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Sustainable Machining and Green Manufacturing

Edited by S. Thirumalai Kumaran and Tae Jo Ko
Copyright: 2024   |   Status: Published
ISBN: 9781394197835  |  Hardcover  |  
338 pages
Price: $195 USD
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One Line Description
In an era defined by rapid technological advancements and an increasing
awareness of environmental sustainability, this book analyses the intersection of science and the manufacturing industry.

Audience
The book will be of importance to manufacturing engineers and policymakers in multiple industries, as well as researchers and postgraduate students in mechanical and manufacturing engineering, robotics, materials science, artificial intelligence and allied fields.

Description
As a knowledge roadmap, this book explains how to reduce, recycle, and reuse materials while promoting environmentally-friendly practices, such as dry machining and eco-friendly cutting fluids .With a thorough investigation of the synergy between natural fibers and epoxy composites— specifically showing how filler materials enhance mechanical properties—this book explores both the potential of sustainable reinforcements in polymer composites and the adaptability of these materials for diverse applications. The volume reveals how manufacturing methods can determine the mechanical prowess of biofiber-reinforced composites, and reviews how advanced composite materials are revolutionizing biomedical devices.
Readers will learn how environmentally conscious manufacturing processes can coexist with industrial production, with attention paid to the intricacies of composite filament production in the innovative world of additive manufacturing. Furthermore, the book explores the delicate balance between material selection and joining techniques, focusing on sustainability in the manufacturing process. Other topics include:
• how natural materials can address environmental challenges, highlighting sustainable wastewater treatment;
• how welding in sustainable manufacturing practices can bridge the gap between tradition and innovation;
• the future of robotics where sustainability plays a central role in engineering design;
• green manufacturing practices in the automotive industry;
• waste reduction, using green principles to optimize manufacturing processes;
• the synergy between design and sustainability in additive manufacturing, illustrating the potential for minimizing waste and energy consumption;
• the intricacies of process optimization in additive manufacturing;
• cutting-edge precision machining technologies that transform the usage of materials.

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Author / Editor Details
S. Thirumalai Kumaran, PhD, is an associate professor in the Department of Mechanical Engineering, PSG Institute of Technology and Applied Research, Chennai, India. He completed his PhD in mechanical engineering in 2015 from Kalasalingam Academy of Research and Education. He has published more than 100 articles in SCI journals and received a gold medal in manufacturing engineering from the Government College of Technology in 2008.

Tae Jo Ko, PhD, is a professor at the School of Mechanical Engineering, Yeaungnam University, Gyeongsan-si, South Korea. He received a PhD in mechanical engineering from POSTECH, South Korea. Professor Tae Jo Koe has more than 300 publications in SCI journals, and has launched new research in rechargeable batteries and digital twins for manufacturing. He is the editor of the International Journal of Precision Engineering and Manufacturing and the Journal of Nanotechnology.

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Table of Contents
Preface
1. Effect of Granite Filler on Mechanical Properties and Free Damping of Silk-Sisal–Reinforced Epoxy Composites
K. Sripriyan and S. Karthick
1.1 Introduction
1.2 Material and Preparation
1.2.1 Materials Involved
1.2.2 Composite Structure Preparation
1.3 Result and Discussion
1.3.1 Silk-Sisal on Mechanical Properties
1.3.1.1 Flexural Strength
1.3.1.2 Impact Strength
1.3.2 Damping Response
1.3.3 Fracture Morphology
1.3.4 Biodegradability
1.4 Conclusions
References
2. Effect of Plastic Particulate Addition on Polymer Composite Reinforced with Prosopis juliflora Fiber
Sakthi Balan G., Aravind Raj S., Jafrey Daniel James D. and Ramesh M.
2.1 Introduction
2.2 Materials and Methods
2.3 Results and Discussion
2.3.1 Influence of Process Parameters
2.3.2 Regression Analysis
2.3.3 Optimized Responses
2.4 Conclusion
References
3. Effect of Various Manufacturing Techniques on Mechanical Properties of Biofiber-Reinforced Composites
M. Sasi Kumar, S. Sathish, M. Makeshkumar, S. Gokulkumar, L. Prabhu, S. Hemalatha, S. Ponnavan and Nancy Chopra
3.1 Introduction
3.2 Manufacturing Methods
3.3 Hand Layup Technique
3.4 Compression Techniques
3.4.1 Mechanical Properties of Products Made by Compression Molding Techniques
3.5 Injection Technique
3.6 Filament Techniques
3.7 Vacuum-Assisted Resin Transfer Molding Technique
3.8 Spray Molding Technique
3.9 Conclusion
References
4. Electrical Discharge Machining of Al-B4C Composite for Biomedical Applications
S. Suresh Kumar, S. Thirumalai Kumaran, G. Kalusuraman and G. S. Samy
4.1 Introduction
4.2 Materials and Methods
4.3 Results and Discussion
4.3.1 Surface Roughness and Overcut
4.3.2 Material Removal Rate
4.3.3 Surface Morphology
4.4 Conclusion
References
5. Green Manufacturing of Natural Fiber Composite
Meenal Batra and Alka Bali
5.1 Introduction
5.2 Characteristics of Natural Fibers
5.3 Classes of Natural Fibers
5.4 Polymer Matrix
5.5 Applications of Natural Fiber Composites
5.5.1 Applications in Automotive and Aerospace Industry
5.5.2 Medical Applications
5.5.3 Construction
5.5.4 Sports and Chemical Industry
5.6 Preprocessing of Natural Fiber Composites
5.6.1 Surface Modification
5.6.2 Modifying the Polymer Matrix with Compatibilizing Agents
5.7 Fabrication of Natural Fiber Composites
5.7.1 Open Molding Techniques
5.7.1.1 Hand Lay Technique
5.7.1.2 Spray Up Technique
5.7.2 Closed Molding Techniques
5.7.2.1 Resin Transfer Molding
5.7.2.2 Resin Injection Molding
5.7.2.3 Compression Molding Technique
5.7.2.4 Vacuum Bagging Process
5.7.2.5 Vacuum-Assisted Resin Transfer Molding
5.8 Additive Manufacturing
5.8.1 Stereolithography
5.8.2 Direct Light Processing
5.8.3 Fused Filament Fabrication
5.8.4 Laminated Object Manufacturing
5.8.5 Direct Ink Writing
5.8.6 Selective Laser Sintering
5.8.7 Binder Jetting
5.8.8 Electron Beam Melting
5.9 Additive Manufacturing of Different Composites
5.10 Critical Issues During Processing of Natural Fiber Composites
5.10.1 Thermal Stability
5.10.2 Hydrophilic Nature of Natural Fibers
5.10.3 Fiber Breakage During Processing
5.10.4 Moisture Absorption and Distribution of Fiber Inside the Matrix
5.11 Conclusion
References
6. Manufacturing Issues and Process Parameters of Composite Filament for Additive Manufacturing Process
Jafrey Daniel James D., Ramesh M., Sakthi Balan G. and Aravind Raj S.
6.1 Introduction
6.2 Materials and Properties
6.2.1 Preparation of HDPE/PBI Filaments
6.2.2 Processing Conditions for HDPE/PBI Nanocomposites
6.3 Results and Discussion
6.3.1 Screw Speed of Volumetric Hopper for the Production of the HDPE/PBI Composite
6.3.2 Temperature Profile Distribution and Zone Barrel Temperatures for the TSE to Fabricate HDPE/PBI Nanocomposites
6.3.3 TSE Screw Speed for HDPE/PBI Composite Material Manufacture
6.3.4 TSE Degassing Pressure for Manufacturing of HDPE/PBI Composites
6.3.5 TSE Cooling Length for Manufactured HDPE/PBI Composite Strands
6.3.6 Extrusion Parameters for Manufacturing of HDPE/PBI Composites
6.3.7 Manufacturing Issues During the Process of Filament Preparation
6.3.7.1 Thinning of Filament
6.3.7.2 Bending of Filament
6.3.7.3 Impurities and Bulges
6.3.7.4 Porosity in Filament
6.3.8 Tensile Test
6.3.9 FE-SEM
6.4 Conclusion
References
7. Material Sustainability During Friction Stir Joining
Raheem Al-Sabur and M. Serier
7.1 Introduction
7.2 FSW Parameters
7.2.1 Rotation Tool Speed and Traverse Velocity
7.2.2 Plunge Depth and Tilt Angle
7.3 FSW Sustainability Review
7.4 FSW Sustainability Aspects
7.4.1 Minimizing the FSW Costs
7.4.2 Minimizing the FSW Energy Consumption
7.4.3 Maximizing the FSW Process Efficiency
7.4.4 Minimizing the Environmental Impact
7.5 Recent Modifications in FSW Processes
7.5.1 Double-Sided FSW Tool
7.5.2 Twin-Tool FSW Process
7.5.3 Dual-Rotation FSW Process
7.5.4 Friction Stir Spot Welding
7.6 Recent Applications of FSW
7.7 Conclusions
References
8. Plant-Based Biosorbents for Heavy Metal Removal From Wastewater
Narmadha V. and Siddhi Sreemahadevan
8.1 Introduction
8.2 Physical and Chemical Techniques for Heavy Metal Removal
8.2.1 Chemical Precipitation
8.2.2 Coagulation
8.2.3 Membrane Separation
8.2.4 Ion Exchange Method
8.2.5 Adsorption
8.3 Biological Methods for Heavy Metal Removal
8.3.1 Phytoremediation
8.4 Biochar
8.4.1 Mechanism of Biochar Adsorption
8.4.1.1 Precipitation
8.4.1.2 Surface Complexation
8.4.1.3 Ion Exchange
8.4.1.4 Electrostatic Sorption
8.4.2 Immobilized Biochar
8.5 Plant-Based Biochar
8.5.1 Biochar From Eichhornia crassipes
8.5.2 Heavy Metal Removal Using Biosorbent-Immobilized Alginate Beads
8.6 A Comparison of Techniques for Removing Heavy Metals
8.7 Conclusion
References
9. Sustainability in Manufacturing: Welding’s Role as a Frontier
P. Arunkumar, N. Muthukumaran, K. S. Ramaneedharan, N. S. Mithun, B. Sanjay, K. Solaiyappan, S. Gokul and B. Arulmurugan
9.1 Introduction
9.2 Sustainability Assessment in Welding
9.2.1 Sustainability Assessment of the SMAW Process
9.2.2 Sustainability Assessment of the GTAW/TIG Process
9.2.3 Sustainability Assessment of the MIG/GMAW Process
9.2.4 Sustainability Assessment of the SAW Process
9.2.5 Sustainability Assessment of the FSW Process
9.2.6 Sustainability Assessment of the Laser Beam Welding Process
9.3 Welding Processes Study on Sustainability Assessment
9.4 5S Lean Strategy for Sustainability Manufacturing
9.5 Conclusion
References
10. Sustainable Development of Redundant Articulated Robot Components Using Simscape Multibody
M. Saravana Mohan, P. S. Samuel Ratna Kumar and P. M. Mashinini
10.1 Introduction
10.2 CAD Modeling
10.3 Assigning Aluminum A308 Alloy for RAR
10.4 Kinematics and Dynamic Studies
10.5 Assigning DH Parameters
10.6 Simscape Multibody Simulation
10.7 Torque Results Using Simscape Multibody
10.8 Static Analysis Under Twisting Moment
10.8.1 Mesh Properties
10.8.2 Postprocess of Max Stress
10.8.3 Postprocess of Deformation
10.9 Work Envelope of RAR
10.10 Fatigue Report of RAR
10.11 Conclusion
References
11. Implementation of Green Manufacturing Practices in Automobile Fields: A Review
Sampath Boopathi
11.1 Introduction
11.2 Green Manufacturing Production
11.2.1 Green Marketing
11.2.2 Government Support and Regulations
11.2.3 Identifying Problems in Automobile Fields
11.2.4 Green Manufacturing: Automotive Research Focus
11.2.5 Green Manufacturing Efficiency
11.3 Green Manufacturing in the Automobile Field
11.3.1 Green Manufacturing for Reduction of Emission
11.3.2 Green Manufacturing to Minimize Automobile Waste
11.3.3 Green Manufacturing: Resource Utilization
11.3.4 Green Manufacturing: Cost Minimization
11.3.5 Implementation of Green Manufacturing in the Automobile Field
11.4 Green Manufacturing Practices in the Automotive Field
11.4.1 Automotive Emission Control Practices
11.4.2 Manufacturing Cost Reduction Practices
11.4.3 Waste Reduction Practices
11.4.4 Resource Utilization Practices
11.4.5 ERP for Green Manufacturing Practices
11.4.5.1 Enterprise Resource Planning
11.4.5.2 Supply Chain Management
11.5 Case Study: Automobile Green Manufacturing Firm
11.5.1 Green Methodology
11.5.2 Implementation Procedures
11.5.2.1 Green Procurement
11.5.2.2 Environment Policies
11.5.2.3 Green Design
11.5.2.4 Green Manufacturing
11.5.2.5 Green Utilization
11.5.2.6 Provide Training for Improving Employee Involvement
11.5.2.7 Customers Responsiveness Program
11.5.2.8 Automobile Industry Commitments
11.5.3 Outcomes
11.6 Case Study: Water Conservation Technologies
11.6.1 Technical Factors for Implementations
11.6.2 Low-Flow Outlets
11.6.3 Waterless Urinals
11.6.4 Washdown in Toilets
11.6.5 Outcomes
References
12. Minimization of Manufacturing Industry Wastes Through the Green Lean Sigma Principle
Sampath Boopathi
12.1 Introduction
12.2 Challenges to the Manufacturing Sector
12.3 GT and Manufacturing Development Procedure
12.3.1 Identification of the Present State
12.3.2 Planning
12.3.3 Implementation
12.3.4 Sustainability
12.4 Green Lean Manufacturing Terminologies
12.4.1 Lean Manufacturing
12.4.2 Green Lean Interactions
12.4.3 Restrictions of the Green Lean Approach
12.4.4 Six Sigma
12.4.5 Define-Measure-Analyze-Improve-Control (DMAIC) Methodology
12.4.6 Green Lean Six Sigma
12.4.7 Capacity and Capacity Waste
12.4.7.1 Concept of Capacity
12.4.7.2 Capacity Utilization: Concept and Significance
12.4.7.3 Estimation of Capacity Waste
12.5 Real-Time Problem Formulation and Research Approach
12.5.1 Integration Measure and Model of GLS
12.5.2 Green Lean Six Sigma Framework
12.5.2.1 Project Identification
12.5.2.2 Assessment of the Project
12.5.2.3 Root and Cause Discussion
12.5.2.4 Finding Solutions
12.5.2.5 Sustain the Best Solution
12.5.3 Green Lean Six Sigma Tools
12.6 Green Lean Six Sigma Barriers
12.6.1 Research Approaches for Barriers
12.6.1.1 Identification and Clustering of Barriers
12.6.1.2 Classification and Prioritization
12.6.2 Practical and Theoretical Implications
12.7 Conclusion
References
13. Design for Sustainable Methods in Additive Manufacturing
Akesh B. Kakarla and Ing Kong
13.1 Introduction
13.2 Ecological Impacts of Additive Manufacturing
13.2.1 Materials
13.2.2 Energy Consumption
13.3 Life Cycle Analysis
13.4 Implications of Sustainable Development in AM
13.4.1 Design and Process of Product
13.4.2 Product Redesign
13.4.3 Process Redesign
13.4.4 Raw Materials
13.4.5 Transformation of By-Product Into Product
13.4.6 Closed-Loop Manufacturing
13.5 Conclusions
References
14. Optimization of Fused Deposition Modeling Control Parameters Using Hybrid Taguchi and TOPSIS Method
B. Singaravel, T. Niranjan, M. Vasu Babu and K. Nagarjuna
14.1 Introduction
14.2 Literature Review
14.3 Experimental Setup
14.4 Methodology
14.5 Results and Discussion
14.6 Conclusions
References
15. Sustainable Machining of Monel 400 Using Cryogenic Treated Tool
S. Balakrishnan, K. Senthilkumar and S. Thirumalai Kumaran
15.1 Introduction
15.2 Materials and Methods
15.2.1 Fabrication of Workpieces
15.2.2 Taguchi Experimental Design
15.2.3 CNC Milling Operation
15.2.4 Cutter Selection
15.3 Results and Discussion
15.4 Conclusion
References
Index

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