Processes for environmentally friendly and/or cost-effective manufacturing

Zhong, Zhang

doi:10.1080/10426914.2021.1885709

Cited by 27 publications

(5 citation statements)

References 233 publications

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“…Taking into account the broader context, it is worth noting that tool wear increases with the addition of fly ash. It makes the technology more environmentally friendly and cost-effective [ 5 , 33 ]. Noting that the cost of parts manufactured by the EDM methods is strongly dependent on the tooling cost, including the material.…”

Section: Resultsmentioning

confidence: 99%

Electric Discharge Machining on Stainless Steel Using a Blend of Copper and Fly Ash as the Electrode Material

et al. 2022

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In the current work, several composites made with fly ash reinforcements are used to conduct electrical discharge machining (EDM) on stainless steel that is commercially accessible. Four composites were prepared with 2.5 to 10% reinforcement of fly ash with steps of 2.5%, copper is used as the matrix material. The specimens were created using the powder metallurgy method, which involved compaction pressures of 450 MPa and 900 °C for 90 min of sintering. The prepared composites are used as the electrode tool for EDM. EDM studies were carried out at two different current amplitudes (5A and 15A) by maintaining the Pulse on time (100 µs), Pulse off time (50 µs), and the depth of machining as 2 mm. The findings show that the addition of more fly ash to the copper matrix increased the material removal rate when cutting the SS304 plate and had a negative impact on the tool. The composite loses its ability to transfer heat during machining as the level of fly ash increases, raising the temperature in the copper matrix and causing the copper to melt more quickly at the electrode interface during machining, leading to increased electrode wear. While tool life was reduced because of the increase in current amplitude, machinability was enhanced.

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Section: Resultsmentioning

confidence: 99%

Electric Discharge Machining on Stainless Steel Using a Blend of Copper and Fly Ash as the Electrode Material

et al. 2022

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“…Applying modern materials and surface finishing processes can save costs during manufacturing by minimizing the requirement for extra materials, processing stages, and assembly procedures. In addition, using additive manufacturing methods may reduce material wastage and lower production expenses, enhancing the affordability and accessibility of wind turbine blades [43]. Further research and development are required to ascertain the characteristics of wind turbine blades only by utilizing advanced materials, surface finishing techniques, and cost-effectiveness.…”

Section: Cost-effectivenessmentioning

confidence: 99%

3D Printing for wind turbine blade manufacturing: a review of materials, design optimization, and challenges

Zarzoor,

Jaber,

Shandookh

2024

ETJ

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3D printing optimizes wind turbine blades for greater cost-effectiveness and durability.• The review emphasizes design optimization to enhance aerodynamics and structural efficiency. • Challenges such as material limitations and the need for structural integrity are identified. • AI and hybrid manufacturing are proposed to address these limitations and reduce costs.Wind energy has become an easy-to-harness source by converting captured wind currents into electrical energy. Powerful and customizable wind turbines are used to convert wind energy efficiently. However, wind turbine development in terms of structure is still an active area of research aiming at efficiently building capable and long-lasting turbines. Additive manufacturing technology, particularly 3D printing, has revolutionized multiple industries, including its potential to create wind turbine blades with high cost-effectiveness and optimizable shapes and rigid structures. In this review, various 3D printing-based techniques, including Fused Deposition Modelling (FDM), Continuous Fiber Reinforcement (CFR), Stereolithography (SLA), and 3D Printing-enhanced Large-Scale Additive Manufacturing (LSAM), are examined in detail for complex and large-scale wind turbine blade production. Materials used in 3D printing wind turbine blades, such as thermoplastic composites, epoxy resins, and fiber-reinforced polymers, are assessed with a focus on their mechanical strength, durability, and environmental considerations. Furthermore, the importance of design optimization and customization for wind turbine blades, including aerodynamic and structural design optimization, is emphasized. Customization for site-specific conditions, infill structural optimization, and infill printing speed and cost are also discussed.The review highlights the importance of structural optimization in developing efficient and cost-effective 3D-printed wind turbine blades, customization for sitespecific conditions, and infill structure. The review also mentions these technologies' challenges, such as material limitations, surface finish quality, size limitations, and structural integrity. Therefore, addressing these challenges to utilize these technologies' potential fully is crucial.

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“…In sustainable and advanced manufacturing processes, cost-effectiveness and resource-efficient manufacturing processes are a priority for achieving long-term economic viability and reducing the environmental footprint [39][40][41].…”

Section: Machining Cost Analysismentioning

confidence: 99%

Assessment of Sustainable and Machinable Performance Metrics of Monocrystalline Silicon Carbide Wafer with Electrophoretic Assisted Multi-Diamond Wire Sawing

Sefene,

Chen,

Tsai

et al. 2024

Preprint

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The rapacious demand for energy in semiconductor wafer manufacturing industries has significant implications for global warming and wafer manufacturing costs. Assessing sustainability in the multi-diamond wire sawing (MDWS) process is crucial for reducing costs and mitigating environmental impacts. However, sustainability assessment integrated with machinability performance metrics in this process has not been investigated. This novel study extensively analyzes sustainability metrics such as processing time, energy consumption, carbon dioxide emission, machining cost, and machinability characteristics, including surface roughness, diamond wear rate, and sawing temperature in monocrystalline silicon carbide (mono-SiC) sawing process. Experiments were conducted using traditional MDWS (T-MDWS), reactive MDWS (R-MDWS), and electrophoretic-assisted reactive MDWS (ER-MDWS) coolants. An autoregressive integrated moving average (ARIMA) model were used to predict the overall energy consumption of the MDWS machine. Results showed significant improvements across various responses such as processing time, energy consumption, carbon dioxide emissions, machining cost, surface roughness, diamond wear rate, and sawing temperature, with reductions of 2.95%, 3.87%, 6.80%, 12.82%, 4.68%, 16.32%, and 4.39%, respectively. Furthermore, the ARIMA model results indicate that the total energy consumption prediction accuracy reaches 98.813%. The findings demonstrated that the ER-MDWS cooling strategy is well-suited for large-scale wafer production without compromising surface quality while minimizing environmental impact.

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Processes for environmentally friendly and/or cost-effective manufacturing

Cited by 27 publications

References 233 publications

Electric Discharge Machining on Stainless Steel Using a Blend of Copper and Fly Ash as the Electrode Material

Electric Discharge Machining on Stainless Steel Using a Blend of Copper and Fly Ash as the Electrode Material

3D Printing for wind turbine blade manufacturing: a review of materials, design optimization, and challenges

Assessment of Sustainable and Machinable Performance Metrics of Monocrystalline Silicon Carbide Wafer with Electrophoretic Assisted Multi-Diamond Wire Sawing

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