Remanufacturing Of Components Research Articles

Mixture reliability analysis of a product consisting of new and remanufactured components

PurposeThe rapid increase in importance of the remanufacturing operation in the present scenario is just because of its ability to retrieve the functional value of the End-of-Use or End-of-Life products which is as good as the original product. However, customers are still concerned about the reliability of the remanufactured product which is considered as one of the major problems in the area of remanufacturing. The purpose of this paper is to study and analyse the behavioural pattern of the mixture failure rate of a remanufactured product.Design/methodology/approachIn order to analyse the behavioural pattern of the mixture failure rate, different proportions of new and remanufactured products are mixed. In this paper, a two-parameter Weibull distribution is used to observe the mixture failure rate characteristics. Also, the mixture failure rate of the remanufactured product is evaluated under two conditions, that is when the shape parameter of new and remanufactured components is the same and when the shape parameter values are different.FindingsFrom the analysis, it is observed that the mixture failure rate is always decreasing in nature when the shape parameter values are same. In that case, the value of the mixture failure rate depends only on the proportion of the new components. When the shape parameter values are different, the mixture failure rate characteristics depend upon the shape parameter value of the remanufactured product.Originality/valueThe results of the research can be applied to any remanufactured automotive product. This study also shows the behavioural characteristics of the mixture failure rate of a remanufactured product at different mixture proportions.

A comprehensive investigation into the mechanism of belt wear influencing heat partition ratio through force and temperature analysis during robotic belt grinding Inconel 718

Robotic belt grinding serves as a pivotal method for achieving precision machining in re-manufacturing of aeroengine components made of Inconel 718. During grinding, the heat partition ratio (Rw) significantly influences the quality of the machined workpiece, which is affected by many grinding parameters. Belt wear, which is an unavoidable phenomenon during grinding, can substantially impact Rw. However, previous research works have paid little attention to the effect of belt wear. In this study, the variation of Rw with belt wear is comprehensively investigated by observing heat generation and heat input. Firstly, the belt wear behaviors are qualitatively and quantitatively described. Then, the impact mechanism of belt wear on force-related characteristics is analyzed to clarify the change rule of heat generation. Following this, the variations of temperature-related characteristics during belt wear are examined. Meanwhile, the heat input is obtained by the combination of finite element analysis and the inverse heat method. Finally, a rapid growth followed by a gradual decrease pattern of Rw with belt wear is derived and analyzed. The findings in this paper lay a crucial foundation for controlling the grinding quality during robotic belt grinding Inconel 718.

Toward developing remanufactured Ti6Al4V alloys with high fatigue crack growth resistance by in-situ cooling during laser remanufacturing

The fatigue performance of remanufactured titanium alloy blade components has garnered significant attention in recent years. The repaired titanium alloy components using the direct energy deposition (DED) method exhibit structural differences, leading to an inhomogeneous microstructure that directly impacts the service life of the remanufactured component. The work presented here aimed to investigate novel approaches for enhancing the resistance to crack propagation and to gain a deeper insight into the fatigue crack propagation characteristics of the Ti6Al4V remanufactured interface with an inhomogeneous microstructure. The research focused on analyzing the microstructure evolution and fracture properties of remanufactured components using in-situ cooling. The results indicate that in-situ cooling has the potential to decrease the anisotropy of the repaired zone (RZ) and enhance the resistance to crack propagation in the heat-affected zone (HAZ) and base metal (BM). The high cooling rate associated with the in-situ cooling can elevate the presence of high-angle grain boundaries (HAGBs) in the RZ, diminish the phase transformation between the HAZ and BM, and decrease the size of the secondary α phase. The research contributes to a deeper comprehension of fatigue crack propagation in remanufactured components and provides a pathway for the improvement of fatigue performance of remanufactured titanium alloy.

Preparation and mechanical properties of LC cladding layer for friction parts

Introduction: In the actual engineering operation, there are some components facing high frequency friction, which have high damage rate and poor direct replacement benefit. In order to achieve sustainable resource utilization and more effective component remanufacturing, research was conducted on the cladding layer of friction components.Methods: Based on the idea of remanufacturing, taking 42CrMo as the raw material of engine piston pin hole, laser cladding technology and ultrasonic rolling technology are used to prepare the cladding layers of Fe, Ni and Co three different substrates.Results and Discussion: The experimental results showed that the Co based cladding layer with ultrasonic rolling technology performed best. The surface roughness reduced by 1.02 μm, only 0.14 μm. The microhardness increased by 101.39%, with 795.38 HV. The friction coefficient was 0.051. The friction rate at high temperature decreased by 85.71%, and it was 1.2%. The friction at high temperature was reduced by 79.24%, with 0.9%.Conclusion: Co based cladding layer combined with ultrasonic rolling technology shows the best performance, which can effectively realize the remanufacturing of engine piston pin hole, providing technical reference and data support for the remanufacturing process of high-frequency friction components.

Microstructure and Properties of FeAlC-x(WC-Co) Composite Coating Prepared through Plasma Transfer Arc Cladding

Tungsten carbide (WC) is widely used in wear-resistant parts due to its excellent wear resistance. Iron-based alloys are used in the repair and remanufacturing of engine components due to their good compatibility with iron-based workpieces. In order to enhance the wear resistance of engine components in service under abrasive conditions, composite coatings have been prepared for cast iron engine components by adding WC-Co to iron-based powders. This study investigates the microstructure and wear properties of composite coatings of iron-based alloys reinforced with different contents of WC particles. The composite coatings mainly contained γ-Fe, α-Fe, WC and Fe3W3C. With the addition of the WC-Co strengthening phase, the average hardness of the FeAlC-x(WC-Co) composite coatings increases from 524 HV0.2 to 814 HV0.2. Wear test results showed that when the WC addition was 20%, it had the lowest frictional coefficient of 0.5 and the lowest wear mass loss of 1.3 mg. Compared to the original Fe-based alloy coatings, the WC particle-reinforced FeAlC composite coatings display improved wear resistance on a reduced friction basis, mainly benefiting from the high wear resistance of the graphite solid lubrication phase and carbides in the cladding.

A brief review on industrial remanufacturing of structural and functional components: Wire-Arc Additive Manufacturing Technique

Many industries rely heavily on the availability and reliability of complex structural and functional components to execute operations efficiently. However, failure of components during service occurs due to exposure to unfavourable operating conditions, causing wear and tear of these components. The damage will result in costly downtime and potential safety hazards. Repairing, remanufacturing and refurbishing these complex parts is critical. Restoring broken structures into operation ensures the smooth operation of the industry, thus preventing losses. Conventionally, repairing parts poses a challenge. However, Wire-arc additive manufacturing (WAAM), which employs the welding principle, has revolutionised component repairing or remanufacturing. This paper reviews the literature on manufacturing complex parts, repair, remanufacture and refurbishment of broken structural and functional parts using WAAM technology. This paper also highlights the various strategies and techniques currently used to improve the quality of WAAM 3D printed parts. The study further covers the immense potential of WAAM in revolutionising the remanufacturing and repair of components. The review study has provided a roadmap for future research and development to take full advantage of this new cutting-edge manufacturing technology.

Optimization of the Flow of Parts in the Process of Brake Caliper Regeneration Using the System Dynamics Method

Remanufacturing processes are one of the key pillars of the so-called closed-cycle economy. Unfortunately, the design and organization of such processes pose a significant problem, due to, among other things, the high variability of the process as a consequence of both the degree of wear and tear and the quality of the remanufactured components. This article presents a method for optimizing the flow of the brake caliper remanufacturing process in the MTO (make-to-order) model. For the optimization process, the system dynamics (SD) method, which belongs to a group of simulation methods, was used. The developed model allows, in particular, the prediction of the number of components at the input to the regeneration process and the method of defining the size of the transport batch and evaluating its impact on the length of the production cycle of the batch of regenerated products. The issues of staffing management at individual positions and the organization of transport operations with variable production batch sizes were also discussed. The provided experiments have shown that reducing the size of the transport batch contributes to shortening the production order execution time, both with standard and increased staffing.

Analysis of global brands’ green procurement strategy: Co-opetitive local sourcing vs. overseas sourcing under delivery disruption

Recently, black swan events, such as the Covid-19 pandemic and the Russia-Ukraine war, have caused disruptions for the local brand with overseas procurement (BOP) who traditionally purchase remanufactured components globally. This induces the BOP to find a local alternative supplier, although the remanufactured components without supply disruption can be of high price, and the local supplier has a self-branded business. In this paper, we consider a BOP's strategic sourcing decisions from a local supplier with self-branded end products (LSP) who sells remanufactured components. We focus on the BOP's incentives toward such a “co-opetitive” relationship and the LSP's willingness to sell remanufactured components to the BOP. We find that having two suppliers may induce a component price war but the component price will not become too low when the probability of overseas supply disruption is high. Interestingly, we find that the BOP will allocate a low proportion of component purchasing orders to the LSP when it faces a high probability of overseas supply disruption. In contrast, the LSP has the incentive to sell remanufactured components to the BOP when the probability of overseas supply disruption is in a moderate range. If the BOP's remanufactured component quality requirement is high, or the probability of overseas supply disruption is low, the LSP might even have a profit loss when selling components to the BOP.

Will you stick to a high-quality collecting standard? order fulfillment vs. limited supply in diseconomy-cost-mattered remanufacturing operations

Consider a remanufacturing system consisting of a brand, a new component supplier (Supplier N), and a remanufactured component supplier (Supplier R). The brand priorly purchases remanufactured components and then assembles them into final products, while Supplier R collects the end-of-life products with random residual quality and then produces them to be “as good as new” components at a diseconomy cost based on the residual quality. Supplier R has the option to provide order fulfillment commitment before production (Scenario O), or, do not provide such a commitment, reserving the right to limit the proportion of the orders to save production costs although it may drive the brand to emergently purchase the new components (Scenario L). Specifically, in Scenario L, Supplier R can set a strict residual quality standard which saves the remanufacturing cost and constrains the brand’s order quantity. We reveal that constraining the brand’s order quantity will not be the optimal choice for Supplier R, because the overreliance on the limited-supply threat will distort Supplier R’s wholesale price decision, resulting in significant profit loss. However, the supply chain system can perform better with the quantity constraint, because it concentrates the channel power in the hands of a single decision maker, which enables the decisions made more closely to the first-best level.

Research on the Impact of New Parts Price Increase on the Stability of Closed-Loop Supply Chain

In the closed-loop supply chain system of component remanufacturing, new parts suppliers are likely to be affected by certain factors that lead to sudden increases in supply prices, and this sudden increase in new parts prices may trigger the chain collapse of the closed-loop supply chain system and impact the stability of the closed-loop supply chain. Therefore, this paper combines closed-loop supply chain theory, evolutionary game theory, and system dynamics theory, which are internalized to construct a complex system model. Furthermore, the impact of different price increases of new parts on the stability of the closed-loop supply chain is analyzed through scenario simulation. The results show that a 25% increase in the price of new parts will delay the time for remanufacturers and retailers to reach a stable state of product flow, reduce the profitability of remanufacturers and retailers, and inhibit the willingness of remanufacturers to carry out high-green production in the early stage. A 50% increase in the price of new parts can break the closed-loop supply chain from the remanufacturer, severely undermining the stability of the closed-loop supply. According to the simulation results, this paper presents a timely government dynamic reward and punishment optimization scheme for remanufacturers to improve the tolerance level of the closed-loop supply chain for the price increase of new parts and to provide a reference for enhancing the stability of the closed-loop supply chain and optimizing the government supervision strategy.

SALE OF SECOND-HAND AND REMANUFACTURED COMPONENTS OF CONSTRUCTION EQUIPMENT: AN EMPIRICAL STUDY OF USER PERCEPTION IN ANDHRA PRADESH

The construction industry plays a pivotal role in shaping infrastructure and development, contributing significantly to economic growth and urbanization. In recent times, the sector has been seeking innovative ways to maximize efficiency, reduce costs, and promote sustainability. One promising avenue is the exploration of second-hand and remanufactured components for construction equipment, which has the potential to bring about substantial benefits for both businesses and the environment. This study explores the utility, availability, and compatibility of second-hand and remanufactured components for construction equipment, aiming to determine their potential to enhance machine productivity and contribute to revenue growth. The research methodology employs quantitative analysis to collect data from second-hand dealers across Andhra Pradesh. Additionally, consumer behavior is observed during the purchase of second-hand components, with a focus on relevant focus groups in this region. The study reveals that customer awareness and understanding of the technical aspects, usability, price comparisons, and compatibility of second-hand construction equipment parts are limited. Due to the lack of accessible testing facilities for remanufactured parts, customers often rely on their instincts and past experiences. Despite this, customers generally hold a positive perception of purchasing second-hand or remanufactured components. Furthermore, the high costs and scarcity of original parts at authorized dealerships drive customers towards buying components from the second-hand market.

Towards autonomous adaptive disassembly of permanent-magnet synchronous motors with industrial robots

On the way to a circular economy, it is necessary to develop new end-of-life (EOL) solutions for critical components and materials. Due to the electrification of personal transportation a rise in production numbers of electric motors is to be expected, necessitating the development of EOL solutions for such motors. Such solutions, like the reuse or remanufacturing of components, necessitate in term the disassembly of the motors. To economically facilitate such disassembly operations, new automation solutions need to be developed. One possible approach is the disassembly with industrial robots coupled with process-specific end effectors. This makes it possible to flexibly execute a variety of disassembly processes without the need for cost-intensive specialized machines. However, due to the inherent uncertainties of products returning from the field, an ideal disassembly procedure cannot be assumed. To address this issue, in this paper we present a new concept for the autonomous adaptive disassembly of permanent-magnet synchronous motors (PSM) with industrial robots. The system will be able to plan possible disassembly sequences while taking different process alternatives for individual steps into account. During the actual disassembly the system will check the outcome of the individual steps, as well as the resulting state of the motor to be disassembled. In case of an unsuccessful operation the system will then be able to autonomously adapt to the actual situation and generate an alternate disassembly sequence utilizing alternative processes. This paper presents the necessary infrastructure, both in hard- and software, to achieve this autonomous adaptability for the example of PSM, thereby making a contribution on the way to intelligent automatic disassembly systems and the change to an economic and ecological circular economy.

Remanufacturer’s downstream encroachment and incumbent brand’s order shifting in Pareto improvement of economic and environmental sustainability

In the recent years, supported by Industry 4.0 techniques and government’s strict quality supervision, remanufactured components can be of high quality “as good as new”. This encourages the supplier of remanufactured components to develop self-branded business and encroach on downstream market to compete with the incumbent brand. In this paper, we build a three-player game-theoretical model to investigate the pros and cons of the remanufactured component supplier’s (Supplier R’s) downstream encroachment, under the incumbent brand’s single sourcing and order shifting strategies, respectively. We formulate Supplier R’s nonlinear remanufacturing cost depending on the random quality of the collected components, based on which we find the incumbent brand’s weak brand advantage will induce Supplier R’s downstream encroachment. We also find that the incumbent brand’s order shifting helps save Supplier R’s remanufacturing cost and hence, limits Supplier R’s downstream encroachment. Regarding the environmental sustainability, we use two indexes to measure it and show that there exist opportunities of Pareto improvement of economic and environmental sustainability for the supply chain system.

Remanufacturing of 3D-Damaged Components Based on LDED Technology

Remanufacturing of 3D-Damaged Components Based on LDED Technology

Special Issue on Advancements in Laser-Based Additive Manufacturing Technologies

As a unique and powerful heat source, lasers are very important for the surface modification, re-manufacturing, and direct fabrication of 3D components [...]

Innovative Technologies for Sustainable Recycling and Re-manufacturing of Materials and Components

The increasing demand for sustainable manufacturing and recycling processes has driven the development of innovative technologies to address the challenges associated with the re-manufacturing and recycling of materials and components. This research paper presents a comprehensive review of the latest advancements in sustainable recycling and re-manufacturing technologies, with a focus on their potential to reduce environmental impact, enhance resource efficiency, and promote circular economy principles. We explore cutting-edge technologies such as additive manufacturing, smart disassembly, and advanced material separation techniques, which have shown promise in enabling efficient recycling and re-manufacturing of materials and components. Additionally, we investigate the integration of digital technologies, including the Internet of Things (IoT), machine learning, and blockchain, to optimize recycling and re-manufacturing processes. Our analysis reveals that these technologies can significantly improve the quality and efficiency of recycled and re-manufactured products, reduce waste generation, and minimize energy consumption. Furthermore, we discuss the potential economic and environmental benefits of adopting these technologies, as well as the challenges and barriers to their widespread implementation. The findings of this research provide valuable insights for policymakers, industry stakeholders, and researchers working towards the development and adoption of sustainable recycling and re-manufacturing technologies.

Towards a Circular Economy: Challenges and Opportunities for Recycling and Re-manufacturing of Materials and Components

The transition towards a circular economy is a critical step in achieving sustainable development and mitigating environmental degradation. This study explores the challenges and opportunities associated with recycling and re-manufacturing of materials and components within the context of a circular economy. We conducted a comprehensive analysis of the current state of recycling and re-manufacturing technologies, identifying key barriers such as material degradation, contamination, and technological limitations. We also examined the potential for innovative solutions, including advanced material characterization techniques, additive manufacturing, and digital twin technologies, to address these challenges. Our findings reveal that the integration of these technologies can significantly enhance the efficiency and effectiveness of recycling and re-manufacturing processes, enabling the recovery of high-quality materials and components. Furthermore, we highlight the importance of establishing a robust regulatory framework and incentivizing industry participation to accelerate the transition towards a circular economy. This study provides valuable insights for policymakers, industry stakeholders, and researchers working towards the development and implementation of sustainable materials management strategies. By addressing the challenges and harnessing the opportunities identified in this study, we can pave the way for a more sustainable and resource-efficient future.

Remanufacturing Process Optimization - Introducing Dynamic New Part Infill to Increase the Utilization Rate of Remanufactured Components for Multi-Variant Cores

Climate change, resource scarcity, and the current energy crisis demand fundamental change to overcome future problems. The Circular Economy represents a sustainable process transformation by closing value chain loops. Remanufacturing is one method that extends the life cycle of materials by returning worn-out products (cores) to the manufacturer to produce like-new remanufactured products. In detail, cores are disassembled into core components, which are inspected, sorted out, cleaned, remanufactured, and reassembled into a remanufactured product. The challenge is that multiple components in different conditions must be combined into one remanufactured product because only a certain quantity of core components can be used for remanufacturing due to quality criteria (yield rates). The cores’ uncertain quantity and different yield rates of core components limit the maximum amount of remanufactured products, and the component with the lowest quantity acts as the bottleneck. In other words, although the rest of the parts have been remanufactured through costly and time-consuming processes, they remain unused, and the output of newly remanufactured products is obstructed. Such inefficiencies must be reduced to increase efficiency and create a sustainable process. This paper proposes a problem formulation and a concept that optimizes the utilization of remanufactured components in remanufacturing processes by modifying the bills of material of remanufactured products. The concept implements a dynamic infill of new parts, applying a dynamic mixture of new and remanufactured components to increase the number of remanufactured products while following technical and process restrictions (e.g., production and material planning, quality requirements). The utilization problem is identified as a combinatorial optimization problem and translated into a general multidimensional knapsack problem. The resulting knapsack problem is optimized with a meta-heuristic to find a satisfying solution for the utilization of remanufactured components. Following the case study methodology, the concept is developed, tested, and validated with an automotive OEM.

Environmental and Economic Benefits of Closed-Loop Supply Chains: A Case Study of Recycling and Re-manufacturing of Materials and Components

In an epoch marked by escalating apprehensions regarding the depletion of resources and the destruction of the environment, the notion of closed-loop supply chains (CLSCs) has garnered recognition as a viable and sustainable resolution. The present study examines the interdependent connection between environmental conservation and economic advancement by analysing the recycling and re-manufacturing procedures inside closed-loop supply chains. This paper utilises an extensive case study to investigate the crucial significance of closed-loop supply chains in the processes of recycling and re-manufacturing materials and components. Through a comprehensive examination of the complex relationship between environmental benefits and economic advantages, this study reveals the diverse and nuanced effects that arise from the implementation of closed-loop systems in contemporary supply chain management. The study utilises a mixed-methods methodology, incorporating both quantitative and qualitative studies. The study used quantitative data to measure the extent to which recycling and re-manufacturing processes contribute to the decrease of raw material usage, energy consumption, and greenhouse gas emissions. The study highlights the capacity of closed-loop supply chains to promote circular economy concepts, reduce waste output, and mitigate the environmental impact of companies. This study provides valuable insights that may be utilised by practitioners, politicians, and corporations to make well-informed decisions that prioritise both environmental protection and economic growth in their supply chain strategy.

Additive manufacturing of titanium alloys – Enabling re-manufacturing of aerospace and biomedical components

This paper describes the state of the art of additive manufacturing of Titanium alloys especially in the high-value-materials industries such as aerospace and biomedical. In such industries, the high value components like aerospace gas engine turbine blades or the coronary angioplasty stents in biomedical industry call especially for the re-manufacturing vision that is only recently enabled by additive manufacturing methodologies. This paper starts by describing the two most common additive manufacturing (AM) methods as characterized by their input material forms: powder and wire. Using examples, it then provides an assessment of the status of these methods as regards to their maturity as production ready processes. Following this, the principal issues that must be addressed before AM can achieve this status are outlined. Perhaps the most critical one among these is development of a rapid qualification method for AM produced components. In this regard, the current method for qualifying different classes of components is outlined. Some suggestions for reducing the time required for qualification are made. Significant benefits of AM are described including part count reduction and the use of design synthesis to achieve significant component weight reduction. Two low risk examples of this are described herein. The Direct Energy Deposition (DED) model is highlighted especially in its role to enable the Re-Manufacturing vision for high-value structural components such as in aerospace and biomedical industries. This paper concludes that there are numerous opportunities for incorporation of components made by AM once some of the issues described are effectively addressed.