Ensuring the reliability and performance criterias of crankshafts

The issues of efficiency improvement of manufacturing crankshafts in order to ensure their reliability and performance criteria are the priorities in modern production of internal combustion engines. Using the capabilities of modern special grinding machines can improve the quality of machining and obtain the necessary running characteristics of crankshafts. In work the questions connected with development of a method of calculation of rigidity of crankshafts for increase of accuracy of their machining, reliability and performance criteria’s are considered. Based on the proposed methodology, numerical calculations have performed and the possibility of determining the deflections and crankshafts rigidity in any section have been justified. The original construction of the following grinding steady rest for CNC grinding machines specified for machining the crankshaft main bearing journal and connecting rod journal is proposed. The construction design of the device allows for compensating the influence of the cutting force on the elastic strain of the part, depending on the change in its rigidity. The practical value of the research includes in develop recommendations for determining the optimal parameters for the round infeed grinding cycle of the crank pins from the point of view of productivity and accuracy

Neural network modelling of Abbott-Firestone roughness parameters in honing processes

In present study, three roughness parameters defined in the Abbott-Firestone or bearing area curve, Rk, Rpk and Rvk, were modelled for rough honing processes by means of artificial neural networks (ANN). Input variables were grain size and density of abrasive, pressure of abrasive stones on the workpiece's surface, tangential or rotation speed of the workpiece and linear speed of the honing head. Two strategies were considered, either use of one network for modelling the three parameters at the same time or use of three networks, one for each parameter. Overall best neural network consists of three networks, one for each roughness parameter, with one hidden layer having 25, nine and five neurons for Rk, Rpk and Rvk respectively. However, use of one network for the three roughness parameters would allow addressing an indirect model. In this case, best solution corresponds to two hidden layers having 26 and 11 neurons.Peer ReviewedPostprint (author's final draft

A Systematic Framework for Quantifying Production System-Specific Challenges in Life Cycle Inventory Data Collection

Understanding the environmental impacts of production setups and process parameters is a necessity for process optimization and new process development within sustainable manufacturing. Previous research studies have focused on developing standard methodologies and frameworks for parametrically modelling the life cycle inventories of unit manufacturing processes. However, these approaches do not fully account for the challenges associated with implementing life cycle inventory models in real-world production setups. Therefore, the time- and cost-intensiveness associated with constructing such models limit their use for identifying sustainability-focused process improvements in complex, real-world production processes. To address the above challenges, this paper proposes a framework to identify process inventory data that have a significant influence on process resource consumption, taking into consideration the difficulties and variabilities in measuring these data. The overarching goal is to identify feasible process improvements from the perspective of process monitoring for sustainable manufacturing. The application of the proposed framework is presented using a case study on a real-world through-feed centerless grinding production process for rotor manufacturing. This study reveals grinding time is the most sensitive process parameter among the other time-related parameters. The manual nature of the process, lack of a data acquisition system, non-standardized sequence of operation, and inability to capture in-process measurements without disrupting real-time production significantly contributes to the difficulty and variability of measuring grinding time

A dynamics-driven approach to precision machines design for micro-manufacturing and its implementation perspectives

Precision machines are essential elements in fabricating high quality micro products or micro features and directly affect the machining accuracy, repeatability and efficiency. There are a number of literatures on the design of industrial machine elements and a couple of precision machines commercially available. However, few researchers have systematically addressed the design of precision machines from the dynamics point of view. In this paper, the design issues of precision machines are presented with particular emphasis on the dynamics aspects as the major factors affecting the performance of the precision machines and machining processes. This paper begins with a brief review of the design principles of precision machines with emphasis on machining dynamics. Then design processes of precision machines are discussed, and followed by a practical modelling and simulation approaches. Two case studies are provided including the design and analysis of a fast tool servo system and a 5-axis bench-top micro-milling machine respectively. The design and analysis used in the two case studies are formulated based on the design methodology and guidelines

Advanced Techniques for Assets Maintenance Management

16th IFAC Symposium on Information Control Problems in Manufacturing INCOM 2018 Bergamo, Italy, 11–13 June 2018. Edited by Marco Macchi, László Monostori, Roberto PintoThe aim of this paper is to remark the importance of new and advanced techniques supporting decision making in different business processes for maintenance and assets management, as well as the basic need of adopting a certain management framework with a clear processes map and the corresponding IT supporting systems. Framework processes and systems will be the key fundamental enablers for success and for continuous improvement. The suggested framework will help to define and improve business policies and work procedures for the assets operation and maintenance along their life cycle. The following sections present some achievements on this focus, proposing finally possible future lines for a research agenda within this field of assets management

ADAPTS: An Intelligent Sustainable Conceptual Framework for Engineering Projects

This paper presents a conceptual framework for the optimization of environmental sustainability in engineering projects, both for products and industrial facilities or processes. The main objective of this work is to propose a conceptual framework to help researchers to approach optimization under the criteria of sustainability of engineering projects, making use of current Machine Learning techniques. For the development of this conceptual framework, a bibliographic search has been carried out on the Web of Science. From the selected documents and through a hermeneutic procedure the texts have been analyzed and the conceptual framework has been carried out. A graphic representation pyramid shape is shown to clearly define the variables of the proposed conceptual framework and their relationships. The conceptual framework consists of 5 dimensions; its acronym is ADAPTS. In the base are: (1) the Application to which it is intended, (2) the available DAta, (3) the APproach under which it is operated, and (4) the machine learning Tool used. At the top of the pyramid, (5) the necessary Sensing. A study case is proposed to show its applicability. This work is part of a broader line of research, in terms of optimization under sustainability criteria.Telefónica Chair “Intelligence in Networks” of the University of Seville (Spain

Application of response surface methodology to laser-induced breakdown spectroscopy : influences of hardware configuration

Response Surface Methodology (RSM) was employed to optimise LIBS analysis of single crystal silicon at atmospheric pressure and under vacuum conditions (pressure ~10-6mbar). Multivariate analysis software (StatGraphics 5.1) was used to design and analyse several multi-level, full factorial RSM experiments. A Quality Factor (QF) was conceived as the response parameter for the experiments, representing the quality of the LIBS spectrum captured for a given hardware configuration. The QF enabled the hardware configuration to be adjusted so that a best compromise between resolution, signal intensity and signal noise could be achieved. The effect on the QF of simultaneously adjusting spectrometer gain, gate delay, gate width, lens position and spectrometer slit width was investigated, and the conditions yielding the best QF determined

Assessment of an expediency of binder material mechanical activation in cemented rockfill

This study is aimed to assess the expediency of applying the binder material mechanical activation in a cemented rockfill (CRF), consisting of ground smelter slag, waste of limestone and rock refuse at one of the largest mines, as well as at any other mines which use these components for CRF. The polynomial dependences have been obtained of strength variation of the CRF, which is used in the conditions of studied mine, on the time of consolidation and the ratio of backfill materials. In the CRF mixtures, the mechanical activation was carried out of the granulated blast-furnace slag, and the compliance has been assessed of CRF with the design strength of the backfill massif. In the studied conditions of the ore mine, with ratio of a binder material to filler of 0.5 and the existing cost of backfill materials, the use of mechanical activation of the binder material according to the two-stage grinding scheme turned out to be insufficiently expedient, since the production cost (materials + grinding) of the most economical backfill mixture is only 2.8% less compared with a basic composition. It is noted that the expediency of using the mechanical activation depends on the remoteness of the mineral raw material base, especially the main inert filler that significantly increases the cost of backfilling works. It is shown that in the operating conditions of other mines with a similar component proportion and a close rich mineral raw base, the mechanical activation of the binder material can be enough effective. It has been determined that with an increase in ratio of Cbin/Cin from 1.0 to 4.6, the difference in costs for the backfill mixture production in the considered compositions, where mechanical activation was performed, increases in a positive direction, but for the most economical backfill mixture, if compared to the basic one, it will be changed from 16.8 to 46.0%. An attention is focused on possible ways to increase the expediency of applying the mechanical activation of the binder material by means of forming the backfill massif with different strength along the height of the stope chamber