectric materials, in particular PcBN, showed the best results, which subsequently leads to an increase in the adhesion of the vacuum arc coating to the substrate. Practical value. The obtained results of investigation are of great practical importance. They can be used for the increasing of tool life and productivity of mechanical engineering.

Effect of laser shock peening as a pretreatment on ion nitriding of precipitation hardened stainless steel

Laser shock peening (LSP) is emerging as an advanced technology to improve the fatigue life of engineering products. Also, this can improve wear and corrosion resistance as add-on benefits to the properties of the materials. In the present investigation, a systematic understanding of the hybrid surface treatment that combines LSP with ion nitriding, also known as plasma nitriding (PN) of precipitated hardened (PH) stainless steel was conducted to improve the effective case hardening layer. The effect of input parameters such as laser spot diameter, the number of superimposed layers, and overlap rate was investigated on the performance characteristics, which include surface morphology, microhardness, and the change in microstructure after the proposed treatment. The surface characterization results reveal that an 80% laser overlap rate modified the surface roughness of PN samples owing to higher surface roughness values induced by ablation during the LSP treatment. The microhardness and optical microscopy (OM) results revealed an increase in the effective hardening layer thickness of about 115% for a 40% overlap rate owing to the absence of blind spots. In addition, XRD analysis revealed the presence of Fe4N and CrN compounds on the surface of the PN samples. Scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS) elemental mapping reveals the presence of a nitrogen-rich phase in the effective hardened layer and increased effective hardened layer thickness owing to grain refinement of LSP pre-processing.

Development of sustainable thermal insulation based on bio-polyester filled with date pits

Date palm pit (DPP)-filled poly (-hydroxybutyrate) (PHB) composites were prepared, evaluated, and characterized to determine their thermal insulation ability. Thermal conductivity values ranged between 0.086 and 0.100 W/(m·K). At a maximum filler concentration (50% (w)), the specific heat capacity and thermal diffusivity were 1 183 J/(kg·K) and 0.068 9 mm2/s, respectively. The DPP increased the thermal stability, and the highest compressive strength obtained was 80 MPa at 30% filler content. The PHB-DPP composites exhibited promising water absorption (less than 6%) and tensile strength (6–14 MPa). Date-pit-based PHB composites could be used in sustainable building engineering and cleaner production.

Theoretical Contribution and Critical Analysis of Indian Dairy Sector: A Review on Sustainable Advantage in Milk Supply Chain

A milk supply chain (MSC) is an operational framework that integrates dairy farmers, suppliers, milk outlets, retailers and users to deliver the milk from the producer to end users. Domestic consumption of milk from 17.0 million tonnes (MT) in the year 1950 increased to 221.6 MT in the year 2022−2023 (Department of Fisheries, Animal Husbandry Dairying, 2023). Now the Indian dairy Sector has become the largest milk production country across the globe. This article aims to review an in-depth analysis of the selected literature corpus, providing a better understanding of a subject domain. More than 300 articles or research papers were retrieved from various journals of production engineering, clinical and medical journals on pertinent topics through academic literature and publishers and were systematically studied and classified. It also gives better insights about publications concerning possible issues related to the number of themes, sub-themes covered in individual journals, future scope, the methodology adopted, number of methods used and publication trends. The literature suggests that milk intake helps prevent various health ailments, contrary to other non-epidemic diseases in humans. Inclusive authors discuss the literature on the trade-off between sustainability and risks or challenges in the MSC.

Analisis Efektivitas Gas Turbine Generator pada PT Mitra Energi Batam

PT Mitra Energi Batam is one of the Gas Power Plants (PLTG) and regulates the electricity supply of Batam city with PT PLN-Batam. According to the tabulation of PT Mitra Energi Batam's production data from September 2022 to September 2023, the rolls-royce Gas Turbine Generator production engine has a downtime value of 805.60 hours. The purpose of the study is to find out the factors that cause high downtime and know how to minimize it. Using the proposed Overall Equipment Effectiveness method as a way to measure Losses due to production disruptions by taking six big loss and Fishbone diagrams to find the cause and effect of Losses that cause failure of machine or equipment operations. The results of the study of the highest OEE value in August 2023 were 98.54%, the lowest OEE value was in April 2023 which was 0%, the cause was severe damage to the power turbine blade which required engine replacement, but was constrained by the time of the engine spare delivery process. The six big Losses factor that contributed the most to the OEE value was idling minor stoppage with an average value of 8.83% and equipment failure Losses with an average value of 8.81%.

Virtual modelling aided safety assessment for ductile structures against high-velocity impact

This paper introduces a virtual modelling-aided computational analysis framework for assessing the safety of a ductile engineering object against high-velocity impact. By evaluating the data feedback continuously collected from the working site, the presented Virtual Modelling Aided Safety Assessment (VMASA) scheme is competent to effectively report the current safety level of the engineering object. The safety level (alternatively known as the reliability), of the impacted system can be quantified by using the first-passage theory. By considering various mercurial factors that are influencing the high-velocity impact for ductile materials, in this research, a new machine learning-aided virtual modelling technique as the clustering extended support vector regression (CXSVR), is implemented to evaluate the capacity of the engineering product against different conditions. Also, the John-Cook failure model is transformed into a random format to simulate the dynamic response of the engineering product against high-velocity impacts. A new T-spline kernel has also been developed within the CXSVR scheme. By using the VMASA, the inherent limit state function can be quantitatively certified by analysing the relationship between the system inputs and outputs. Both experimental and numerical investigations are implemented to demonstrate the accuracy, practicability, and efficiency of the proposed safety assessment framework.

Physicochemical Characterization and Reverse Engineering of Reference Market Product for Generic Formulation Development

The present study aimed to carry out reverse engineering of reference innovator product (Xarelto® 20 mg film-coated tablets) to decode the critical scientific information that is needed for successfully develop a stable and bio-equivalent generic formulation of rivaroxaban 20 mg film-coated tablets. The innovator product characterization was done followed by deformulation of the reference product (Xarelto® 20 mg film-coated tablets) to quantity critical excipients to decode the innovator product’s quantitative composition and to identify the manufacturing process used to manufacture the innovator product. The particle size distribution and particle size distribution of rivaroxaban API used in the innovator product were performed using hot-stage microscopy. The polymorphic form of rivaroxaban API used was identified using DSC and XRD methods. Visual, tactile and microscopic evaluation of granules obtained from crushed tablets of the innovator product revealed that the granulation process was used in the manufacturing of the innovator product. It was further concluded that the manufacturing process is wet granulation process due to the presence of organic solvent in the innovator core tablet. Physical evaluation was done to know the tablet weight, shape, size, coating appearance, tablet hardness and disintegration time. Chemical analysis was performed to record the drug content, percentage impurity and dissolution profile. The decoded information can serve as a reference for a faster and bioequivalent generic formulation development with reduced cost, time, effort, and a higher success rate

Microstructure and mechanical properties of AlTiCrFe and AlTiCrCu alloys processed by Laser Powder Bed Fusion

Additive manufacturing (AM) of aluminium alloys urges new alloy compositions to meet the requirements for high-strength and processability of the engineering products. This research focuses on the development of two Al alloys, AlTiCrFe and AlTiCrCu, with the goal to exploit the potential of transition element additions for grain refinement and increasing strength. Robust processability and build rates are reached for the two alloys, with no cracks and high density up to 99.8%. AlTiCrFe shows a bimodal microstructure, with the presence of ultrafine and fine grained zones, that can be attributed to a dual precipitation stage. Al3Ti precipitates are present in the ultrafine grained zone, confirming the effectivity of Ti as grain refiner. In addition, Al6Fe precipitates are present in the fine grained region, as a consequence of the later precipitation stage. AlTiCrCu, on the contrary, shows an homogeneous ultrafine grain microstructure, with Cu segregating at the grain boundaries. SAED analyses confirm the phase identification with the presence of high volume density cubic precipitates of Al3Ti_L12. AlTiCrFe and AlTiCrCu exhibit a yield strength value of 363 ± 1 MPa and 340 ± 1 MPa, respectively. These findings indicate that the two alloys open up new possibilities for a novel class of aluminium alloys for AM, leveraging the incorporation of transition elements, which aids in achieving strength during the as-built state, eliminating the requirement for supplementary heat treatment.