Experimental investigations of heat transfer coefficients of cutting fluids in metal cutting processes: analysis of workpiece phenomena in a given case study

This paper reports an experimental method to estimate the convective heat transfer of cutting fluids in a laminar flow regime applied on a thin steel plate. The heat source provided by the metal cutting was simulated by electrical heating of the plate. Three different cooling conditions were evaluated: a dry cooling system, a flooded cooling system and a minimum quantity of lubrication cooling system, as well as two different cutting fluids for the last two systems. The results showed considerable enhancement of convective heat transfer using the flooded system. For the dry and minimum quantity of lubrication systems, the heat conduction inside the body was much faster than the heat convection away from its surface. In addition, using the Biot number, the possible models were analyzed for conduction heat problems for each experimental condition tested.

Sustainable processes using heterogeneous acid catalysts. Some examples of industrial interest.

In recent years the need for the design of more sustainable processes and the development of alternative reaction routes to reduce the environmental impact of the chemical industry has gained vital importance. Main objectives especially regard the use of renewable raw materials, the exploitation of alternative energy sources, the design of inherently safe processes and of integrated reaction/separation technologies (e.g. microreactors and membranes), the process intensification, the reduction of waste and the development of new catalytic pathways. The present PhD thesis reports results derived during a three years research period at the School of Chemical Sciences of Alma Mater Studiorum-University of Bologna, Dept. of Industrial Chemistry and Materials (now Dept. of Industrial Chemistry “Toso Montanari”), under the supervision of Prof. Fabrizio Cavani (Catalytic Processes Development Group). Three research projects in the field of heterogeneous acid catalysis focused on potential industrial applications were carried out. The main project, regarding the conversion of lignocellulosic materials to produce monosaccharides (important intermediates for production of biofuels and bioplatform molecules) was financed and carried out in collaboration with the Italian oil company eni S.p.A. (Istituto eni Donegani-Research Center for non-Conventional Energies, Novara, Italy) The second and third academic projects dealt with the development of green chemical processes for fine chemicals manufacturing. In particular, (a) the condensation reaction between acetone and ammonia to give triacetoneamine (TAA), and (b) the Friedel-Crafts acylation of phenol with benzoic acid were investigated.

Ansätze zur Verbesserung von Qualität und Wirtschaftlichkeit bei generativen Verfahren durch Optimierung des Pre-Processes

Mittels generativer Fertigung ist es heute möglich die, Entwicklungszeit und Ferti-gungsdauer von Prototypen, Produkten und Werkzeugen zu verkürzen. Neben dieser Zeitersparnis sind die im Vergleich zu konventionellen Fertigungsverfahren unwe-sentlichen Geometriebeschränkungen für den Anwender von besonderem Interesse. Dieses Alleinstellungsmerkmal der generativen Fertigung macht es möglich auch komplexe Geometrie wirtschaftlich herzustellen. Voraussetzung für eine wirtschaftli-che und fehlerminimierte Fertigung ist hierbei eine möglichst optimale Prozessvorbe-reitung (Pre-Processing). Dabei sind insbesondere die Schritte der Bauteilorientie-rung, der Stützkonstruktionserzeugung, der Schichtzerlegung sowie der Bauraum-ausnutzung von Interesse. Auch wenn diese Punkte wesentlich zur Qualität und Wirtschaftlichkeit beitragen, sind die Erkenntnisse für den unerfahrenen Anwender nur unzureichend dokumentiert, wodurch eine möglichst effiziente Fertigung zu-nächst ausgeschlossen werden kann. Anhand unterschiedlicher Beispiele sollen dem Anwender hier die Möglichkeiten zur Optimierung dieser Pre-Processing Schritte er-läutert werden. In diesem Rahmen werden die aktuellen Forschungsergebnisse des Lehrstuhls Rechnereinsatz in der Konstruktion, Institut für Produkt Engineering der Universität Duisburg-Essen in Bezug auf die Optimierung der Bauteilorientierung, der variablen Schichtzerlegung und der Optimierung der Bauraumausnutzung vorgestellt.

Auslegung, Konstruktion und Fertigung von strömungsmechanischen Funktionsprototypen mittels Rapid Manufacturing

Bei der Fertigung von Funktionsbauteilen für Strömungsversuche spielt das Design und die Komplexität der Bauteilgeometrie eine wesentliche Rolle. Ziel der interdisziplinären Zusammenarbeit der Lehrstühle Strömungsmaschinen, Rechnereinsatz in der Konstruktion und Fertigungstechnik mit dem Rapid Technology Center (RTC) an der Universität Duisburg-Essen ist es, das Potenzial der additiven Fertigungsverfahren bei der Herstellung von Funktionsprototypen für strömungsmechanische Anwendungen effektiv zu nutzen. An verschiedenen, auf dieser Kooperation beruhenden, Best Practise Beispielen wird gezeigt wie das Laser-Sintern in die Prozesskette zur Herstellung von Laufrädern u. Ä. in unterschiedlichen Größenordnungen integriert werden kann. In diesem Zusammenhang werden auch die Vorüberlegungen (z. B. durch Simulation), Wechselwirkungen und Folgeprozesse, die mit dieser Fertigungstechnologie verbunden sind, aufgezeigt.

Auslegung, Konstruktion und Fertigung von strömungsmechanischen Funktionsprototypen mittels Rapid Manufacturing

Bei der Fertigung von Funktionsbauteilen für Strömungsversuche spielt das Design und die Komplexität der Bauteilgeometrie eine wesentliche Rolle. Ziel der interdisziplinären Zusammenarbeit der Lehrstühle Strömungsmaschinen, Rechnereinsatz in der Konstruktion und Fertigungstechnik mit dem Rapid Technology Center (RTC) an der Universität Duisburg-Essen ist es, das Potenzial der additiven Fertigungsverfahren bei der Herstellung von Funktionsprototypen für strömungsmechanische Anwendungen effektiv zu nutzen. An verschiedenen, auf dieser Kooperation beruhenden, Best Practise Beispielen wird gezeigt wie das Laser-Sintern in die Prozesskette zur Herstellung von Laufrädern u. Ä. in unterschiedlichen Größenordnungen integriert werden kann. In diesem Zusammenhang werden auch die Vorüberlegungen (z. B. durch Simulation), Wechselwirkungen und Folgeprozesse, die mit dieser Fertigungstechnologie verbunden sind, aufgezeigt.

Ansätze zum Management der Additive Manufacturing Supply Chain

Da sich Additive Manufacturing (AM) von traditionellen Produktionsverfahren unterscheidet, entstehen neue Möglichkeiten im Produktdesign und im Supply Chain Setup. Die Auswirkungen der Aufhebung traditionellen Restriktionen im Produktdesign werden unter dem Begriff „Design for Additive Manufacturing“ intensiv diskutiert. In gleicher Weise werden durch AM Restriktionen im traditionellen Supply Chain Setup aufgehoben. Insbesondere sind die folgenden Verbesserungen möglich: Reduktion von Losgrössen und Lieferzeiten, bedarfsgerechte Produktion auf Abruf, dezentrale Produktion, Customization auf Ebene Bauteil und kontinuierliche Weiterentwicklung von Bauteilen. Viele Firmen investieren nicht selbst in die AM Technologien, sondern kaufen Bauteile bei Lieferanten. Um das Potential der AM Supply Chain mit Lieferanten umzusetzen, entstehen die folgenden Anforderungen an AM Einkaufsprozesse. Erstens muss der Aufwand pro Bestellung reduziert werden. Zweitens brauchen AM Nutzer einen direkten Zugang zu den Lieferanten ohne Umweg über die Einkaufsabteilung. Drittens müssen geeignete AM Lieferanten einfach identifiziert werden können. Viertens muss der Wechsel von Lieferanten mit möglichst geringem Aufwand möglich sein. Ein mögliche Lösung sind AM spezifische E-Procurement System um diese Anforderungen zu erfüllen

An Alternative Method to Achieve Metrological Confirmation in Measurement Processes

Metrological confirmation process must be designed and implemented to ensure that metrological characteristics of the measurement system meet metrological requirements of the measurement process. The aim of this paper is to present an alternative method to the traditional metrological requirements about the relationship between tolerance and measurement uncertainty, to develop such confirmation processes. The proposed way to metrological confirmation considers a given inspection task of the measurement process into the manufacturing system, and it is based on the Index of Contamination of the Capability, ICC. Metrological confirmation process is then developed taking into account the producer risks and economic considerations on this index. As a consequence, depending on the capability of the manufacturing process, the measurement system will be or will not be in adequate state of metrological confirmation for the measurement process.

Arquitectura de información para medicion de rendimiento en entornos e-manufacturing

La implantación de las tecnologías Internet ha permitido la extensión del uso de estrategias e-manufacturing y el desarrollo de herramientas para la recopilación, transformación y sincronización de datos de fabricación vía web. En este ámbito, un área de potencial desarrollo es la extensión del virtual manufacturing a los procesos de Performance Management (PM), área crítica para la toma de decisiones y ejecución de acciones de mejora en fabricación. Este trabajo doctoral propone un Arquitectura de Información para el desarrollo de herramientas virtuales en el ámbito PM. Su aplicación permite asegurar la interoperabilidad necesaria en los procesos de tratamiento de información de toma de decisión. Está formado por tres sub-sistemas: un modelo conceptual, un modelo de objetos y un marco Web compuesto de una plataforma de información y una arquitectura de servicios Web (WS). El modelo conceptual y el modelo de objetos se basa en el desarrollo de toda la información que se necesita para definir y obtener los diferentes indicadores de medida que requieren los procesos PM. La plataforma de información hace uso de las tecnologías XML y B2MML para estructurar un nuevo conjunto de esquemas de mensajes de intercambio de medición de rendimiento (PMXML). Esta plataforma de información se complementa con una arquitectura de servicios web que hace uso de estos esquemas para integrar los procesos de codificación, decodificación, traducción y evaluación de los performance key indicators (KPI). Estos servicios realizan todas las transacciones que permiten transformar los datos origen en información inteligente usable en los procesos de toma de decisión. Un caso práctico de intercambio de datos en procesos de medición del área de mantenimiento de equipos es mostrado para verificar la utilidad de la arquitectura. ABSTRAC The implementation of Internet technologies has led to e-Manufacturing technologies becoming more widely used and to the development of tools for compiling, transforming and synchronizing manufacturing data through the Web. In this context, a potential area for development is the extension of virtual manufacturing to Performance Measurement (PM) processes, a critical area for decision-making and implementing improvement actions in manufacturing. This thesis proposes a Information Architecture to integrate decision support systems in e-manufacturing. Specifically, the proposed architecture offers a homogeneous PM information exchange model that can be applied trough decision support in emanufacturing environment. Its application improves the necessary interoperability in decision-making data processing tasks. It comprises three sub-systems: a data model, a object model and Web Framework which is composed by a PM information platform and PM-Web services architecture. . The data model and the object model are based on developing all the information required to define and acquire the different indicators required by PM processes. The PM information platform uses XML and B2MML technologies to structure a new set of performance measurement exchange message schemas (PM-XML). This PM information platform is complemented by a PM-Web Services architecture that uses these schemas to integrate the coding, decoding, translation and assessment processes of the key performance indicators (KPIs). These services perform all the transactions that enable the source data to be transformed into smart data that can be used in the decision-making processes. A practical example of data exchange for measurement processes in the area of equipment maintenance is shown to demonstrate the utility of the architecture.

Development of a tanks line for waxing landing gear parts

The aim of this article is to define the technical specifications and to design the implementation of a line of tanks that would be used in the process of waxing and de-waxing large pieces. As it is based in a real case, it is also analyzed the process of dismantling the former installation that supported these functions. The origin of this project is due to a new rating for the maintenance of landing gears which makes the previous waxing line that was prepared to work on smaller aircraft?s pieces, no longer adequate to the current workflow and processes.

Performance measurement integrated information framework in e-Manufacturing

The implementation of Internet technologies has led to e-Manufacturing technologies becoming more widely used and to the development of tools for compiling, transforming and synchronising manufacturing data through the Web. In this context, a potential area for development is the extension of virtual manufacturing to performance measurement (PM) processes, a critical area for decision making and implementing improvement actions in manufacturing. This paper proposes a PM information framework to integrate decision support systems in e-Manufacturing. Specifically, the proposed framework offers a homogeneous PM information exchange model that can be applied through decision support in e-Manufacturing environment. Its application improves the necessary interoperability in decision-making data processing tasks. It comprises three sub-systems: a data model, a PM information platform and PM-Web services architecture. A practical example of data exchange for measurement processes in the area of equipment maintenance is shown to demonstrate the utility of the model.

CSR Policies: Effects on Labour Productivity in Spanish Micro and Small Manufacturing Companies

This paper analyses empirical evidence of efforts to enable Spanish micro and small manufacturing companies to boost their labour productivity rates through the development of the main pillars of their corporate social responsibility (CSR) policies. This study aims to develop new approaches and sensibilities towards work from an ethical, values (virtues) and CSR perspective, showing how internal dimensions of CSR, such those related to relationships with employees and responsibility in processes and product quality, can improve labour performance and labour efficiency, thereby contributing to a better society. The results of a sample of 929 small businesses indicate that the social responsibility policies that most contributed to a short-term increase in labour productivity are those related to internal aspects of the company, in particular its involvement in the quality of processes and products, promotion of innovation and employee care. However, the impact on labour productivity of CSR policies related to external factors, such as relationship with stakeholders and environmental concern, could not be empirically proven in this paper.

Improving manufacturing performance by standardization of interprocess communication

A number of environmental forces such as increasing value chain network complexity, decreasing product life-cycle cost, and time-to-market requirements or increasing product complexity act upon manufacturing organizations, enhancing the acute need for organizational routines that foster efficient and effective communication between processes. Such organizational routines erode quickly in the absence of common standards for knowledge sharing, that is why successful manufacturing systems benefit from interprocess standardization. The purpose of this paper is to offer a standardization model of interprocess communication that increases manufacturing operational performance (MOP). First, we propose a novel holistic model that makes standardized interprocess communication possible in manufacturing organizations. Second, we propose a model for quantifying the implications of standardizing interprocess communication upon MOP. Finally, as a matter of application, we show the results of its successful implementation in one Japanese manufacturing organization.

Analysing the complexity of the model-based decision making processes within the industrial management context

PURPOSE The decision-making process plays a key role in organizations. Every decision-making process produces a final choice that may or may not prompt action. Recurrently, decision makers find themselves in the dichotomous question of following a traditional sequence decision-making process where the output of a decision is used as the input of the next stage of the decision, or following a joint decision-making approach where several decisions are taken simultaneously. The implication of the decision-making process will impact different players of the organization. The choice of the decision- making approach becomes difficult to find, even with the current literature and practitioners’ knowledge. The pursuit of better ways for making decisions has been a common goal for academics and practitioners. Management scientists use different techniques and approaches to improve different types of decisions. The purpose of this decision is to use the available resources as well as possible (data and techniques) to achieve the objectives of the organization. The developing and applying of models and concepts may be helpful to solve managerial problems faced every day in different companies. As a result of this research different decision models are presented to contribute to the body of knowledge of management science. The first models are focused on the manufacturing industry and the second part of the models on the health care industry. Despite these models being case specific, they serve the purpose of exemplifying that different approaches to the problems and could provide interesting results. Unfortunately, there is no universal recipe that could be applied to all the problems. Furthermore, the same model could deliver good results with certain data and bad results for other data. A framework to analyse the data before selecting the model to be used is presented and tested in the models developed to exemplify the ideas. METHODOLOGY As the first step of the research a systematic literature review on the joint decision is presented, as are the different opinions and suggestions of different scholars. For the next stage of the thesis, the decision-making process of more than 50 companies was analysed in companies from different sectors in the production planning area at the Job Shop level. The data was obtained using surveys and face-to-face interviews. The following part of the research into the decision-making process was held in two application fields that are highly relevant for our society; manufacturing and health care. The first step was to study the interactions and develop a mathematical model for the replenishment of the car assembly where the problem of “Vehicle routing problem and Inventory” were combined. The next step was to add the scheduling or car production (car sequencing) decision and use some metaheuristics such as ant colony and genetic algorithms to measure if the behaviour is kept up with different case size problems. A similar approach is presented in a production of semiconductors and aviation parts, where a hoist has to change from one station to another to deal with the work, and a jobs schedule has to be done. However, for this problem simulation was used for experimentation. In parallel, the scheduling of operating rooms was studied. Surgeries were allocated to surgeons and the scheduling of operating rooms was analysed. The first part of the research was done in a Teaching hospital, and for the second part the interaction of uncertainty was added. Once the previous problem had been analysed a general framework to characterize the instance was built. In the final chapter a general conclusion is presented. FINDINGS AND PRACTICAL IMPLICATIONS The first part of the contributions is an update of the decision-making literature review. Also an analysis of the possible savings resulting from a change in the decision process is made. Then, the results of the survey, which present a lack of consistency between what the managers believe and the reality of the integration of their decisions. In the next stage of the thesis, a contribution to the body of knowledge of the operation research, with the joint solution of the replenishment, sequencing and inventory problem in the assembly line is made, together with a parallel work with the operating rooms scheduling where different solutions approaches are presented. In addition to the contribution of the solving methods, with the use of different techniques, the main contribution is the framework that is proposed to pre-evaluate the problem before thinking of the techniques to solve it. However, there is no straightforward answer as to whether it is better to have joint or sequential solutions. Following the proposed framework with the evaluation of factors such as the flexibility of the answer, the number of actors, and the tightness of the data, give us important hints as to the most suitable direction to take to tackle the problem. RESEARCH LIMITATIONS AND AVENUES FOR FUTURE RESEARCH In the first part of the work it was really complicated to calculate the possible savings of different projects, since in many papers these quantities are not reported or the impact is based on non-quantifiable benefits. The other issue is the confidentiality of many projects where the data cannot be presented. For the car assembly line problem more computational power would allow us to solve bigger instances. For the operation research problem there was a lack of historical data to perform a parallel analysis in the teaching hospital. In order to keep testing the decision framework it is necessary to keep applying more case studies in order to generalize the results and make them more evident and less ambiguous. The health care field offers great opportunities since despite the recent awareness of the need to improve the decision-making process there are many opportunities to improve. Another big difference with the automotive industry is that the last improvements are not spread among all the actors. Therefore, in the future this research will focus more on the collaboration between academia and the health care sector.

Project Neos; a general study of processes for the realization of design configurations in materials

"Cornell Aeronautical Laboratory. Contract: AF 33(600)-42921. ASD project NR 7-867."

Project Neos; a generalized study of processes for the realization of esign configurations in materials. [Final] technical documentary report no. ML-TDR-64-311. MTD project no.7-867.

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