Modern Manufacturing Processes

Opis

Modern Manufacturing Processes draws on the latest international research on traditional and non-traditional practices, to provide valuable advice on the digitization and automation of the manufacturing industry. In addition to providing technical details for the correct implementation of the latest tools and practices, the impacts on productivity and design quality are also examined.

The thorough classification of manufacturing processes will help readers to decide which technology is most effective for their requirements, and comparisons between modern and traditional methods will clarify the case for upgrading. This comprehensive assessment of technologies will include additive manufacturing, and industry 4.0, as well as hybrid methods where exceptional results have been gained through the use of traditional technology.

This collection of work by academics at the cutting edge of manufacturing research will help readers from a range of backgrounds to understand and apply these new technologies.

Explains how the correct implementation of modern manufacturing processes can help a factory gain the characteristics of an industry 4.0 business
Explores what the main technical and business drivers for new manufacturing processes are today
Provides detailed classifications and comparisons of traditional, non-traditional, and hybrid manufacturing processes

Spis treści

Front Cover 2
Modern Manufacturing Processes 5
Copyright Page 6
Contents 7
List of contributors 11
Preface 15
1 Advances in Manufacturing Processes 21
- 1. Advanced manufacturing techniques for composite structures used in aerospace industries 23
  - 1.1 Polymer matrix composites 23
  - 1.2 Processing methods 25
  - 1.3 Molding techniques 26
  - 1.4 Hand lay-up process 27
  - 1.5 Resin transfer molding process 28
  - 1.6 Compression molding 29
  - 1.7 Vacuum bagging 30

Front Cover 2
Modern Manufacturing Processes 5
Copyright Page 6
Contents 7
List of contributors 11
Preface 15
1 Advances in Manufacturing Processes 21
- 1. Advanced manufacturing techniques for composite structures used in aerospace industries 23
  - 1.1 Polymer matrix composites 23
  - 1.2 Processing methods 25
  - 1.3 Molding techniques 26
  - 1.4 Hand lay-up process 27
  - 1.5 Resin transfer molding process 28
  - 1.6 Compression molding 29
  - 1.7 Vacuum bagging 30
  - 1.8 Vacuum enhanced resin transfer molding technology 30
  - References 32
- 2. Advances in manufacturing analysis: fractal theory in modern manufacturing 33
  - 2.1 Introduction 33
  - 2.2 Theory of fractals 34
    - 2.2.1 Definition and properties 34
    - 2.2.2 Methods of computing fractal dimension 37
      - 2.2.2.1 Box counting method 39
      - 2.2.2.2 Fractal Brownian motion 40
      - 2.2.2.3 Variogram method 41
      - 2.2.2.4 Power spectrum 43
      - 2.2.2.5 Area-based methods 44
    - 2.3 Case studies: fractal analyses in manufacturing 44
      - 2.3.1 Fractal analyses in thin films 44
      - 2.3.2 Fractal analyses in laser manufacturing 49
      - 2.3.3 Fractal analyses in machining 51
      - 2.3.4 Fractal analyses in friction stir 52
    - 2.4 Conclusions 54
    - Acknowledgment 54
    - References 55
  - 2 Application in Modern Manufacturing Processes 61
    - 3. Weldability appraisement of dissimilar metal joints: application of ultrasonic spot welding to Li-ion batteries 63
      - 3.1 Introduction 63
      - 3.2 USW process 64
      - 3.3 USW system 65
        
        3.3.1 Lateral drive spot welding system 65
        
        3.3.2 Wedge-reed spot welding system 66
      - 3.4 General process parameters 67
      - 3.5 Mechanical analysis of joints 69
        
        3.5.1 Tensile and T-peel strength results 69
        
        3.5.2 Microhardness 70
        
        3.5.3 Fracture surface morphology 72
      - 3.6 Microstructural analysis of joints 73
        
        3.6.1 Optical microscopy of weld cross-section 73
        
        3.6.2 Scanning electron microscopy of fracture surface 76
        
        3.6.3 Energy-dispersive X-ray spectroscopy analysis 76
        
        3.6.4 X-ray diffraction analysis 79
        
        3.6.5 Electron backscatter diffraction analysis 80
        
        3.6.6 Transmission electron microscopy analysis 84
      - 3.7 Conclusions 84
      - References 87
    - 4. Applications of coconut shell ash/particles in modern manufacturing: a case study of friction stir processing 89
      - 4.1 Introduction 89
        
        4.1.1 Application of coconut shell as concrete reinforcement, aggregate, and as filler 90
      - 4.2 Application of coconut shell ash as activated carbon or as charcoal 92
      - 4.3 Application of coconut shell particle as water purification and heavy metals removal 94
      - 4.4 Application of coconut shell in metal, polymer, and ceramic matrix composites 96
      - 4.5 Materials and methods 100
        
        4.5.1 Materials collection and preparation 100
        
        4.5.2 Methodology of friction stir processing 102
      - 4.6 Characterization of the friction stir processed Al7075/CCSA 103
        
        4.6.2 Mechanical properties: tensile analysis 103
        
        4.6.1 Structural integrity of Al7075/CCSA 103
        
        4.6.3 Surface integrity evaluation 104
      - 4.7 Results and discussion 105
        
        4.7.1 Mechanical properties: tensile behavior 105
        
        4.7.3 Structural evaluation analysis: X-ray diffraction results 109
        
        4.7.2 Evaluation of surface integrity for the processed samples 109
      - References 113
      - 4.8 Conclusion 113
      - Conflict of interest 113
    - 5. Fractography analysis and constitutive modeling for dynamic plasticity of austenite stainless steel (ASS 304) at hot-w... 117
      - 5.1 Introduction 117
      - 5.2 Material and experimental details 120
      - 5.3 Microstructure examination and fractography 121
      - 5.4 Constitutive models 126
      - 5.5 Constitutive model (m-FB) modified Fields–Backofen 127
      - 5.6 Constitutive model (KHL) Khan–Huang–Liang 131
      - 5.7 Johnson–Cook (JC) model 136
      - 5.8 Constitutive equation (m-Arr.) type 137
      - 5.9 Zerilli–Armstrong (m-ZA) model 139
      - 5.10 Constrained optimization 139
      - 5.11 Result and discussion 140
      - 5.12 Conclusion 147
      - Acknowledgment 147
      - References 147
    - 6. Laser transmission welding of dissimilar plastics: analyses of parametric effects and process optimization using grey-b... 151
      - 6.1 Introduction 151
      - 6.2 Grey-based Taguchi method 153
      - 6.3 Experimental work 155
      - 6.4 Parametric analysis 157
      - 6.5 Multiobjective optimization 160
      - 6.6 Conclusion 162
      - References 163
    - 7. Investigations on effect of thickness and rolling direction of thin metal foil on forming limit curves in microformin... 165
      - 7.1 Microforming 165
      - 7.2 Experimental investigations 167
        
        7.2.1 Limiting dome height test—specimen 167
        
        7.2.3 Surface strain measurement 168
        
        7.2.2 Experimental setup 168
        
        7.2.4 Forming limit diagrams 169
        
        7.2.5 Effect of rolling direction on forming limit curve 171
        
        7.2.6 Effect of foil thickness on forming limit curve 172
      - References 174
      - 7.3 Conclusions 174
    - 8. Evaluation and characterization of rolling of brass at cryogenic conditions 177
      - 8.1 Introduction 177
      - Nomenclature 177
      - 8.2 Materials and methods 179
        
        8.2.2 Experimental plan 179
        
        8.2.1 Work piece preparation 179
        
        8.2.3 Experimental setup 181
      - 8.3 Results and discussion 182
      - 8.4 Analysis of variance and regression equation 184
      - 8.5 Conclusions 185
      - References 186
    - 9. Multiaxis CNC programming and machining 187
      - 9.1 Numerical control of machine tools 187
      - 9.2 Integrating CNC and automation 188
        
        9.2.1 5-Axis machining 189
      - 9.3 Flow of commands for 5-axis machine 189
      - 9.4 CNC programming validation 190
      - 9.5 Continuous improvement without editing the CNC program 194
        
        9.5.1 Complex tool path programing in multiaxis machining centers 194
        
        9.5.2 Cutting tool path definition in multiaxis machine tools 195
      - References 195
    - 3 Sustainability in Modern Manufacturing Processes 197
      - 10. Recycling of polyethylene: an attempt to sachet and bottled water sustainability in Ghana 199
        
        10.1 Introduction 199
        
        10.2 Sachet water in Ghana 201
        
        10.3 Challenges of water PE-packaging 202
        
        10.4 Recycling 206
        
        10.4.1 Recycling legislation 206
        
        10.4.2 Recyclates 209
        
        10.4.3 Recycling processes 211
        
        10.4.4 Method of sachet-water waste recycling 214
        
        10.4.5 Cost-benefit analysis of recycling 215
        
        10.5 The way forward 217
        
        References 220
      - 11. Sustainability and survivability in manufacturing sector 225
        
        11.1 Introduction 225
        
        11.2 Elementary concepts of sustainability in manufacturing 227
        
        11.2.1 Metrics 227
        
        11.2.2 Evaluation of manufacturing system performance 229
        
        11.3 Manufacturing process 232
        
        11.3.1 Measures taken in manufacturing process 234
        
        11.4 Survivability of a communication network 235
        
        11.5 Challenges in sustainable development 237
        
        References 238
      - Index 241
      - Back Cover 250

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