Sustainability Enhancement of a Turbine Vane Manufacturing Cell through Digital Simulation based Design

Modern manufacturing systems should satisfy emerging needs related to sustainable development. The design of sustainable manufacturing systems can be valuably supported by simulation, traditionally employed mainly for time and cost reduction. In this paper, a multi-purpose digital simulation approach is proposed to deal with sustainable manufacturing systems design through Discrete Event Simulation (DES) and 3D digital human modelling. DES models integrated with data on power consumption of the manufacturing equipment are utilized to simulate different scenarios with the aim to improve productivity as well as energy efficiency, avoiding resource and energy waste. 3D simulation based on digital human modelling is employed to assess human factors issues related to ergonomics and safety of manufacturing systems. The approach is implemented for the sustainability enhancement of a real manufacturing cell of the aerospace industry, automated by robotic deburring. Alternative scenarios are proposed and simulated, obtaining a significant improvement in terms of energy efficiency (−87%) for the new deburring cell, and a reduction of energy consumption around −69% for the coordinate measuring machine, with high potential annual energy cost savings and increased energy efficiency. Moreover, the simulation-based ergonomic assessment of human operator postures allows 25% improvement of the workcell ergonomic index.

Modelling the Geometry of the Repeat Unit Cell of Three-Dimensional Weave Architectures,

The three-dimensional (3D) weaving process offers the ability to tailor the mechanical properties via design of the weave architecture. One repeat of the 3D woven fabric is represented by the unit cell. The model accepts basic weaver and material manufacturer data as inputs in order to calculate the geometric characteristics of the 3D woven unit cell. The specific weave architecture manufactured and subsequently modelled had an angle interlock type binding configuration. The modelled result was shown to have a close approximation compared to the experimentally measured values and highlighted the importance of the representation of the binder tow path.