To be competitive in a manufacturing environment by providing optimal performance in terms of cost-effectiveness and swiftness of system changes, there is a need for flexible production systems based on a well-defined strategy. Companies are steadily looking for methodology to evaluate, improve and update the performance of manufacturing systems for processing operations. Implementation of an adequate strategy for these systems' flexibility requires a deep understanding of the intricate interactions between the machining process parameters and the manufacturing system's operational parameters. This paper proposes a framework/generic model for one of the most common metal cutting operations-the boring process of an engine block machining system. A system dynamics modelling approach is presented for modelling the structure of machining system parameters of the boring process, key performance parameters and their intrinsic relationships. The model is based on a case study performed in a company manufacturing engine blocks for heavy vehicles. The approach could allow for performance evaluation of an engine block manufacturing system condition. The presented model enables a basis for other similar processes and industries producing discrete parts.

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Our life is strongly linked with the usage of natural resources. Energy is a necessity in everyday life and is often generated using non-renewable natural resources which are finite. Energy consumption in manufacturing industry is increasing and the way it is consumed is not sustainable. There is great concern about minimizing consumption of energy in manufacturing industry to sustain the natural carrying capacity of the ecosystem. This is one of the challenges in today's industrial world.In this paper two case studies have been carried out in crankshaft machining and cylinder head casting processes. The outcome of this research enables the company to identify potential avenues to optimize energy usage and offers a decision support tool.

The paper present theoretical and experimental studies of the energy dissipation performance of a composite structure composed in a multilayer nano-composite damping coating applied on a tungsten carbide shim and placed beneath the cutting insert. The coated shim placed closed to the cutting zone is subjected to high compressive and shear stresses as well as high temperature. Therefore, apart from high damping capacity it requires high stiffness and high thermal resistance. The coated shim dissipates the high frequency oscillations produced at the tool-chip and tool-workpiece interfaces during the chip forming process. The use of coated shims demonstrates that the tool life is considerably extended, while the machined surface integrity is improved. The Reuss model of the composite structure composed of a phase with a stiff, low loss factor and a phase with high loss factor is used to calculate the optimal coating thickness that gives high loss factor combined with high stiffness. The synthesis process of the coating material using HiPIMS process is discussed. The physical characteristics of the coating and the machining performance are presented in the experimental section.