Design of a Spiral Double-Cutting Machine for an Automotive Bowden Cable Assembly Line

The manufacture of automotive components requires innovative technologies and equipment. Due to the competitiveness in the sector, the implementation of automatic and robotic equipment has been vital in its development to produce the largest number of products in the shortest amount of time. Automation leads to a significant reduction in defects and enables mass production and standardization of the final product. This work was based on the need of an automotive components’ company to increase the rate of spiral cable cutting, used as protection for Bowden (control) cables. Currently, this component, used in automotive systems, is processed with simple cutting machines and cleaning machines. Based on the design science research (DSR) methodology, this work aims to develop a machine capable of performing the cutting and cleaning of two spiral cables simultaneously and automatically. The development of this machine was based on existing machines, and the biggest challenge was the implementation of a double-cutting system. The designed machine met the initial requirements, such as enabling the simultaneous cut of two spirals, being fully automatic, doubling the output over the current solution, and fully complying with the current legislation.info:eu-repo/semantics/publishedVersio

Improving the Efficiency of the Bowden Cable Terminal Injection Process for the Automotive Industry

Control cables transfer force between two separate locations by a flexible mean, and hence, they are important in the automotive industry and many others; their terminals interact with both moving and moved mechanisms, so they must be strong. Cable terminals are commonly made of ZAMAK and are created by injection molding. However, such a production method requires leaving extra material to allow the correct molding, also known as sprues, which are removed later in the process. In this case, the sprues were separating from the terminals in an uncontrolled way. In this work, the cause of sprues separating prematurely from the terminals in a production line is addressed. The whole process was analyzed, and each possible solution was evaluated using process improvement techniques and the Finite Element Method, leading to the best solutions. Molds, mold structures, and auxiliary equipment were improved, resulting in a minimally invasive intervention and remaining compatible with other equipment. Cost analyses were done, indicating an investment return in less than a year. The modification led to a reduction of 62.6% in the sprue mass, while porosity was reduced by 10.2% and 55.9%, corresponding to two terminal models. In conclusion, the interventions fulfilled the requirements and improved the operation of the line.info:eu-repo/semantics/publishedVersio

Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Recent advances in technology and refinement of available computational resources paved the way for the extensive use of computers to model and simulate complex real-world problems difficult to solve analytically. The appeal of simulations lies in the ability to predict the significance of a change to the system under study. The simulated results can be of great benefit in predicting various behaviors, such as the wind pattern in a particular region, the ability of a material to withstand a dynamic load, or even the behavior of a workpiece under a particular type of machining. This paper deals with the mathematical modeling and simulation techniques used in abrasive-based machining processes such as abrasive flow machining (AFM), magnetic-based finishing processes, i.e., magnetic abrasive finishing (MAF) process, magnetorheological finishing (MRF) process, and ball-end type magnetorheological finishing process (BEMRF). The paper also aims to highlight the advances and obstacles associated with these techniques and their applications in flow machining. This study contributes the better understanding by examining the available modeling and simulation techniques such as Molecular Dynamic Simulation (MDS), Computational Fluid Dynamics (CFD), Finite Element Method (FEM), Discrete Element Method (DEM), Multivariable Regression Analysis (MVRA), Artificial Neural Network (ANN), Response Surface Analysis (RSA), Stochastic Modeling and Simulation by Data Dependent System (DDS). Among these methods, CFD and FEM can be performed with the available commercial software, while DEM and MDS performed using the computer programming-based platform, i.e., "LAMMPS Molecular Dynamics Simulator," or C, C++, or Python programming, and these methods seem more promising techniques for modeling and simulation of loose abrasive-based machining processes. The other four methods (MVRA, ANN, RSA, and DDS) are experimental and based on statistical approaches that can be used for mathematical modeling of loose abrasive-based machining processes. Additionally, it suggests areas for further investigation and offers a priceless bibliography of earlier studies on the modeling and simulation techniques for abrasive-based machining processes. Researchers studying mathematical modeling of various micro- and nanofinishing techniques for different applications may find this review article to be of great help

Energy System 4.0: Digitalization of the Energy Sector with Inclination towards Sustainability

The United Nations’ sustainable development goals have emphasized implementing sustainability to ensure environmental security for the future. Affordable energy, clean energy, and innovation in infrastructure are the relevant sustainable development goals that are applied to the energy sector. At present, digital technologies have a significant capability to realize the target of sustainability in energy. With this motivation, the study aims to discuss the significance of different digital technologies such as the Internet of Things (IoT), artificial intelligence (AI), edge computing, blockchain, and big data and their implementation in the different stages of energy such as generation, distribution, transmission, smart grid, and energy trading. The study also discusses the different architecture that has been implemented by previous studies for smart grid computing. Additionally, we addressed IoT-based microgrids, IoT services in electrical equipment, and blockchain-based energy trading. Finally, the article discusses the challenges and recommendations for the effective implementation of digital technologies in the energy sector for meeting sustainability. Big data for energy analytics, digital twins in smart grid modeling, virtual power plants with Metaverse, and green IoT are the major vital recommendations that are discussed in this study for future enhancement

Development of Carbon Nanotube (CNT)-Reinforced Mg Alloys: Fabrication Routes and Mechanical Properties

Properties such as superior specific strength, being imponderous, and the ability to reprocess are the key features that have drawn attention to magnesium. In the last few years, applications such as automotive, aerospace, and medical applications have been seeking light-weight equipment, and light-weight materials are required for making them. These demands were matched by developing metal matrix composites with magnesium as a base and reinforced with carbon nanotubes (CNTs), grapheme nanoplatelets (GNPs), or ceramic nanoparticles. CNTs have been adopted for developing high-strength metal matrix composites (MMCs) because of their delicately superior thermal conductivity, surface-to-volume ratio, and tensile strength, but lower density. In developing high-performance light-weight magnesium-based MMCs, a small number of CNTs result in refined properties. However, making Mg-based MMCs has specific challenges, such as achieving uniform reinforcement distribution, which directly relates to the processing parameters. The composition of CNT, CNT sizes, their uniform distribution, Mg-CNT interfacial bonding, and their in-between alignment are the characteristic deciding factors of Mg-CNT MMCs. The current review article studies the modern methods to develop Mg-CNT MMCs, specifications of the developed MMCs, and their vital applications in various fields. This review focuses on sifting and summarizing the most relevant studies carried out on the methods to develop Mg-CNT metal matrix composites. The article consists of the approach to subdue the tangled situations in highlighting the Mg-CNT composites as imminent fabrication material that is applicable in aerospace, medical, and automotive fields

Sensitivity Analysis for Decisive Design Parameters for Energy and Indoor Visual Performances of a Glazed Façade Office Building

The large size of a glazed component allows greater access to natural light inside and a wider view of the outdoors while protecting the inside from extreme weather conditions. However, glazed components make buildings energy inefficient compared to opaque components if not designed suitably, and sometimes they create glare discomforts too. In order to protect against excessive natural light and direct sunlight and for privacy, dynamic shading devices are integrated into the glazed façade. In this study, the impact of various glazing and shading design parameters has been investigated by performing uncertainty and sensitivity analyses. The uncertainty analysis indicates that the variance coefficients for the source energy use, lighting energy use, useful daylight illuminance (UDI), and shade-deployed time fraction are in the ranges of 15.04–30.47, 39.05–45.06, 40.57–49.92, and 19.35–52%, respectively. The dispersion in the energy and indoor visual performance is evident by the large variation in the source energy consumption and UDI (500–2000), which vary in the ranges of 250–450 kWh/(m2-year) and 5–90%. Furthermore, a sensitivity analysis identified the window-to-wall ratio (WWR), aspect ratio (ASR), glazing type (Gt), absorptance of the wall (Aw), and shade transmittance (ST) as major influences of the parameters. Each of the identified parameters has a different proportionate impact depending on the façade orientation and performance parameters

Significance of Alloying Elements on the Mechanical Characteristics of Mg-Based Materials for Biomedical Applications

Magnesium alloys are widely employed in various applications due to their high strength-to-weight ratio and superior mechanical properties as compared to unalloyed Magnesium. Alloying is considered an important way to enhance the strength of the metal matrix composite but it significantly influences the damping property of pure magnesium, while controlling the rate of corrosion for Mg-based material remains critical in the biological environment. Therefore, it is essential to reinforce the magnesium alloy with a suitable alloying element that improves the mechanical characteristics and resistance to corrosion of Mg-based material. Biocompatibility, biodegradability, lower stress shielding effect, bio-activeness, and non-toxicity are the important parameters for biomedical applications other than mechanical and corrosion properties. The development of various surface modifications is also considered a suitable approach to control the degradation rate of Mg-based materials, making lightweight Mg-based materials highly suitable for biomedical implants. This review article discusses the various binary and ternary Mg alloys, which are mostly composed of Al, Ca, Zn, Mn, and rare earth (RE) elements as well as various non-toxic elements which are Si, Bi, Ag, Ca, Zr, Zn, Mn, Sr, Li, Sn, etc. The effects of these alloying elements on the microstructure, the mechanical characteristics, and the corrosion properties of Mg-based materials were analyzed. The mechanical and corrosion behavior of Mg-based materials depends upon the percentage of elements and the number of alloying elements used in Mg. The outcomes suggested that ZEK100, WE43, and EW62 (Mg-6% Nd-2% Y-0.5% Zr) alloys are effectively used for biomedical applications, having preferable biodegradable, biocompatible, bioactive implant materials with a lower corrosion rate

Significance of Alloying Elements on the Mechanical Characteristics of Mg-Based Materials for Biomedical Applications

Magnesium alloys are widely employed in various applications due to their high strength-to-weight ratio and superior mechanical properties as compared to unalloyed Magnesium. Alloying is considered an important way to enhance the strength of the metal matrix composite but it significantly influences the damping property of pure magnesium, while controlling the rate of corrosion for Mg-based material remains critical in the biological environment. Therefore, it is essential to reinforce the magnesium alloy with a suitable alloying element that improves the mechanical characteristics and resistance to corrosion of Mg-based material. Biocompatibility, biodegradability, lower stress shielding effect, bio-activeness, and non-toxicity are the important parameters for biomedical applications other than mechanical and corrosion properties. The development of various surface modifications is also considered a suitable approach to control the degradation rate of Mg-based materials, making lightweight Mg-based materials highly suitable for biomedical implants. This review article discusses the various binary and ternary Mg alloys, which are mostly composed of Al, Ca, Zn, Mn, and rare earth (RE) elements as well as various non-toxic elements which are Si, Bi, Ag, Ca, Zr, Zn, Mn, Sr, Li, Sn, etc. The effects of these alloying elements on the microstructure, the mechanical characteristics, and the corrosion properties of Mg-based materials were analyzed. The mechanical and corrosion behavior of Mg-based materials depends upon the percentage of elements and the number of alloying elements used in Mg. The outcomes suggested that ZEK100, WE43, and EW62 (Mg-6% Nd-2% Y-0.5% Zr) alloys are effectively used for biomedical applications, having preferable biodegradable, biocompatible, bioactive implant materials with a lower corrosion rate