Manufacturing Tools Research Articles

3D manufacturing creates new opportunities

Additive manufacturing (AM) allows a tool manufacturer to create products that would otherwise be difficult or impossible to manufacture. Advantages include shorter lead times, improved tool life and increased sustainability.

Progress in grinding performance by additive manufacturing of grinding wheels integrated with internal venturi cooling channels and surface slots

Among the most promising features of additive manufacturing are tool or form-free manufacturing and the ability to create intricate geometries that are difficult or even impossible to fabricate with traditional methods. These advantages can be employed to produce enhanced grinding tools. Efficient coolant fluid delivery into the cutting zone of the grinding operation has been a challenging problem since high frictional contact in the arc zone deteriorates the resin bond and lessens the grinding performance. This research study was dedicated to assessing the influence of internal cooling along with surface structures on the grinding performance of resin-bonded grinding wheels fabricated via additive manufacturing. This research introduced a novel structure that benefits from internal venturi shape cooling channels to provide exceptional fluid velocity in the tool and workpiece interaction zone. The grinding wheels have been produced employing vat photopolymerization. Grinding experiments with and without internal cooling were conducted on an aluminium plate to study the impact of introduced structures on the main aspects of grinding performance, such as cutting forces, surface roughness, tool wear, and dimensional accuracy. Two different grinding scenarios comprising shallow (10 μm depth of cut) and deep grinding (100 μm depth of cut) were carried out to reveal the influence of the material removal rate on the grinding experiments. The measured grinding forces revealed that integrating internal cooling channels and surface slots in a grinding tool could significantly reduce the grinding forces, which was more pronounced in the case of using venturi channels. Measured tool wear and dimensional accuracy together with calculated grinding ratio revealed that using cooling channels could participate in a notable increase in tool life and material removal ability, especially for venturi channels, due to improved cutting conditions, by which higher dimensional accuracy was obtained as well for the ground parts. Besides, it was discovered that the cooling channels could improve the surface quality of the ground part, which was less noticeable with the venturi channel grinding wheel. Furthermore, the optical and confocal microscopy detection confirmed that internal cooling channels could reduce chip loading on the grinding wheel surface, decrease the required number of dressing intervals, and cause effective promotion of tool life.

Energy Consumption Prediction of Electric City Buses Using Multiple Linear Regression

The widespread electrification of public transportation is increasing and is a powerful way to reduce greenhouse gas (GHG) emissions. Using real-world driving data is crucial for vehicle design and efficient fleet operation. Although electric powertrains are significantly superior to conventional combustion engines in many aspects, such as efficiency, dynamics, noise or pollution and maintenance, there are several factors that still hinder the widespread penetration of e-mobility. One of the most critical points is the high costs—especially of battery electric buses (BEB) due to expensive energy storage systems. Uncertainty about energy demand in the target scenario leads to conservative design, inefficient operation and high costs. This paper is based on a real case study in the city of Seville and presents a methodology to support the transformation of public transportation systems. We investigate large real-world fleet measurement data and introduce and analyze a second-stage feature space to finally predict the vehicles’ energy demand using statistical algorithms. Achieving a prediction accuracy of more than 85%, this simple approach is a proper tool for manufacturers and fleet operators to provide tailored mobility solutions and thus affordable and sustainable public transportation.

Method of preparation individual instrument for knee arthroplasty

Objective. To improve the results of total knee arthroplasty by developing a methodology for the design and manufacture of an individual instrument for the implants accuracy installation. Methods. An analysis of the literature on various concepts of alignment was carried out. In practice, one of them was chosen depending on the clinical case. For preoperative planning, a CT scan of the lower extremities was performed with the capture of the pelvis or hip joint; feet completely or up to the calcaneus (CT 64 or 128 slices were used for better visualization and increased accuracy). With the help of RadiAnt DICOM, the 3D model was converted into an STL file, which was uploaded to the FreeformPlus program, where preoperative planning was done. The program allows not only to assess the presence of varus or valgus deformity of the limb, to determine its degree, but also other deformities of the lower legs. In the program, after assessing the deformity, we perform preoperative planning using one of the concepts: anatomical, mechanical, or kinematic. After choosing the concept and virtual correction of the limb, we prepare an individual instrument and print is with additive technology. In addition, we print joint parts of the femur and tibia, which allows the surgeon to orient himself intraoperatively. Results. Thanks to the completed work and software, it was possible to improve the results of knee arthroplasty by increasing accuracy implants installing. The developed technique of 3D-design and manufacture of an individual tool allowed us to use any of the alignment concepts with high accuracy. Preoperative planning increases the deformity understanding because surgeon himself, not the engineer, does it. Conclusions. Developed technique of three-dimensional modeling of the lower extremity makes it possible to correctly plan, manufacture and put into practice a patient specific tool for knee arthroplasty, taking into account the individual characteristics of the lower extremity.

Hand anthropometric survey of Iranian healthcare workers

AbstractBackgroundHand anthropometric data can help properly design hand tools and protective equipment for healthcare workers. This study aimed to measure and analyze the hand anthropometric data of Iranian healthcare workers.MethodsIn this cross‐sectional study, 33 hand dimensions were measured among 540 Iranian healthcare workers (270 male and 270 female) in six ethnic groups. Two‐dimensional imaging and traditional measurement methods were used. The data were classified and compared based on gender and ethnicity.ResultsThe results revealed a difference between the dimensions of males' and females' hands, which indicated that the dimensions of males' hands were larger. The results showed significant differences between different regions of Iran and other countries including the United States, Bangladesh, Nigeria, and Colombia.ConclusionDifferences in hand anthropometric dimensions should be considered in the design and manufacture of hand tools and hand protection equipment to prevent reduced productivity, occupational injuries, and diseases.

Digital Standardization of Lean Manufacturing Tools According to Industry 4.0 Concept

Standardization is a key element in the effective use of lean manufacturing methodologies and tools for achieving process sustainability. Their combination is conducive to eliminating waste and improving the efficiency of production processes and guarantees the company that employees use the most efficient tools and do not waste time on unnecessary activities. These activities can be further improved by using digital solutions, in accordance with the concept of Industry 4.0. Therefore, the authors have developed the e-Lean system, whose task is to digitize selected lean manufacturing tools. The subject of this work is analysis of the functionality and effectiveness of the essential part of the e-Lean system in the form of specialized TPM (Total Productive Maintenance) software as an application. During implementation in a construction production company, the TPM application was tested by lean manufacturing and maintenance specialists. The research consisted of assessing the functionality and efficiency of processes in relation to conventional TPM solutions. Additional functionalities of the e-Lean system have been confirmed, such as systemic approval of machinery inspection, which requires passing all necessary steps at individual inspection points, direct access for supervisors to the results of inspection activities and their status, direct and easy access to photographic documentation of machines added during inspection both in optimization of working time and its course (e.g., the optimal number of steps taken by the employee during the inspection), as well as an efficient system of motivating employees (collecting points). The improvement in the effectiveness of processes was determined by measuring the control times for three control points (polymerization furnace, packing area, and defibering machines). The average control time was reduced from 16,200 to 13,923 s. Thus, thanks to the use of the application, it was found that the efficiency of using the TPM tool was increased by approx. 15% compared to previously used non-digital solutions.

OPTIMIZATION OF THE REPLACEMENT PROCESS FOR THE BRAKE SHOES ISUZU GIGA TRUCK AT PT AI-ISO DM JAKARTA BRANCH

PT AI-ISO workshop on DM Jakarta provides various repair and periodic maintenance services. In periodic maintenance, brake repair jobs have problems replacing the brake pads (brake shoe set) of Isuzu Giga Trucks, which takes about 9 hours. To reduce the processing time, an improvement process is carried out to shorter processing time, so the customer feels more satisfied with repairing his vehicle. From observations, the length of work time was due to the process of changing the brake pads outside the workshop due to the absence of tools to install the brake pads. The repair shop offers to replace a set of brake pads, but the price is higher than just replacing the brake pads, so the customer makes this choice. The improvement made was the manufacture of a rivet installation tool on the brake pads based on the workings of a rivet machine. First, it is necessary to make a brake pad holder so that it does not shift when pressed and ensures that the pressure acting on the rivet is as requested. This tool is also equipped with a Standard Operation Procedure to make it easier for technicians to replace brake pads. The result is a decrease in processing time for the brake pad replacement process from an average of 9 hours to 5 hours. With these tools, repairing the brake system can be accelerated and within the safe limits required in the vehicle's manual, and the customer will be more satisfied.

Modeling and Simulation of Low Carbon Oriented Machining Centre Machines

The whole country is working hard to achieve the goal of carbon peak and carbon neutrality, and carry out energy-saving and emission-reduction measures. In order to realize the low-carbon manufacturing of machine tools, the carbon emissions in the processing process of the machining center are analyzed, the carbon emission boundary and its composition are determined, and the mathematical model of carbon emissions of the machining center is established. The VERICUT software was used to simulate the machining center, and the carbon emission model was verified by orthogonal design by simulating the machining process in the software. The results show that the carbon emission model of the processing center established in this paper has high accuracy, and the error is within 4% compared with the actual processing carbon emission value, indicating that the model can accurately reflect the size of the carbon emission and verify the effectiveness of the model.

Tools for Industrial Enterprises Management Based on the Principles of Lean Manufacturing and ESG

Relevance. To date, most industrial enterprises focus on "green" and environmental standards. Driven by stricter regulations, pressure from investors and changing customer preferences, companies are forced to use technologies that are either completely harmless or the least harmful in comparison with traditional production methods. Such actions involve modifications in many directions, including changes in supply chains, production processes and business models. Companies are also rethinking how their products are developed, designed and used, looking for ways to meet performance and quality requirements while using fewer resources throughout the life cycle of everything they produce.The purpose – the study of the management process of industrial enterprises based on the principles of lean manufacturing and ESG.Objectives: compare the similarities and differences between the principles of lean manufacturing and ESG; assess the current state of their implementation at industrial enterprises; as well as consider the criteria for assigning ratings.Methodology. In this research, theoretical (for example, analytical, descriptive, historical, etc.) and empirical (for example, comparative; forecasting and measurement) research methods are used.Results. The relevance of such industrial enterprise management tools, which are based on the principles of lean manufacturing and ESG, is revealed – today they are a priority for the economy. Conclusions. If an enterprise wants to be highly competitive, it should adhere to the continuous development and improvement of equipment that could reduce emissions into the environment. Such an indicator can be achieved with the introduction of lean manufacturing and ESG tools at the enterprise. Thus, it becomes clear that concern for the environment is closely linked to the success of firms.

A design for additive manufacturing tool for parts obtained through a material extrusion process

A design for additive manufacturing tool for parts obtained through a material extrusion process

Development and printability of diamond-containing composite filament for material extrusion

PurposeMaterial extrusion technology is considered to be an effective way to realize the accurate and integrated manufacturing of high-performance metal diamond tools with complex structures. The present work aims to report the G4 binder that can be used to create metal composite filament loading high concentrations of large diamond particles through comparative experiments.Design/methodology/approachThe quality of filaments was evaluated by surface topography observation and porosity measurement. And the printability of filaments was further studied by the tensile test, rheological test, shear analysis and printing test.FindingsThe results show that the G4 binder exhibits the best capacity for loading diamonds among G1–G4. The L4 filament created with G4 has no defects such as pores, cracks and patterns on the surface and section, and has the lowest porosity, which is about 1/3 of the L1. Therefore, the diamond-containing composite filament based on G4 binder exhibits the best quality. On the other hand, the results of the tensile test of L5–L8 filaments reveal that as the diamond content increases from 10% to 30%, the tensile strength of the filament decreases by 29.52%, and the retention force coefficient decreases by 15.74%. This can be attributed to the formation of inefficient bonding areas of the clustered diamond particles inside the composite filament, which also leads to a weakening of the shear strength. Despite this, the results of the printing test show that the diamond-containing composite filament based on the G4 binder has reliable printability.Originality/valueTherefore, the G4 binder is considered to solve the most critical first challenge in the development of diamond-containing filament.

Ultrafast Laser Additive Manufacturing: A Review

Ultrafast lasers are proven and continually evolving manufacturing tools. Concurrently, additive manufacturing (AM) has emerged as a key area of interest for 3D fabrication of objects with arbitrary geometries. Use of ultrafast lasers for AM presents possibilities for next generation manufacturing techniques for hard-to-process materials, transparent materials, and micro- and nano-manufacturing. Of particular interest are selective laser melting/sintering (SLM/SLS), multiphoton lithography (MPL), laser-induced forward transfer (LIFT), pulsed laser deposition (PLD), and welding. The development, applications, and recent advancements of these technologies are described in this review as an overview and delineation of the burgeoning ultrafast laser AM field. As they mature, their adoption by industry and incorporation into commercial systems will be facilitated by process advancements such as: process monitoring and control, increased throughput, and their integration into hybrid manufacturing systems. Recent progress regarding these aspects is also reviewed.

Digital Technologies’ Risks and Opportunities: Case Study of an RFID System

Smart technologies have been the subject of a growing interest for the past few years due to the growing market demand. They are believed to improve human life, existence, and companies’ performance. Considering the recent advances, X.0 concept has proven to be a mindset changing so that companies can now see that they can improve their competitiveness, ensure an innovative, sustainable and resilient environment, and smarten and develop their lean manufacturing tools. Nevertheless, if X.0 adoption is still not at its highest level, it is because of the relevant challenges and difficulties that occur during the implementation process. Within this scope, this paper aims, through a systematic literature review, to identify risks and opportunities of X.0 technologies to constitute a referential to be taken into consideration for a successful implementation. Results are validated by the modelling and simulation of an RFID system applied within the automotive industry, for which we identified risks and opportunities from one side and the system contribution in terms of smart Lean Manufacturing. From one hand, the value added of this paper, on the contrary of previous researches, is mainly regrouping risks and opportunities of most relevant digital technologies to conclude on those of X.0 revolution as a concept as described in following sections. From another hand, we were able to prove, through a real case study, that X.0 concept directly contribute in smartening and improving lean manufacturing principles.

Screw Extrusion Additive Manufacturing of Carbon Fiber Reinforced PA6 Tools

The creation of tools by additive manufacturing is becoming increasingly convenient for CFRP one-off and small batch production. Screw extrusion additive manufacturing of thermoplastic polymers has boosted the development of large format manufacturing solutions. Interlayer adhesion and anisotropic properties of a 3D printed part are indisputably key aspects of tool manufacturing process. In this study, thermal and mechanical properties of large format 40% carbon fiber reinforced polyamide 6 3D printed tools were determined. Moreover, the influence on part performance of two main printing parameters, deposition temperature and extruding pressure, was analyzed with respect to polymer melt rheology. The printed material revealed a highly anisotropic thermal and mechanical behavior associated with the alignment of the high carbon fiber content. The optimal process window was identified in terms of substrate deposition temperature. Along the print direction, no major impact on tensile and flexural mechanical properties was detected, while the injection molding values were exceeded by approximately 10%. The layer adhesion was estimated by measuring the stress at break on transversely Z-oriented specimens. Higher deposition temperatures and pressures, combined with lower viscosity, promote wetting and bond formation between layers, ultimately leading to more consistent performances. The best results in the transverse direction were achieved between 140 and 160 °C, reaching roughly a fifth of the longitudinal values. A significant drop in performance was detected below 120 °C, which was identified as the minimum process temperature. A post-process annealing heat treatment was also investigated, no beneficial outcomes were reported.

A SEMINAR PAPER ON “OVERALL EQUIPMENT EFFECTIVENESS: A CASE STUDY AT A BOTTLING PLANT”

Overall Equipment Effectiveness (OEE) is the crucial tool of Total Productive Manufacturing (TPM). OEE evaluates the workability of the equipment in relation to its performance capacity provided that it should be operated in the optimal manufacturing conditions. It considers the whole manufacturing environment not merely the availability of the machine for performing the particular work, but also the efficiency of the product during the equipment availability together with losses in efficiency due to various factors such as yield waste, rework, scraps, etc. Such analysis provides a broad view of machine operation and manufacturing efficiency and assists to formulate efficient strategies to enhance the productivity of the manufacturing line. This paper implements the OEE tool to identify the root causes responsible for affecting system line efficiency. For this, a case study on a production line of VBNPL, one of the reputed beverage companies in Nepal working as the franchise of the international brand “PepsiCo. Int”, is done. Initially, the OEE of a single production line called “GRB 400” is calculated by recording the total planned breakdown, unplanned breakdown, and filler breakdown. Onwards, becoming specific the OEE of the Filler is computed and all possible reasons for the drop in the efficiency are identified, for instance falling of bottle, bottle burst, bottle jam, loose vent tube, etc. by using various techniques such as Pareto chart and Fishbone diagram. Finally, suitable recommendations are provided to mitigate the issues that hampered the efficiency of the production line.

Pengolahan Limbah Serat Fiber sebagai Substitusi Material Pengisi Media Tanam Organik di Mitra WBS Fiberglass Poncokusumo

Micro-enterprises in the community still need a helping hand in the form of a service program from the campus. It is known that the micro-enterprise community belongs to the lower middle class, so there is still a lack of interest in seeking information/literacy and this results in the absence of business development in the future in a better direction. In Karanganyar Village, Poncokusumo, Malang, a fiber business was found in the manufacture of tools made of plastic, this business has been running for 3 years and there is still no high enough development. In addition, another problem is the problem of fiber waste that has not been utilized at all. There was no processing or conversion into useful and economically valuable materials. The solution offered is the manufacture of organic pots/growing media. The method of implementing this service used three stages, namely preparation, implementation, and reporting. The data collected in the form of documentation, observation, and the results of filling out the respondent's questionnaire which was then analyzed descriptively qualitatively. The results of the service showed that organic growing media from fiberglass can be applied and attract partners' interest. Knowledge of occupational health and safety has enthusiastically educated partners. The results of the partner satisfaction questionnaire showed that this service activity has a very satisfied response category of 65.7% and a satisfied response of 34.3%. So, WBS fiberglass partners have received, supported, appreciated, and followed this service well.

Vibration transmitted to the hands of power drill operators: Effect of arm posture and type of drilled material

This study investigated the effect of the arm posture and the type of material on the vibration measured at the hands during drilling operation. An experiment was conducted using three different materials (concrete, steel, and wood) and two different arm postures characterized as 90° and 180° angle between the upper arm and forearm. Six male subjects stood on a force platform to measure and control the feed force during the drilling operation. The vibration was measured at the interface between the drill and both hands. The results showed that the effect of arm posture was dependent on the type of material being drilled. For example, drilling in concrete yielded higher frequency-weighted acceleration with the 90° arm posture than the 180° posture while drilling in wood showed an opposite trend. The results tend to suggest no correlation between the material hardness and the vibration at the hands. Higher vibration was also observed at the right hand than the left hand. It is recommended to not use the vibration emission data reported by manufacturers of power tools to evaluate incidences of hand-arm vibration syndrome (HAVS) but to rely on real measurements taken in the field under typical operating conditions.

Robotic Cell Reliability Optimization Based on Digital Twin and Predictive Maintenance

Robotic systems have become a standard tool in modern manufacturing due to their unique characteristics, such as repeatability, precision, and speed, among others. One of the main challenges of robotic manipulators is the low degree of reliability. Low reliability increases the probability of disruption in manufacturing processes, minimizing in this way the productivity and by extension the profit of the company. To address the abovementioned challenges, this research work proposes a robotic cell reliability optimization method based on digital twin and predictive maintenance. Concretely, the simulation of the robot is provided, and emphasis is given to the reliability optimization of the robotic cell’s critical component. A supervised machine learning model is trained, aiming to detect and classify the faulty behavior of the critical component. Furthermore, a framework is proposed for the remaining useful life prediction with the aim to improve the reliability of the robotic cell. Thus, following the results of the current research work, appropriate maintenance tasks can be applied, preventing the robotic cell from serious failures and ensuring high reliability.

Process analytical technology as in-process control tool in semi-continuous manufacturing of PLGA/PEG-PLGA microspheres

Nowadays, among 3rd generation drug delivery systems, biodegradable polymeric based long-acting injectable depot has achieved tremendous success in clinical application. So far, there have been two dozen of commercial products of Poly (lactic-co-glycolic acid) microspheres available in the market. Recently, continuous manufacturing concept has been successfully applied on oral solid formulation from buzzword to reality. However, the polymeric injectable microspheres are still stayed at batch manufacturing phase due to the lack of understanding of knowledge matrix. In this study, micro-mixer as a plug-and-play emulsification modules, Raman spectroscopy and focused beam reflectance measurement as real-time monitoring modules are integrated into a novel semi-continuous manufacturing streamline to provides more efficient upscaling flexibility in microspheres production. In this end to end semi-continuous manufacturing process, amphiphilic block polymer monomethoxy-poly (ethylene glycol) modified PLGA (mPEG-PLGA) was used for encapsulating Gallic acid. Additionally, with guarantee of good robustness, the correlation relationship between critical process parameters, critical material attributes and critical quality attributes were investigated. The time-space evolution process and mechanism for formation of PEG-PLGA microsphere with particular morphology were elaborated. Altogether, this study firstly established semi-continuous manufacturing streamline for PLGA/PEG-PLGA microspheres, which would not only lower the cost of production, narrow process variability and smaller equipment/environmental footprint but also applied in-process control (IPC) and QbD principle on complicated production process of microspheres. Therefore, this study build confidence in the industrial development of PLGA/PEG-PLGA microspheres and establish best practice standards, which might be a quantum leap for developing PLGA microspheres in the future.

High‐Resolution Patterning of Organic–Inorganic Photoresins for Tungsten and Tungsten Carbide Microstructures

Tungsten is an important material for high‐temperature applications due to its high chemical and thermal stability. Its carbide, that is, tungsten carbide, is used in tool manufacturing because of its outstanding hardness and as a catalyst scaffold due to its morphology and large surface area. However, microstructuring, especially high‐resolution 3D microstructuring of both materials, is a complex and challenging process which suffers from slow speeds and requires expensive specialized equipment. Traditional subtractive machining methods, for example, milling, are often not feasible because of the hardness and brittleness of the materials. Commonly, tungsten and tungsten carbide are manufactured by powder metallurgy. However, these methods are very limited in the complexity and resolution of the produced components. Herein, tungsten ion‐containing organic–inorganic photoresins, which are patterned by two‐photon lithography (TPL) at micrometer resolution, are introduced. The printed structures are converted to tungsten or tungsten carbide by thermal debinding and reduction of the precursor or carbothermal reduction reaction, respectively. Using TPL, complex 3D tungsten and tungsten carbide structures are prepared with a resolution down to 2 and 7 μm, respectively. This new pathway of structuring tungsten and its carbide facilitates a broad range of applications from micromachining to metamaterials and catalysis.