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2011 | Book

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Advanced Modeling and Optimization of Manufacturing Processes

International Research and Development

Author: R. Venkata Rao

Publisher: Springer London

Book Series : Springer Series in Advanced Manufacturing

Part of: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik" , Springer Professional "Wirtschaft"

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About this book

Advanced Modeling and Optimization of Manufacturing Processes presents a comprehensive review of the latest international research and development trends in the modeling and optimization of manufacturing processes, with a focus on machining. It uses examples of various manufacturing processes to demonstrate advanced modeling and optimization techniques. Both basic and advanced concepts are presented for various manufacturing processes, mathematical models, traditional and non-traditional optimization techniques, and real case studies. The results of the application of the proposed methods are also covered and the book highlights the most useful modeling and optimization strategies for achieving best process performance. In addition to covering the advanced modeling, optimization and environmental aspects of machining processes, Advanced Modeling and Optimization of Manufacturing Processes also covers the latest technological advances, including rapid prototyping and tooling, micromachining, and nano-finishing. Advanced Modeling and Optimization of Manufacturing Processes is written for designers and manufacturing engineers who are responsible for the technical aspects of product realization, as it presents new models and optimization techniques to make their work easier, more efficient, and more effective. It is also a useful text for practitioners, researchers, and advanced students in mechanical, industrial, and manufacturing engineering.

Table of Contents

Frontmatter
Chapter 1. Overview
Abstract
Manufacturing is the backbone of any industrialized nation. Its importance is emphasized by the fact that, as an economic activity, it comprises approximately 20–30% of the value of all goods and services produced. A country’s level of manufacturing activity is directly related to its economic health. In general, the higher the level of manufacturing activity in a country, the higher the standard of living of its people.
R. Venkata Rao
Chapter 2. Modeling and Optimization of Machining Processes
Abstract
Machining operations have been the core of the manufacturing industry since the industrial revolution. Machining is a process of material removal using cutting tools and machine tools to accurately obtain the required product dimensions with good surface finish. The manufacturing industries strive to achieve either a minimum cost of production or a maximum production rate, or an optimum combination of both, along with better product quality in machining.
R. Venkata Rao
Chapter 3. Modeling and Optimization of Modern Machining Processes
Abstract
AWJM process uses a high velocity water jet in combination with abrasive particles for cutting different types of materials using a setup as shown in Fig. 3.1. A stream of small abrasive particles is introduced and entrained in the water jet in such a manner that water jet’s momentum is partly transferred to the abrasive particles. The process thus combines the benefit of the two other advanced machining processes namely, WJM and AJM. This process relies on erosive action of an abrasive laden water jet for applications of cutting, drilling, and general cleaning and descaling of thick sections of very soft to very hard materials at high rates. Visual examination of the cutting process in AWJM suggests two dominant modes of material removal. First is erosion by cutting wear due to particle impact at shallow angles on the top surface of the kerf. Second is deformation wear due to excessive plastic deformation caused by particle impact at large angles, deeper into the kerf.
R. Venkata Rao
Chapter 4. Modeling and Optimization of Nano-finishing Processes
Abstract
Finishing operations represent a critical and expensive phase of overall production processes. The most labor intensive, uncontrollable area in the manufacturing of precision parts involves final finishing operations, which frequently demand as much as 15% of the total manufacturing cost. The dimensional and alignment accuracy and quality of surface finish are taken care of by finishing processes such as grinding, lapping, honing, and super-finishing (i.e. traditional methods of finishing). But, the applications of these traditional abrasive finishing processes are limited to the production of work pieces of basic forms such as flat, cylindrical, etc. These finishing processes are being pushed to their limits of performance especially in components of hard materials and complicated shapes. The need to develop finishing processes with wider bounds of application areas, better quality performance, higher productivity, and automatic operation has led to the development of nano-finishing processes.
R. Venkata Rao
Chapter 5. Modeling and Optimization of Rapid Prototyping Processes
Abstract
In a competitive market, the speed with which a product flows from concept to marketable product plays a crucial role. It is well known that products that are introduced before their competitors are generally more profitable and enjoy a larger share of the market. At the same time, there are important concerns regarding the production of high-quality products. For these reasons, there is a concerted effort to bring high-quality products to market quickly.
R. Venkata Rao
Chapter 6. Environmental Aspects of Manufacturing Processes
Abstract
Nowadays, ever-increasing environmental problems are becoming a serious threat to the survival and development of society. After the publishing of ISO 9000 quality management standards, the ISO 14000 environmental management system standards, and the OHSAS 18001 occupational health and safety assessment series, one of our greatest strategic challenges is to apply the three series integrated into a management system in enterprises, not only from an engineering but also from a business and marketing perspective. The manufacturing industry is one of the main roots of environmental pollution. Therefore, minimizing the environmental impact of the manufacturing industry has become an important topic for all manufacturers. During these critical times, an advanced manufacturing mode, green manufacturing, suitable for a sustainable development strategy has been presented.
There is a growing interest in green manufacturing [also called environmentally conscious manufacturing (ECM)]. The current focus on green manufacturing is different from the traditional focus on pollution control. Here, the emphasis is on life cycle assessment (LCA). Products or processes are seen as interacting with the environment, and could have chain reaction effects on environmental pollution. Thus, rather than looking at any product or process in isolation, the manufacturer needs to adopt a cradle-to-grave approach for the product or process. For example, how much energy is expended in unit product manufacturing, how much resources are used, how much waste is created, and what are the product requirements for transportation and distribution? These are not issues that product designers are accustomed to considering. Their traditional role has been to look at the product on its own, and design products that meet specific guidelines and that may become environmental pollution laws. Today’s focus is different. Manufacturers must take a product stewardship approach, and this will predict their survival in today’s competitive environment [33].
R. Venkata Rao
Backmatter
Metadata
Title
Advanced Modeling and Optimization of Manufacturing Processes
Author
R. Venkata Rao
Copyright Year
2011
Publisher
Springer London
Electronic ISBN
978-0-85729-015-1
Print ISBN
978-0-85729-014-4
DOI
https://doi.org/10.1007/978-0-85729-015-1

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