Sustainable manufacturing and parametric analysis of mild steel grade 60 by deploying CNC milling machine and Taguchi method

Design and manufacturing are the key steps in the sustainable manufacturing of any product to be produced. Within the perspective of injection molds production, increased competitiveness and repeated changes in the design require a complete optimized manufacturing process. Local and minor improvements in the milling process do not generally lead to an optimized manufacturing process. The goal of the new geometry and parametric analysis of the mould is to reduce the quality issues in mild steel grade 60. In this explicit research, the surface roughness (smoothness) of indigenously produced injection moulds in the local market in Pakistan is investigated. The CNC milling machine (five-axis) is used for the manufacturing of an injection mould, and the Taguchi method of the design of the experiment is applied for parameters optimization. Hence, the overall process is assisted in balancing the milling machine parameters to trim down the surface roughness issue in mild steel moulds and increase their sustainability. The spindle speed (rpm), the depth of cut (mm), and the feed rate (mm/rev) are considered as input variables for process optimization, and the experiments are performed on mild steel grade 60. It is deduced that the combination of a spindle speed of 800 rpm, feed rate of 10 mm/rev and depth of cut of 0.5 mm is the best case in case of minimum surface roughness, which leads to sustainable products. It is also deduced from ANOVA, that the spindle speed is a factor that affects the surface roughness of mild steel products, while the feed rate turns out to be insignificant

Synthesis and physico-chemical studies on transition metal complexes of macrocyclic ligand derived from 2,6-diacetylpyridine dihydrazone

556-561A novel series of Schiff base decaazamacrocyclic complexes [ML/ X2] [M = Mn(II), Fe(II), Co(II), Ni(II) and Zn (II)] ; and [CuL/]X2 ( X = Cl, NO3) have been synthesized by the reaction between pre-synthesized 2,6-diacetylpyridine dihydrazone (L) and formaldehyde in the presence or metal ions in methanol medium at room temperature.The formation of ligand (L) and the proposed macrocyclic complexes have been confirmed from the results of elemental analyses, the comparative band positions for v(C=N) and appearance of proton resonance peaks for secondary amine group (N-NH-C) in 1H NMR spectra of complexes. The nature of the complexes and their overall geometry have been inferred from electrical conductivity data, observed band positions in electronic spectra and magnetic moment values

Synthesis, physico-chemical and antimicrobial screening studies on 14 and 16-membered hexaazamacrocyclic complexes bearing pendant amine groups

The synthesis and characterization of a series of 14 and 16-membered hexaazamacrocyclic complexes, which were obtained via template condensation of 1,2- diaminoethane or 1,3-diaminopropane, formaldehyde and hydrazine hydrate in the presence of first row transition metal salts are reported. Complexes of the types, [ML¹(NO3)2]; [CuL¹](NO3)2 and [ML²Cl2]; [CuL²]Cl2 (where M = Co(II), Ni(II) and Zn(II)), were obtained. Elemental analyses, IR spectra, ¹H NMR, EPR, UV-Vis, magnetic susceptibility and conductivity measurements have ascertained the overall geometry and stereochemistry of the complexes. An octahedral geometry has been suggested for all the complexes, except for copper compounds, in which the metal centre coordinates to the four nitrogen atoms of macrocyclic ligand in a square planar fashion. These complexes were screened against different fungi and bacteria in vitro and were found to be potentially active in the concentration 5 mg mL-1

Multi response optimization of injection moulding process parameters of polystyrene and polypropylene to minimize surface roughness and shrinkage’s using integrated approach of S/N ratio and composite desirability function

The present study is intended to optimize and develop a prediction model for horizontal injection moulding process parameters. The processing materials are polystyrene (PS) and polypropylene (PP), while the final products are cups. The mould material used is aluminum alloy 6061-T651. The process parameters investigated are injection temperature, injection pressure, injection speed and mould temperature while the response variables are surface roughness, shrinkage inflow and cross-flow directions. Taguchi orthogonal array L9 is designed for experimental runs, while the levels are defined based on screening experiments. For optimization of process parameters, an integrated approach of signal to noise (S/N) ratio and composite desirability function is applied. The results show that injection temperature has a significant effect on surface roughness, shrinkage inflow and cross-flow directions for both polystyrene and polypropylene. Injection pressure has a significant effect on surface roughness and shrinkage in parallel flow direction for PS, while for polypropylene PP it has a significant effect on surface roughness and shrinkage in cross-flow direction. The optimal process parameters identified for PS are injection temperature at 533.15 K, injection pressure at 60 MPa, injection speed at 80 mm/s and mould temperature at 313.15 K. While for PP the optimal process parameters are injection temperature at 513.15 K, injection pressure at 60 MPa, injection speed at 70 MPa, mould temperature at 313.15 K. The novelty of this paper lies by optimizing injection moulding process parameters to minimize surface roughness and shrinkages using proposed integrated approach for the said mould

Implementation of POLCA Integrated QRM Framework for Optimized Production Performance—A Case Study

Quick response manufacturing (QRM) is a relatively new concept that enfolds all the preceding approaches, namely, just in time (JIT), flexible manufacturing, agile manufacturing, and lean production. QRM is compatible with existing materials requirement planning (MRP) systems and can be implemented efficiently. The ideas from QRM have been highly influential in custom-made engineer-to-order and make-to-order (ETO/MTO) high-mix and low-volume production environments. This study investigates the effectiveness of the POLCA (paired cell overlapping loops of cards) integrated QRM framework for reducing lead time. The POLCA integrated QRM approach was implemented in a precise product manufacturing industry. The industry was facing high penalties due to improper planning and uncontrolled lead times. The implementation of QRM with the POLCA framework indicated optimized production scheduling and significant improvement in lead time and work in process (WIP). After implementing the new manufacturing strategy, the performance parameters showed significant improvement in terms of reducing the percentage loss of profit