Machining and Additive Manufacturing

Additive Manufacturing (AM) technology has emerged as a game changer for manufacturing organizations. In comparison to conventional manufacturing technologies, AM is sustainable and its sustainability advantages are visible in the present scenario. Manufacturing organizations consider the sustainability criteria with all its pillars as economic, environmental, and social factors in their decision-making. The current work aims to rank the sustainability drivers for AM. In this regard, 16 sustainability drivers regarding AM have been identified from the literature and analyzed using Best Worst Method (BWM). The most important and worst driver data and their pairwise comparison have been collected through expert’s opinion. Further, the weight and rank of each driver have been computed using BWM. The study identified the three top-weighted drivers in each aspect of sustainability as design flexibility, less carbon and greenhouse gas emission, and reduced health risks and occupational hazards. The consistency ratio has also been calculated to check the reliability level of the obtained result.

Sustainable manufacturing has become an increasingly important area of research and practice, as manufacturers strive to reduce their environmental impact and improve their business performance. This present study provides a comprehensive review of sustainable manufacturing literature and practices, drawing upon 30 different academic articles. The review covers a range of topics, including the use of technology and digitalization in sustainable manufacturing, sustainable manufacturing practices in specific industries such as the automotive industry, and sustainable supply chain management. The review also explores sustainability assessment methodologies and the use of building information modeling in sustainable construction. The findings suggest that there are numerous opportunities for manufacturers to implement sustainable practices, such as reducing energy consumption, improving waste management, and implementing sustainable supply chain management practices. However, there are also significant challenges to implementing sustainable manufacturing, including a lack of awareness, difficulty in measuring sustainability performance, and the need for significant capital investment. Overall, the review highlights the importance of sustainable manufacturing and provides insights into the challenges and opportunities of implementing sustainable practices. The review also identifies areas for further research, such as exploring the role of policy and regulation in promoting sustainable manufacturing and the potential for circular economy approaches to reduce waste and improve sustainability in manufacturing.

Additive manufacturing has become very handy now a days to check the performance of a prototype product, before launching it to the market. This includes 3D printing of a product layer by layer using various technologies, such as fusion deposition modelling, Vat Photopolymerization, Powder Bed Fusion,Material Jetting etc. in this paper fusion deposition modelling (FDM) technology has been used to print Portable Vacuum cleaner. This paper carries out the performance analysis of a vacuum cleaner based on the performance of the impeller fitted in it. Three different design of impellers are 3D printed with varied design as Open, closed and semi-closed impelers. The performance of these three impellers has been checked using three common parameters, i.e., noise level, particle size of sucking, and battery running hours. AHP analysis has been carried out to find the best-performing impeller. The portable vacuum cleaner has been fabricated using a 3D printer in an additive manufacturing lab. These three impellers have been fabricated using an in-house 3D printer. It is found that closed impeller fitted Vacuum cleaner is giving the best result. This paper will be usefull to academicians as well industrialist to understand the varied performance of any Vacuum cleaner due to change of its Impeller.

The advancement in 3D printing technology has opened great avenues for the fabrication of complex structures for numerous applications. One of the sectors which is influenced by this is electronics. Even though printed electronics have been utilized previously for various applications. However, the adoption of 3D printing for the fabrication of electronic components and devices shows great potential. Moreover, the development of viable materials for the fabrication of electronic components and devices has further paved the way for the utilization of the 3D printing approach for printed electronics. This noncontact type method is developing at the quickest rate right now, which is gaining importance for media, healthcare, aerospace, transportation, and other sectors. The present paper discusses the recent advancements in 3D printing technologies and materials for electronics. A comparison of contact and noncontact type printing is also presented.

Electrochemical micromachining (ECMM) is an advanced non-traditional machining process that utilizes electrochemical principles to shape and contour various conductive materials. This review paper aims to provide an overview of ECMM including its principles, processes, and applications. Electrochemical micromachining (ECMM) has attracted a lot of research interest due to its unique ability to produce flawless surfaces. This is because there is a growing need for perfect surface quality in micro-applications like microfluidic systems and the production of intricate precision holes in complex shapes for the automotive and aerospace manufacturing industries. The paper begins by elucidating the fundamental principles underlying ECMM emphasizing the interaction between the workpiece and the electrolyte in the presence of an electric field. The electrochemical reactions involved in ECMM such as anodic dissolution and metal deposition are explained in detail to elucidate the material removal mechanisms. This review paper aims to provide a comprehensive understanding of ECMM, its underlying principles various processes, and diverse applications. It serves as a valuable resource for researchers, engineers, and practitioners interested in exploring the potential of ECMM for precision machining in modern industries.

Lubrication is a crucial factor in improving the tribological performance of various components and thus, the overall working performance of an internal combustion engine. This paper addresses the lubrication performance of different lubricants, which are commercially available and used in automobile engines. The experiments are conducted on a four-ball tester for evaluating the tribological performance of selected lubricants, namely SAE20W-50, SAE15W-40, and SAE10W-30. The tests are designed according to ASTM D4172, and the friction and wear performance of the lubricants are characterized for better lubrication performance. The lubricant SAE15W-40 has shown excellent lubrication performance with lower friction coefficient and wear scar diameter among all the tested lubricants.

Digitalisation and intelligentalisation of industrial processes have become a crucial component for the survival of enterprises. Instead of relying on bulk production, businesses are emphasising on personalised manufacturing. Industry 4.0, also known as the fourth industrial revolution, offers a new degree of control over the whole production processing operations, with a particular emphasis on meeting personalised needs. The goal of sustainable energy use is more important than ever. Without inflicting more damage to the environment, companies are seeking more efficient and effective delivery methods. With the support of sector 4.0, the sustainable energy industry has developed intelligent energy networks to minimise new path dependence. Utilising energy derived from solar photovoltaic or wind systems may aid decentralisation. This will allow the user to monitor and regulate their energy use. The purpose of this article is to examine the recent developments in the fourth Industrial Revolution towards a sustainable future. Various elements of Industry 4.0, including its components, prospects, difficulties, and obstacles in the implementation of Industry 4.0 technology, as well as new trends and streams relevant to Industry 4.0, are explored in this article.

The need of fabrication and control of prosthetic hand is a major concern which needs to be addressed. The unavailability of economical prosthetic hand with adequate functionality further deepens the issue. With the advancement in technology, techniques such as 3D printing and artificial intelligence/machine learning have emerged. These technologies can be utilized for the development of prosthetic hand. 3D printing fills the gap by providing a way to fabricate low-cost prostheses without any need for tools. On the other hand, the use of sensors and AI/ML techniques can provide better control features and functionality in the printed prosthetic hand. The present paper discusses the role of various AI/ML techniques, which can be used for the control of 3D printed prosthetics.

Fractals are structures that repeat themselves in a unique manner such that they appear similar at various scales. These fractals are very evident in structures like snowflakes and veins of a leaf and have inspired mankind for decades. They have also helped us by providing a viable solution for issues like cache locality, micro-mixing and many more. In this work, formation of such fractals on conical plates and the process of making moulds out of it for further use cases has been discussed.

The technique of additive manufacturing (AM), more commonly known as 3D printing, is expanding quickly and enables the production of 3D things from computer-generated models. AM constructs products layer by layer, employing materials including plastics, metals, and ceramics, as opposed to conventional manufacturing methods, which often entail the removal of material to obtain the desired form. There are a lot of benefits to utilizing this technology, such as more design freedom, less waste, and the capacity to make complicated geometries that would be difficult or impossible to make using more conventional methods. The design, prototyping, and manufacturing processes of many different sectors are being influenced by the revolutionary potential of additive manufacturing. These industries include aerospace, automotive, healthcare, and consumer goods. The ultimate goal of this study was to provide the groundwork for further study and development of 3D printing by providing a summary of the technology and an examination of its advantages and disadvantages.

In modern industrial practices, implementation of automation is a primary necessity. Conventional robots aid in manufacturing by increasing efficiency of production processes far beyond human capabilities. Soft robotics, however, provides a better edge, as these robots are more compliant to their environment, relatively safer to work with taking human–machine interactions into account, better at handling fragile objects, and much more. Therefore, their implementation in industrial applications is a desirable change. One such implementation of soft robots is in the form of an arm. However, most of their applications are limited to picking up and placing objects from one location to another. To enhance their scope in industries, they must be capable of performing simple manufacturing operations such as drilling, grinding, etc. Therefore, this study concerns with reviewing past studies on the same line of work with the outcome to propose a design idea of a soft robotic drilling arm.

Every material, product, and production process has an ecological impact. The present study focused on the environmental impact assessment of finishing Polylactic Acid (PLA) parts using hydrogel-based and polymer-based abrasive media. The PLA parts, fabricated using the Fused Deposition Modeling (FDM) process, have been finished through AFM. Then, Life Cycle Assessment (LCA) analysis was performed using SimaPro (Version 9.1.0.8) software. The energy consumed during media preparation, workpiece printing, AFM, media constituents, and work material were considered inventory for LCA analysis. The ReCiPe 2016 V 1.04 midpoint (E) and endpoint(E) modules were used for impact assessment. The LCA results showed that the hydrogel-based AFM process has a less adverse effect on the environment than the polymer-based AFM process. Also, power consumed at different stages was a significant contributor to the impact on the environment. The results of this LCA analysis provide a base for sustainability assessment in the AFM process.

Wire Arc Additive Manufacturing (WAAM) technology has great application potential in the aerospace and automotive industries. The main challenges that substantially impede the widespread use of this technology are the residual stresses in additively manufactured (AM) metal parts. Simulation and investigation studies are carried out to analyze the residual stresses. The present study has developed a finite element model that predicts the residual stress distribution and temperature fields in plates. Goldak’s Heat source model is used to predict the residual stresses and thermal cycles on the SUS 304 and the Python run script is developed to run the model. It has been found that the residual stresses developed during the simulation are 381 MPa and under the yield stress of the material. The simulation has been carried out in the ABAQUS CAE 2020 Software. The maximum yield stress developed in the plate is 679 MPa and the maximum principle stress is 285 MPa. The study has focused on the effort, which is required to establish a relationship between the moving heat source model and residual stresses which helps researchers working in this area to get an insight into the FEM of wire arc additive manufacturing.

For innovators, the fourth industrial transformation is a boon. It has provided a greater and broader scope for the improvement of existing findings, and the development of new and emerging proof of concepts. It has introduced elements that are completely new to the core-manufacturing sectors as well as the research sectors, including cloud computing, internet of things (IoT), big data analytics, additive manufacturing (AM), and many others. When it is up to a manufacturing unit, or a research and development center, prototyping is one of its crucial functions, which is done to analyze the functionality of that particular component before it is actually manufactured for production. Years ago, prototyping was about making conceptual sketches and paper prototypes, but now, it is not the same as it was. The modern world has evolved to the latest prototyping techniques that include digital techniques such as virtual and augmented reality, and AM (3D printing). The quality of the parts produced by the AM method gets better with time therefore to current technical developments in electrical, electronic, and material sciences. The objective of this study is to determine how AM can be applied to provide faster-to-market solutions, prototype parts with reduced mass, and retain its functional efficiency. This work represents an explicit study on how the latest AM techniques can benefit prototyping, and the research & development unit of commercial vehicle manufacturing industries, the impact of implementing AM for making fully functional products, and its scope for mass production in the future.

As a matter of personal and national security, the development of ballistic helmets to defend against attacks from various sources is becoming more and more important. According to research in the military, projectiles that are launched into a soldier’s head are thought to be the cause of about half of their deaths on the battlefield. New threats are always a challenge for the design and manufacture of modern military helmets. The aim of this paper is to discuss the design of the customized helmet based on the size and shape of the head using the photogrammetry method. A human head 3D model is obtained by photogrammetry, and by using the human head model as a reference, a customized helmet is modelled and analysed for various strength criteria. It is found that the deflection of the helmet when a 9 × 19 parabellum bullet strikes it from the side ranges from 0 to 51.68 mm, and the deflection when the bullet strikes from top ranges from 0 to 32.23 mm, which means that the strength of the helmet at the sides is greater than the top portion.

Additive Manufacturing (AM) is one of the innovative technology under Industry 4.0 umbrella, which has captured the interest of academia and industry due to its exponential growth. Successful implementation of AM will enable change in Business models. However, theoretical development in the field of AM with regard to its impact on supply chain management is rare. Further, the main goal is to identify the benefits of AM technologies over conventional manufacturing and their impact on business models. Particularly, this study provides quick access to key arguments about AM impact on the supply chain and conceptual model to enhance sustainability by mediating the role of the supply chain.

The automotive industry has undergone significant transformations in the recent past, and metal 3D printing has emerged as a promising technology that is revolutionizing the way automobile components are manufactured. Metal 3D printing technology, also known as metal additive manufacturing (AM), refers to a process of building metal components by adding metal layers successively until the required geometry is achieved. The process eliminates the need for molds, jigs, and fixtures, thus providing manufacturers with an opportunity to produce intricate and complex components in a short time and at a lower cost. In this review paper, we will examine the applications of metal 3D printing technology in the automobile/automotive industry, the challenges, and the opportunities that it presents. The paper will begin by introducing metal 3D printing and its various types and metal materials that are suitable for the process. The paper will then discuss the applications of metal 3D printing technology in the automobile industry, the benefits, and challenges that come with the technology, and finally, the future of metal additive manufacturing in the automobile industry.

Digital twins of hybrid additive and subtractive manufacturing systems refer to the creation of virtual replicas of these systems, which combine both additive and subtractive manufacturing processes. These digital twins are designed to simulate and optimize the entire manufacturing process, from the initial design to the finished product, using data from the physical system. Hybrid additive and subtractive manufacturing systems are becoming increasingly popular in modern manufacturing processes due to their ability to combine the benefits of both additive and subtractive processes. These systems can produce complex geometries with high precision and accuracy, while also being able to remove excess material and achieve smoother surface finishes. Digital twins of these systems allow manufacturers to simulate and optimize the entire manufacturing process in a virtual environment, before implementing it in the physical system. This enables them to identify and mitigate any potential issues or inefficiencies in the process, leading to reduced costs, improved quality, and faster time-to-market. The creation of digital twins involves the use of advanced modeling and simulation tools, as well as the integration of data from multiple sources, such as CAD models, sensor data, and historical performance data. These tools enable manufacturers to create accurate and realistic virtual replicas of their hybrid additive and subtractive manufacturing systems, which can be used for a variety of purposes, such as design optimization, process validation, and performance monitoring. Overall, digital twins of hybrid additive and subtractive manufacturing systems are a powerful tool for modern manufacturers, providing them with the ability to optimize their manufacturing processes and achieve better results with reduced costs and faster turnaround times.