Manufacturing Tools Research Articles

Enhancing sustainability in manufacturing: A methodology for quantitative assessment and improvement of life-cycle design conflict managing capabilities

In response to the escalating need for sustainable production and consumption, manufacturers increasingly adopt Life-Cycle Design (LCD) to address environmental and social challenges. However, the complex nature of cross-organizational collaborations in LCD often leads to conflicts among stakeholders, hindering effective implementation. This study aims to address this gap by proposing a comprehensive method framework for characterizing, evaluating, and improving manufacturers' LCD Conflict Managing Capabilities (LCD-CMC). The study begins by explicating conflicts in LCD and introduces the People-Process-Technology Framework. This framework serves to comprehensively characterize LCD-CMC and to break down the abstract LCD-CMC concept into specific elements in three dimensions. Subsequently, a Maturity Model is developed for quantitatively evaluating LCD-CMC, utilizing a hybrid method integrating Decision-making Trial and Evaluation Laboratory (DEMATEL) and Analytical Network Process (ANP). DEMATEL enables the identification and quantification of interrelations among multiple criteria of the LCD-CMC evaluation system, while ANP facilitates the weighting of each criterion based on its significance. Together, these methodologies enable a comprehensive assessment of the maturity level of LCD-CMC. Building upon this foundation, a systematic approach for generating improvement strategies for LCD-CMC is proposed, leveraging the Total Adversarial Interpretive Structure Model (TAISM) to analyze the inter-relations among contributing capability elements. TAISM offers a practical approach to generating robust improvement strategies, ensuring effective and efficient improvements in LCD-CMC over time. Through a case study involving a prominent Chinese machine tool manufacturer, the feasibility and efficacy of our framework are demonstrated, providing valuable insights into potential improvements. Overall, this paper offers valuable insights into managing conflicts in LCD, providing a structured methodology for evaluating and improving LCD-CMC. By leveraging advanced models and methods, it contributes to addressing LCD conflicts and enhancing collaboration in LCD implementation. Furthermore, it contributes to enriching the knowledge of Life-Cycle Design in the context of conflict management, ultimately advancing sustainable production and consumption practices.

Virtual instrumentation-based data collection and analysis for CNC machining process

Using Computer Numerical Control (CNC) machine tools in manufacturing is crucial for exact processing materials. The quality of the machined product heavily relies on the machine's condition. Therefore, monitoring and assessing the machine's status is essential to ensure product quality and enhance its lifespan. However, due to cost, space, and technical limitations, only a few physical variables, such as acceleration, force, displacement, acoustic radiation, temperature, and flow conditions, can be measured. Efficient transfer and extraction of these data are critical for monitoring machine status using statistical methods or valuable signatures. Traditional measurement instruments are complex and numerous, whereas measurement and analysis systems based on virtual instrumentation technology collect necessary data from sensors and data acquisition cards, meeting the needs of test analysis. Virtual instrumentation utilizes computer hardware resources, modularization hardware, and software systems for data analysis, communication, and operation interface, providing greater versatility, flexibility, compatibility, and repeatability. Previous research has shown successful attempts at developing LabVIEW-based systems for monitoring CNC milling machines and analyzing cutting parameters and forces. This project aims to collect and process data from the CNC machining process. The main objectives include writing a LabVIEW software program, recording data from CNC machine programs using the provided hardware (myRIO) and LabVIEW program, processing the data using MATLAB software, and analyzing and discussing the obtained results. The report consists of four parts, starting with an introduction to the project's background and literature review, followed by a description of the project steps, methods, experiments, and data processing. The processed data graphs will be presented and discussed, and recommendations for future research will be provided before concluding with a study summary.

Design, motion-planning, and manufacturing of custom-shaped tools for five-axis super abrasive machining of a turbomachinery blade type component

Free-form surfaces generated by non-uniform rational B-splines (NURBS) are evolving to face turbomachinery component requirements, such as turbine blades to enhanced efficiency. Super abrasive machining (SAM) is presented as a potential process for high-added value components using custom-shaped tools to be adapted to any surface. The adaptability and flexibility of these tool concepts are specifically designed to fit these complex surfaces. This paper presents an innovative manufacturing approach for blade type components using a custom-shaped tool designed through an optimization process that simultaneously optimizes both the shape of the tool and its motion. The proposed method with SAM finishing using a custom-shaped tool is compared against a standard tool and traditional machining process. The result obtained on the blade test case shows that the custom-shaped tools need fewer paths, yet produce more accurate surface finish.

Development and performance of additively manufactured Tungsten carbide tool insert: An application of additive manufacturing towards flexible and customized machining

Carbide tool manufacturing is proposed by Additive Manufacturing to introduce flexibility and customization in machining industries. Development and performance of the additively manufactured (AM) tool is reported. Crack-free deposition of 88 wt%WC was obtained at 800 °C substrate-preheat temperature. An insert was dimensioned and progressive turning of Aluminium 6061-T6 alloy was performed upto 65 min at various cutting speeds. Cutting force, chip-reduction-coefficient, shear angle, built-up-edge, flank wear, crater wear and tool life of AM tool were analysed. The flank wear of AM tool was observed as 0.219 and 0.314 µm respectively at cutting speeds of 120 and 140 m/min after 65 min of machining. The cutting performance of the AM tool was then compared with that of K20 conventional cutting tool insert.

Implementing Additive Manufacturing in Orthopedic Shoe Supply Chains—Cost and Lead Time Comparison

Background: Additive manufacturing (AM) for patient-specific medical care products offers great opportunities. However, evidence about the supply chain (SC) performance impact based on empirical data is limited. Methods: In this case study, we gathered real-life data about a traditional manufacturing orthopedic shoe SC and developed future scenarios in which AM is introduced at various points and with different degrees of penetration in the SC. Results: Presently, AM can only replace traditional manufacturing of tools and shoe components at a higher total cost. However, with maturing technology, the complete AM production of orthopedic shoes is expected to become feasible. Theoretically, that could disrupt existing SCs, eliminating 70% of the SC steps, improving SC lead time by 90%, and altering SC relations. However, certain thresholds currently prevent disruption. Specifically, the AM of complete orthopedic shoes has to become possible, manufacturing prices have to drop, and traditional craftsmanship has to be integrated into the digital product design. Conclusions: A framework for transition pathways, including directions for future research, is formed. Findings provide valuable insights for scholars and decision makers in the patient-specific products industry, health insurance providers, and healthcare policy makers to be better prepared by adjusting SC designs, relationships, and remuneration programs while AM technology develops towards maturity.

Comparative analysis of modern technologies of additive production

In today's conditions, 3D printing is used to create unique models, prototypes, and equipment necessary for conducting experiments and studying various phenomena and processes, for the rapid prototyping of various parts and devices in scientific and engineering research. 3D printing technologies are actively used to create individual medical implants, prostheses, and organ models for training and planning operations, which significantly improves the quality of medical care. In the aerospace and automotive industries, additive manufacturing is used to create lightweight and durable parts helping to reduce weight and improve vehicle efficiency. The use of additive manufacturing methods, technologies, and tools allows you to check and test designs and concepts before mass production. In this work, a detailed analysis of various existing 3D printers is carried out depending on the tasks, and modern technologies of additive manufacturing are investigated depending on the set goals and scientific and applied tasks. Such technologies include Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, and Digital Light Processing. In the work, a comparative analysis of these technologies was carried out according to various criteria, such as principle of operation, materials, resolution, surface finish, accuracy, speed, strength, application, cost, complexity of parts, and post-processing. For each technology, the advantages and disadvantages of its use are determined depending on the goals and objectives. It should be noted that some materials may not be suitable for printing complex parts or require additional support during the printing process. This can lead to complexity in the processing of products and increase the time and costs of printing. Improper selection of materials for 3D printing can be harmful to the environment or human health when used incorrectly. For example, some plastic materials may emit toxic elements or have low biodegradability. Also, using excess expensive material unnecessarily can increase the cost of the project. Keywords: additive manufacturing, 3D printing, additive manufacturing technologies, Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, Digital Light Processing.

Cooperative Vehicle Infrastructure System or Autonomous Driving System? From the Perspective of Evolutionary Game Theory

In this paper, we explore the trade-offs between public and private investment in autonomous driving technologies. Utilizing an evolutionary game model, we delve into the complex interaction mechanisms between governments and auto manufacturers, focusing on how strategic decisions impact overall outcomes. Specifically, we predict that governments may opt for strategies such as constructing and maintaining infrastructure for Roadside Infrastructure-based Vehicles (RIVs) or subsidizing high-level Autonomous Driving Vehicles (ADVs) without additional road infrastructure. Manufacturers’ choices involve deciding whether to invest in RIVs or ADVs, depending on governmental policies and market conditions. Our simulation results, based on scenarios derived from existing economic data and forecasts on technology development costs, suggest that government subsidy policies need to dynamically adjust in response to manufacturers’ shifting strategies and market behavior. This dynamic adjustment is crucial as it addresses the evolving economic environment and technological advancements, ensuring that subsidies effectively incentivize the desired outcomes in autonomous vehicle development. The findings of this paper could serve as valuable decision-making tools for governments and auto manufacturers, guiding investment strategies that align with the dynamic landscape of autonomous driving technology.

Three-dimensional mechanical characteristics analysis of double-shoulder tool joint under complex loads

Taking a new type of special threaded drill pipe joint as the research object, a 3D nonlinear finite element model of the double-shoulder tool joint (DSJ) including the engage and retract groove structure is established by considering the factors of structural asymmetry and contact of each engaging surface. ABAQUS/Explicit finite element method (FEM) is used to study the stress and contact pressure distribution characteristics of the critical structure of DSJ under make-up torque and axial tension. The accuracy of the finite element model was verified by combining with a full-scale physical test, and the connection strength and sealing performance of DSJ are evaluated. The results show that the stress concentration occurs at the key structure of DSJ under the make-up torque. The geometry size and structural discontinuity at the transition fillet of the double-shoulder structure have a significant effect on the stress and contact pressure distribution on the shoulder. Under axial tension, the stress level and stress concentration area of the whole joint and the key structure change, especially in the thread section. The sealing performance on the shoulder decreases significant, while that of the thread section increases slightly. The test results are consistent with the finite element analysis findings, and this joint shows good mechanical properties, which can meet the design requirements of drilling tool manufacturers and provide data support for its optimal design and application.

Quenching optimization of a hot stamping line for aluminum automotive components

The rising cost of fuel and harder environmental regulations driving the need for more eco-friendly vehicles have compelled automotive manufacturers to search for innovative lightweight solutions. Consequently, hot stamped aluminum alloys are gaining prominence due to their exceptional specific strength and improved formability compared to cold formed components. Unfortunately, the current state of knowledge in the field lacks the necessary depth to establish a reliable, fast and optimized process for aluminum hot forming. To address this gap, a collaborative effort between Mondragon Unibertsitatea (knowledge provider), Fagor Arrasate (hot stamping line supplier), and Batz (tool manufacturer) has been initiated. The collaborative endeavour aims to conduct semi-industrial trials involving the hot stamping of an authentic automobile bumper employing high-strength 6xxx and 7xxx aluminum alloys. The hot stamping trials have been performed under different in-die quenching times and mechanical properties of the stamped bumpers have been empirically tested. These results have helped to define the optimal quenching time. With that aim, first, a thermophysical and rheological characterization of the aluminum has been performed, followed by the development of a model to predict mechanical properties of aluminum alloys. This predictive model, together with the aluminum material data, has been then integrated into the simulation framework to enable accurate forecasting of mechanical properties and, consequently, the identification of the optimal quenching duration. The results revealed that quenching times as brief as 1 second could be employed while maintaining acceptable mechanical properties in a rapid cycle hot stamping process. These expedited quenching times have the potential to boost production by an impressive 70 % when compared to the conventional hot stamping process applied to the equivalent steel bumper.

Expediting online liquid chromatography for real-time monitoring of product attributes to advance process analytical technology in downstream processing of biopharmaceuticals

The application of Process Analytical Technology (PAT) principles for manufacturing of biotherapeutics proffers the prospect of ensuring consistent product quality along with increased productivity as well as substantial cost and time savings. Although this paradigm shift from a traditional, rather rigid manufacturing model to a more scientific, risk-based approach has been advocated by health authorities for almost two decades, the practical implementation of PAT in the biopharmaceutical industry is still limited by the lack of fit-for-purpose analytical methods. In this regard, most of the proposed spectroscopic techniques are sufficiently fast but exhibit deficiencies in terms of selectivity and sensitivity, while well-established offline methods, such as (ultra-)high-performance liquid chromatography, are generally considered as too slow for this task. To address these reservations, we introduce here a novel online Liquid Chromatography (LC) setup that was specifically designed to enable real-time monitoring of critical product quality attributes during time-sensitive purification operations in downstream processing. Using this online LC solution in combination with fast, purpose-built analytical methods, sampling cycle times between 1.30 and 2.35 min were achieved, without compromising on the ability to resolve and quantify the product variants of interest. The capabilities of our approach are ultimately assessed in three case studies, involving various biotherapeutic modalities, downstream processes and analytical chromatographic separation modes. Altogether, our results highlight the expansive opportunities of online LC based applications to serve as a PAT tool for biopharmaceutical manufacturing.

A knowledge-driven, integrated design support tool for additive manufacturing

AbstractIncreasing adoption of additive manufacturing (AM) makes software support for design for additive manufacturing (DfAM) more relevant. This paper presents a novel, knowledge-driven design support tool for AM that leverages a central knowledge base to provide extensible and powerful DfAM support early in the development process. The approach was implemented using Python for the knowledge base and as a plugin for Siemens NX. It offers automated design checks, optimizations, and further information through an integrated Wiki. Evaluation confirms the feasibility and benefits of the approach.

Sustainability risk assessment in manufacturing: A Life Cycle Assessment-based Failure Mode and Effects Analysis approach

This study introduces a methodology integrating Life Cycle Assessment (LCA) with Failure Mode and Effects Analysis (FMEA) to identify and assess environmental sustainability risks in manufacturing processes in alignment with the Corporate Sustainability Reporting Directive (CSRD) and European Sustainability Reporting Standards (ESRS). In contrast to existing top-down approaches at sector and company level, this methodology specifically addresses the challenge of transitory sustainability risks in manufacturing, driven by rapid changes in regulatory frameworks and market expectations, by providing a robust and adaptable framework for comprehensive, bottom-up risk assessment directly on the manufacturing shop floor. Through a detailed literature review, the paper identifies gaps in current risk assessment methods and proposes a novel approach that enhances traditional FMEA by incorporating LCA results, thereby facilitating a comprehensive, quantitative analysis of sustainability risks. The practical application of this methodology is demonstrated through a case study, underscoring its effectiveness in real-world settings and potential for broader applications in sustainable manufacturing. The results presented in the paper also include quantitative sustainability performance benchmarks for the EU28 industrial sector, offering a strategic tool for manufacturers to improve sustainability practices, align operations with environmental standards, and mitigate transitory sustainability risks. This research contributes to the sustainable evolution of manufacturing, providing a methodological foundation for understanding and managing sustainability risks.

VQ-CAD: Computer-Aided Design model generation with vector quantized diffusion

Computer-Aided Design (CAD) software remains a pivotal tool in modern engineering and manufacturing, driving the design of a diverse range of products. In this work, we introduce VQ-CAD, the first CAD generation model based on Denoising Diffusion Probabilistic Models. This model utilizes a vector quantized diffusion model, employing multiple hierarchical codebooks generated through VQ-VAE. This integration not only offers a novel perspective on CAD model generation but also achieves state-of-the-art performance in 3D CAD model creation in a fully automatic fashion. Our model is able to recognize and incorporate implicit design constraints by simply forgoing traditional data augmentation. Furthermore, by melding our approach with CLIP, we significantly simplify the existing design process, directly generate CAD command sequences from initial design concepts represented by text or sketches, capture design intentions, and ensure designs adhere to implicit constraints.

How the multi-phase microstructure of a novel tool steel determines its corrosion behaviour in sulphuric acids

The corrosion behaviour of a Fe81Cr15V3C1 steel was analysed compared to commercial X90CrMoV18 (1.4112) in 0.01–1 mol/L H2SO4 solutions. The rapidly cooled steel comprises martensite dendrites, carbide networks (M7C3, MC) and austenite interdendritic areas. Electrochemical measurements with surface analysis (SEM, EDX, AES, GD-OES) revealed the phase impact on corrosion. Active corrosion of austenite occurs at martensite-carbide boundaries leading to narrow bands. A unique oxidation between passivity and transpassivity with dissolution along lamellar carbides and vanadyl(IV) cation release enhances with increasing acid concentration. Both steels exhibit similar corrosion resistance, a superior mechanical performance of Fe81Cr15V3C1 explains its potential for tool manufacturing.

Between the Camp and the Makerspace: Commoning Practices, Temporal Autonomy and Care

ABSTRACT The paper explores the chronopolitics of place-making in the refugee makerspace Habibi-Works and the neighbouring Katsikas refugee camp in Ioannina, in Northern Greece. Camps are created to be ephemeral and this ephemerality is reflected in their materiality and conditions the possibilities available to those that inhabit them. Camp temporalities work by way of destabilising the residents' sense of self in the present, severing their connections with the past and limiting their future aspirations. In sheer antithesis to the camp, the makerspace disrupts these (temporal) dynamics: it enables the camp residents to manage time as a common resource (commoning), creating autonomous communities of collective care. Through mundane encounters and practices, the makerspace plays an instrumental role in enacting the residents' autonomy by facilitating access to digital technologies, low-tech manufacturing tools, and skills to reproduce a sense of lost normality. We adopt an ethnographic approach to engage with the makerspace and the camp as well as the various people involved (migrants, volunteers, makers) and understand how migrants narrate their past, negotiate their present and imagine their futures in the context of everyday life. Building on the concepts of peer production, temporal autonomy and radical care, we argue that Habibi-Works opens up a new socio-political space between the camp, the makerspace and the world.

The Application of Ancient Chinese Creation Wisdom in Contemporary Product Design

The creation activity is the product of culture. Human beings started the creation activity from the manufacture of tools and daily necessities. With the help of dexterous hands, the creator uses the surrounding materials to create exquisite daily necessities on the basis of personal life and cultural cultivation, and realizes the interaction between craft creation and real life. Chinese traditional craft and culture are inseparable, and the spirit of traditional creation has become an indispensable part of Chinese culture. These core features of traditional creative spirit are not only reflected in the technical level, but also contain rich cultural connotation and philosophical concepts. By studying and summarizing the characteristics of traditional Chinese creative wisdom, this paper understands the deep thinking of craftsmen in functional design in ancient creative culture, as well as the exquisite skills in material selection and form shaping period, and probes into the important significance and application value of traditional creative wisdom in contemporary product design, hoping to provide some reference and inspiration for today's contemporary design.

Lubricant transportation mechanism and wear resistance of different arrangement textured turning tools

The textured tools present improved cutting efficiency and tool wear and be applied to the turning of difficult-to-cut materials. The unique transport performance of lubricant in the second deformation zone of the cutting zone is one of the advantages for sustainable manufacturing, which is significantly affect by micro-textured arrangement. However, the direct observation of infiltration phenomenon is rarely studied. The anti-friction performance and machinability of cast iron MQL turning with micro-textured tool is needed. This paper undertook theoretical analysis, infiltration and turning experiments of six typical arrangements of textured tools to provide a comprehensive understanding of the transportation and antifriction mechanism. Firstly, a theoretical analysis of the transport mechanism of different textured tools was conducted, revealing variations in surface wetting speeds due to the capillary action mechanism during the transport process. Secondly, confirmation was obtained through the capture of real-time infiltration processes using a high-speed camera, showing that, compared to non-textured tools, the infiltration speed noticeably slowed. This increased lubricant storage time and enhanced lubrication performance. Lastly, it was revealed through turning performance experiments that the 45° textured tools demonstrated outstanding performance in enhancing material removal efficiency and reducing heat accumulation. The wear resistance was superior, with reductions of 15.3%, 16.7%, and 25.4% in cutting forces in the three directions compared to non-textured tools, and a 12.2% decrease in cutting heat. Thus, validating the correctness of the capillary action theoretical analysis lays the foundation for the future application of textured tools in aerospace, automotive manufacturing, mold industry, and other fields.

Comparison of Softening Behavior and Abrasive Wear Resistance between Conventionally and Additively Manufactured Tool Steels

Directed energy deposition (DED) is a powerful method for hard‐facing the existing tool components. Herein, three tool steel grades including a newly developed maraging steel (NMS), a cold work tool steel (V4E), and a high boron steel (HBS) are cladded on a hot work tool steel substrate. After tempering, the cladded tool steels are exposed to high temperatures at 600, 700, and 800 °C for 3 h to evaluate their softening resistance. The results show that all three tool steel grades have a significant hardness drop when the softening temperature reaches 700 °C. The investigated NMS has the lowest initial hardness in the tempered state but the best softening resistance. In contrast, HBS has the highest initial hardness but the worst softening resistance among the three steel grades. V4E tool steel has a moderate softening resistance compared to the other two steel grades. The factors contributing to the softening resistance have been discussed. Corresponding conventional tool steels are also adapted as references for comparison. Except for the NMS, the additive manufacturing tool steel samples have a better softening resistance than the conventional counterparts owing to more alloying elements trapped in the matrix. The abrasive wear resistance of the tempered and softened tool steels manufactured by DED and conventional methods is also evaluated and the wear mechanism is discussed. Besides the hardness, the free spacing λ between coarse hard particles is one of the major factors influencing the abrasive wear resistance.

Hydrodynamic processes in designing diamond drilling tools

Relevance. The rational choice of drilling tools is one of the components of a positive result of exploration, mining, drilling operations. The function of a complex solution of problems arising when drilling wells is assigned to a modern drilling tool. Today there is a great variety of designs of rock cutting drilling tools. However, scientific achievements in improving the material and technical production base contribute to the development of drilling technology and creation of new, more efficient tool designs. The most promising and effective in various mining conditions is a diamond drilling tool. During the operation of such a tool, flushing fluid circulation is of great importance, especially in the bottomhole zone of the well being constructed. When designing the structures of a diamond rock cutting tool, it is necessary to take into account not only the strength, cutting, and stabilizing properties, but also the possibility of an effective fluid flow in its circulation system, i.e. without flow energy consumption to overcome resistance, with sufficient capacity for cuttings removal and the necessary level of cooling, lubrication and implementation of other functions of the flushing fluid, which contribute to improving drilling results. At the same time, modern methods of designing a drilling tool should take into account the influence of the drilling fluid, its properties, and the nature of the flow on the rock destruction mechanism, i. e. require a thorough study of the nature of the fluid flow in the contact zone of the tool cutters with the rock. The article proposes the position of considering the design of a diamond drilling tool cutting surface from the point of view of the influence of hydrodynamic processes on the nature of cutters rock interaction. The results of the study of both the author herself and well-known world manufacturers of diamond drilling tools are given as arguments. Aim. To study the influence of the design features of the existing diamond drilling tool on the nature of the fluid flow in the bottomhole zone of the well during drilling. Objects. Designs of diamond drilling tools, hydrodynamic processes associated with drilling. Methods. Analytical method, computer simulation method. Results. Differences in fluid circulation in certain types of diamond drilling tools are determined. The zones of the diamond rock-cutting tool are distinguished. They differ in the nature of the fluid flow. Directions for reducing hydraulic resistance in the bottomhole zone of the well due to changes in the design features of the drilling tool were established.

Identifying and minimizing critical driving range thresholds for electric vehicles in intercity networks

It is well known that range anxiety faced by electric vehicle (EV) drivers nowadays can be effectively mitigated by either increasing the driving range of vehicles or increasing the distribution density of charging stations. To enact an effective research and development plan, vehicle manufacturers should understand well the relationship between the EV adoption and usage rates and the performance level of battery and energy management technologies. On the other hand, the underlying relationship between EV adoption and usage rates and the number and distribution of charging stations is also critical for charging infrastructure investors in determining their construction plans. This paper is dedicated to analytically identifying two critical driving range thresholds and further reducing these driving range thresholds as much as possible by optimally deploying charging station locations in intercity highway networks. These critical thresholds represent the turning points of individual routing convenience conditions or satisfaction levels for long-distance trips, implying that the inconvenient travel restrictions may be largely overcome if the driving range of EVs goes beyond these thresholds. For this purpose, we develop two integer programming models and dynamic programming algorithms for the driving range threshold identification problems, and extend the modeling framework to accommodate two relevant driving range threshold minimization problems as well, which are solved by a branching algorithm encapsulating the aforementioned dynamic programming procedures. The output of this research offers a set of new analytical tools for EV manufacturers to make strategic decisions on extending the driving range of their products and for charging infrastructure investors to make planning decisions on selecting charging station locations.