Green manufacturing: effect of vortex tube on machinability of Mild steel

This research presents a study on the effect of chilled air application through Vortex Tube during dry machining on the machinability of mild steel. Through the full factorial design of experiment, there is a total of 36 experiments had been conducted for two levels of spindle speed (100rpm and 215 rpm), three levels of depth of cut (1mm, 2mm and 3mm) and three levels of freed rate (0.10 mm/rev, 0.18 mm/rev and 0.28 mm/rev) under both traditional dry machining and chilled air dry machining condition by lathe machine with coated carbide cutting tool. The power consumption, surface finish and tool life is measured as the output of material’s machinability justification with the used of equipment such as power analyzer, surface profiler and optical video measurement system. The results showed that the better power efficiency had been obtained by the application of Vortex Tube which lowered the temperature by 11.17% in average; even it increased power consumption by 2.87% in average but decreased specific energy consumption by 22.11%. The performance of dry machining in tool life is better and 15.11% better in surface roughness compare to Vortex Tube. This happen due to the cooling effect of Vortex Tube that reduce machining temperature, lowered specific energy consumption but formed rapid harden strain on machined surface lead to higher value of surface roughness, while the surface material of coated carbide tool is easier to detached as the adhesive bond formed by removed chip and tool is stronger than the bond within base material of tool due to cooling effect which lead to tool wear easier. Recommendation of higher spindle speed and freed rate selection for this research had been proposed to observe the effectiveness of Vortex Tube on the performance of tool life and surface finish

Modelling and simulation of spine layout design for flexible manufacturing system in digital factory platform / Phoon Sin Ye

This research presents the integration of information technology and digital three-dimensional (3D) modelling and simulation technology to build a digital factory in a virtual environment. Within the digital factory platform, a robotic work-cell and multi-stations flexible manufacturing system were developed to serve as an alternative decision-making tool in solving manufacturing system problems intuitively. The general framework for digital factory platform development was designed by utilizing various software such as 3D modelling, computer graphic programming, virtual reality (VR) and programming language. In the first phase of this study, a virtual robotic work-cell is built as a test model to determine the degree of interaction between the user and the digital factory, the capability of work-cell simulation, and the data collection from the digital factory platform to aid in decision-making. The digital platform enables intuitive interaction between the user and the virtual robotic work-cell while being capable of data collection. Through multiple simulation scenario of various process sequence of the same manufacturing part, simulation result shows that the difference in travel distance of part is up to 441.96% for different process sequence. In the second phase, a virtual loop layout model is developed and validated with a difference of 1.0% to 1.2% comparing to numerical results from literature study. A case study of allocation of shortcut conveyor in various positions within the developed virtual loop layout is then conducted to investigate the capability of digital factory platform to solve plant layout design problem. The digital factory platform simulated the impact of shortcut conveyor allocation in different position, and the results show that proper design of layout successfully reduced the loop congestion by 33.33% and total part travel distance by 10.64%. The developed digital factory platform in a virtual environment shows its capability to model and simulate manufacturing activities in 3D and to control and receive manufacturing data intuitively. The platform also acts as a scenario-based decision-making tool for optimizing process sequences and layout design

Interactive Solution Approach For Loop Layout Problem Using Virtual Reality Technology

Development of the manufacturing sector has sparked a wide interest in the study of facility layout problem since the past century. The traditional methods of solving facility layout planning are mainly numerical- and analytical-based simulation which might not reveal the actual situation of a manufacturing system. This paper proposed an interactive solution approach using virtual reality technology for loop layout planning to reduce the gap between numerical results and the real situation through enhanced human-machine interface. In this proposed approach, a virtual loop layout model has been developed as an intuitive and interactive platform for loop layout planning and evaluation in real-time control. This platform allows the user to modify the layout through direct interaction and evaluate the performance of the designed layout for multiple times to obtain the optimal layout design. A case study with the allocation of a shortcut conveyor in a loop layout in different locations conducted within the virtual platform has proven that this platform is an effective alternative solution tool for loop layout decision. The case study shows that the allocation of shortcut conveyor can improve the loop layout performance as it can reduce the traffic congestion of a part and reduce its travel distance by 18.77 %

APPLICATION OF INTEGRATED SUSTAINABILITY ASSESSMENT: CASE STUDY OF A SCREW DESIGN

Sustainability can be referred to as meeting the needs of the present generation without compromising the ability of future generations to meet their own needs. For politicians, it is an attempt to shape the social; sustain the economy and preserved the environment for future generations. Balancing these three criteria is a difficult task since it involves different output measurements t. The aim of this paper is to present a new approach of evaluating sustainability at the product design stage. There are three criteria involved in this study which is manufacturing costs, carbon emission release into the air and ergonomic assessment. Analytic hierarchy process (AHP) is used to generalize the outputs of the three criteria which is then ranked accordingly. The highest score is selected as the best solution. In this paper, a simple screw design is presented as a case study

Application of integrated sustainability assessment: Case study of a screw design

Sustainability can be referred to as meeting the needs of the present generation without compromising the ability of future generations to meet their own needs. For politicians, it is an attempt to shape the social; sustain the economy and preserved the environment for future generations. Balancing these three criteria is a difficult task since it involves different output measurements t. The aim of this paper is to present a new approach of evaluating sustainability at the product design stage. There are three criteria involved in this study which is manufacturing costs, carbon emission release into the air and ergonomic assessment. Analytic hierarchy process (AHP) is used to generalize the outputs of the three criteria which is then ranked accordingly. The highest score is selected as the best solution. In this paper, a simple screw design is presented as a case stud