Energy and raw material consumption analysis of powder bed fusion: case study: CNC machining and laser additive manufacturing

Laser additive manufacturing (LAM), known also as 3D printing, is a powder bed fusion (PBF) type of additive manufacturing (AM) technology used to manufacture metal parts layer by layer by assist of laser beam. The development of the technology from building just prototype parts to functional parts is due to design flexibility. And also possibility to manufacture tailored and optimised components in terms of performance and strength to weight ratio of final parts. The study of energy and raw material consumption in LAM is essential as it might facilitate the adoption and usage of the technique in manufacturing industries. The objective this thesis was find the impact of LAM on environmental and economic aspects and to conduct life cycle inventory of CNC machining and LAM in terms of energy and raw material consumption at production phases. Literature overview in this thesis include sustainability issues in manufacturing industries with focus on environmental and economic aspects. Also life cycle assessment and its applicability in manufacturing industry were studied. UPLCI-CO2PE! Initiative was identified as mostly applied exiting methodology to conduct LCI analysis in discrete manufacturing process like LAM. Many of the reviewed literature had focused to PBF of polymeric material and only few had considered metallic materials. The studies that had included metallic materials had only measured input and output energy or materials of the process and compared to different AM systems without comparing to any competitive process. Neither did any include effect of process variation when building metallic parts with LAM. Experimental testing were carried out to make dissimilar samples with CNC machining and LAM in this thesis. Test samples were designed to include part complexity and weight reductions. PUMA 2500Y lathe machine was used in the CNC machining whereas a modified research machine representing EOSINT M-series was used for the LAM. The raw material used for making the test pieces were stainless steel 316L bar (CNC machined parts) and stainless steel 316L powder (LAM built parts). An analysis of power, time, and the energy consumed in each of the manufacturing processes on production phase showed that LAM utilises more energy than CNC machining. The high energy consumption was as result of duration of production. Energy consumption profiles in CNC machining showed fluctuations with high and low power ranges. LAM energy usage within specific mode (standby, heating, process, sawing) remained relatively constant through the production. CNC machining was limited in terms of manufacturing freedom as it was not possible to manufacture all the designed sample by machining. And the one which was possible was aided with large amount of material removed as waste. Planning phase in LAM was shorter than in CNC machining as the latter required many preparation steps. Specific energy consumption (SEC) were estimated in LAM based on the practical results and assumed platform utilisation. The estimated platform utilisation showed SEC could reduce when more parts were placed in one build than it was in with the empirical results in this thesis (six parts).

The biophysical perspective of a middle income economy: material flows in Mexico

We analyse natural resource use dynamics in the Mexican economy during the last three decades. Despite low and uneven economic growth, the extraction and use of materials in the Mexican economy has continuously increased during the last 30 years. In this period, population growth rather than economic growth was the main driving force for biophysical growth. In addition, fundamental changes have taken place in the primary sectors, in manufacturing, and in household consumption and these are reflected in an increasing emphasis on the use of fossil fuels and construction materials. Mexico’s economy has been strongly influenced by international trade since the country commenced competing in international markets. In the 1970s, Mexico mainly exported primary resources. This pattern has changed and manufactured goods now have a much greater importance due to a boom in assembling industries. In contrast with other Latin American countries, Mexico has achieved a diversification of production, moving towards technology-intensive products and a better mix in its export portfolio. However, crude oil exports still represent the single most important export good. Mexico’s material consumption is still well below the OECD average but is growing fast and the current resource use patterns may well present serious social and environmental problems to the medium and long term sustainability of Mexico’s economy and community. Information on natural resource use and resource productivity could provide valuable guidance for economic policy planning in Mexico.

Production of an axial piston: Impacts resulting from the substitution of steel by a polymer-based material

The substitution of steel as a raw material in the production of axial pistons for pressure washers by polyphthalamide, polytetrafluoroethylene and glass fiber-based composite was studied. The new production process with composite consists of only two steps, while the production of the steel piston is to comprise of thirteen steps. This replacement would result in an estimated reduction of 80% of water consumption, 83% of electricity consumption, 73% of the total cost and 88% of the final mass. With regard to the main mechanical properties required for the end product, the composite was found to withstand the critical axial loads and it shows acceptable wear resistance in an environment without lubrication, an additional advantage of this replacement. © 2012 Elsevier Ltd. All rights reserved.

Desenvolvimento de um modelo de procurement e abastecimento para uma união de mutualistas

Mestrado em Engenharia Mecânica – Gestão Industrial

Estudo de Ferramentas FEA Comerciais na Simulação Numérica de Processos de Conformação de Chapas Metálicas. Aplicação à Indústria Automóvel.

Os componentes obtidos através da conformação plástica de chapas têm uma grande importância, tanto na etapa de concepção do produto como na etapa de produção na indústria automóvel. Isto comprova-se pelo facto de, em média, cada automóvel integrar cerca de 500 componentes estampados para construir o chassis e a carroçaria [Alves 2003]. Deste total de componentes, 50 são de grandes dimensões (portas, tejadilho, painéis inferior e laterais, entre outros) e necessitam, em média, de cinco ferramentas para o seu fabrico, sendo o custo estimado para cada ferramenta de 230 000 € [Col 2000, Alves 2003]. Para além da indústria automóvel, a conformação plástica de chapas metálicas é um processo tecnológico presente nas indústrias relativas à aeroespacial, petrolífera, decoração, alimentar, entre outras. Do ponto de vista do enquadramento económico, cerca de 20% do custo total de um automóvel novo é devido à incorporação de componentes metálicos estampados. [Alves 2003]. A pressão do “Mercado Global” faz com que os custos relativos à matéria-prima, energia e mão-de-obra sejam uma constante em termos de redução do seu impacte no orçamento das empresas fornecedoras destes produtos. É neste contexto que surge a necessidade da realização deste estudo de Benchmark de Softwares, tornando-se bastante importante, quer ao nível da competitividade industrial, quer ao nível da inovação para novos produtos. A análise por elementos finitos desempenha um papel primordial no tryout virtual e otimização das ferramentas e processos de conformação plástica. Os objetivos principais deste estudo de simulação numérica são a identificação e comparação dos resultados obtidos pelo AUTOFORM e pelo PAMSTAMP, para cada uma das variáveis identificadas como as mais influentes na robustez dos processos de estampagem de chapa metálica. Estas variáveis identificadas são: consumo de material (Draw-in) após conformação; forças de conformação; valores de variação de espessura e dos valores de extensão e resultados de Springback. Os resultados obtidos são comparados com os resultados experimentais e, desta forma, avalia-se a capacidade inovadora e a eficácia de cada um dos softwares, obtendo-se assim, uma orientação mais real para o software mais indicado aos objetivos impostos pela indústria automóvel. Para este efeito, a indústria automóvel, como maior impulsionador e motor da investigação na área da simulação numérica aplicada aos processos de estampagem, tem aderido em peso ao Benchmarking. Um exemplo disto, é o que acontece nas conferências Numisheet. O Benchmark #2 da conferência Numisheet 2008 é analisado pormenorizadamente e os resultados numéricos e experimentais são comparados e apresentados. Dois materiais distintos (aço HC260LAD e liga de alumínio AC170), assim como três modelos com geometrias diferentes (com e sem freios) são apresentados neste relatório. Com vista à redução dos ciclos tentativa-erro, tem-se adotado ciclos virtuais ou numéricos e tem-se incrementado a interatividade entre as fases de concepção e projeto, num conceito muito próprio, mas cada vez mais abrangente, denominado “produção virtual”. É nesta filosofia que se insere a simulação numérica dos processos de conformação de chapa.

Friction surfacing of aluminium alloys

Dissertação para a obtenção do grau de Mestre em Engenharia Mecânica

Ideas, Possibilities and Limitations of Sustainable Economic Policy – the Example of Ecological Economics

A mesura que el suport del creixement econòmic constitueix un objectiu fonamental de la formulació de polítiques econòmiques, cal assenyalar que aquest tipus de creixement està limitat naturalment per un planeta finit. Aquest article argumenta que, des del punt de vista de la justícia intergeneracional, la realització d'un concepte de desmaterialització i, com a efecte, d'una economia que no creix (en el sentit de dissociació absoluta del creixement econòmic i consum d'energia i materials) es pot justificar. Per tant, el creixement pot ser també entesa com la millora de la qualitat de vida sobretot en comptes d'ampliar quantitats escarpats de sortida. Per tant, una dràstica reducció del cabal de material es necessita, sobretot en els països d'alts ingressos. Després de presentar alguns crítica de les propostes, en el focus d'aquest article es dibuixen en els arguments de per què la política econòmica en el futur han de ser etiquetats com "ecològic" i, a continuació, les opcions de posar en acció les idees del teòric presentat marc en tasques manejables polítiques seran discutides. En aquest cas, s'argumentarà que l'enfocament clàssic de internalització d'efectes externs sovint seguides de decisions de política econòmica ortodoxa no és completament capaç de reflectir canvis ecològics en les estructures de preus dels mercats. Per tant, formal (industrial i l'establiment de la política de consum) i institucions informals (llars) representen punts clau de la política econòmica sostenible, assenyalant l'individu com així com la responsabilitat col · lectiva per omplir aquest buit substancial.

Toiminnanohjausjärjestelmän laajentaminen tuotannonohjaukseen

Diplomityössä perehdytään rakennustuotteita valmistavan teollisuusyrityksen toiminnanohjausjärjestelmän laajentamiseen tuotannonohjaukseen. Järjestelmä on tällä hetkel-lä valjastettu vain hallinnolliseen käyttöön, eli tarjouspyyntöjen ja myyntitilauksien kirjaamiseen, laskutukseen ja reskontraan. Järjestelmän laajentamista tuotantoon puoltaa hankalasti ennustettavat toimitusajat ja kapasiteetin käyttöasteen hahmotettavuus. Laajentaminen on määrä toteuttaa vaiheittain, ensimmäisenä yrityksen suurimman liikevaihdon tekevällä osastolla. Diplomityön ensimmäinen tavoite oli selvittää teoriaosuuden avulla toiminnanohjausjärjestelmään liittyvät keskeiset asiat, joiden pohjalta laajentamista alettiin suunnitella. Lisäksi selvitettiin toiminnanohjausjärjestelmien käyttöönottojen epäonnistumisiin johtaneita syitä. Suurimmiksi syiksi on havaittu epärealistiset odotukset, projektin jättäminen vain atk-osaston huoleksi sekä johdon tuen puuttu-minen. Toisessa vaiheessa tavoitteena oli laatia suunnitelma, jonka perusteella laajentaminen on tarkoitus tehdä yrityksen ensimmäisellä käyttöönotto-osastolla. Tärkeimmät huomioitavat seikat ovat kuormitusryhmien suunnittelu, kuormitusryhmien sisäiset kuormituspisteet ja tuotteiden valmistusrakenteen järkevä määrittäminen toiminnanohjausjärjestelmään. Case-yrityksessä huomioitavaa oli myös työajanseurantalaitteiston hankinta, joka palvelee samalla toiminnanohjausjärjestelmää työmääräinten kuittaamisessa integroinnin jälkeen. Kolmas vaihe oli tehdä työn perusteella suositukset jatkotoimenpiteille. Järjestelmän toimiessa suunnitellusti ensimmäisellä osastolla, aletaan projektia viedä muille osastoille. Lisäksi suositellaan toiminnanohjausjärjestelmän laajentamista varastoihin sekä ostoihin, jotta materiaalinkulutuksesta saadaan mahdollisimman paljon tietoa.

Parametrisen kustannusmallin validointi ja implementointi

Parametric cost modeling is a technique, where cost estimating relationships are built to meet products’ parameters. Parameters are directly defined from product features, when it is possible to solve product cost exact before even a single product is manufactured and calculated with general cost accounting. The parametric model can be used in product design, sourcing and comparing product cost of similar products. The model reveals the cost origin more clear than general accounting. The purpose of this thesis was to find out parameters for modeling elevator doors and validate the parameters to meet actual costs. The other target was to simulate cost impact and changes in the cost structure. The results were compared to previous calculations and actual costs and model was tested in new product design. The results of the calculations revealed, that material consumption is the most significant issue in design effectiveness as well as the complexity of the components and structure. To develop the model more research is needed for other continents cost structure and waste calculation principles.

Green welding in practice

Efficient production and consumption of energy has become the top priority of national and international policies around the world. Manufacturing industries have to address the requirements of the government in relation to energy saving and ecologically sustainable products. These industries are also concerned with energy and material usage due to their rising costs. Therefore industries have to find solutions that can support environmental preservation yet maintain competitiveness in the market. Welding, a major manufacturing process, consumes a great deal of material and energy. It is a crucial process in improving a product’s life-cycle cost, strength, quality and reliability. Factors which lead to weld related inefficiencies have to be effectively managed, if industries are to meet their quality requirements and fulfil a high-volume production demand. Therefore it is important to consider some practical strategies in welding process for optimization of energy and material consumption. The main objective of this thesis is to explore the methods of minimizing the ecological footprint of the welding process and methods to effectively manage its material and energy usage in the welding process. The author has performed a critical review of the factors including improved weld power source efficiency, efficient weld techniques, newly developed weld materials, intelligent welding systems, weld safety measures and personnel training. The study lends strong support to the fact that the use of eco-friendly welding units and the quality weld joints obtained with minimum possible consumption of energy and materials should be the main directions of improvement in welding systems. The study concludes that, gradually implementing the practical strategies mentioned in this thesis would help the manufacturing industries to achieve on the following - reduced power consumption, enhanced power control and manipulation, increased deposition rate, reduced cycle time, reduced joint preparation time, reduced heat affected zones, reduced repair rates, improved joint properties, reduced post-weld operations, improved automation, improved sensing and control, avoiding hazardous conditions and reduced exposure of welder to potential hazards. These improvement can help in promotion of welding as a green manufacturing process.

Materials management in state transport undertakings in india with special reference to kerala state road transport corporation

Scientific studies on the materials management systems and practices actually followed in various organizations in India are rather limited. This is particularly true with respect to service industries. In this context ,the present study on the “materials management in state transport undertakings in India, with special reference to kerala state road corporation” assumes particular significance . This study, examines critically, the prevailing set up, procedures and practices of materials management in the Kerala state road transport corporation and compares them with the prevailing practices in other similar state transport undertakings. It indicates several areas for improvement with respect to the organization, materials planning, purchasing, store keeping and other aspects. It also seeks to develop a comprehensive inventory control system for KSRTC.

Jämförelsestudie avseende stomsystem : Ramverk eller fackverk/balk/pelar-system

Projektet omfattade en jämförelsestudie avseende stomsystem. Studien undersökte ramverk och fackverk/balk/pelar-system och genomfördes självständigt med stöttning av Ramböll AB´s kontor i Falun. Syftet var främst att undersöka vilka skillnader det finns mellan tvåledsramar och fackverk/balk/pelar-system för lätta hallbyggnader och försöka få klarhet i varför fackverk/balk/pelar-system är det dominerande systemet i Sverige eftersom övriga Europa har tagit en annan utveckling och domineras av tvåledsramar. Studien undersöker skillnaderna mellan systemen i en hallbyggnad med förutbestämda mått i stål.Inledningsvis gjordes en litteraturstudie för att få en bredare bakgrund av systemen och en bättre förståelse om förutsättningarna för varje system. Efter litteraturstudien kunde sedan ett typhus och beräkningsunderlag för jämförelsestudien tas fram. Även en enkätstudie gjordes med syftet att skapa en tydlig bild av vilket stomsystem konstruktörer i Sverige oftast väljer och varför. Resultatet av studien visade att tvåledsramar ger en ökad kostnad jämfört med fackverk/balk/pelar-system i materialåtgång och framställning samt att beräkningarna blir mer komplicerade. Skulle fortsatta studier göras med dessa system i byggnader med andra mått skulle det kanske gå att få fram speciella mått på byggnader där kostnaden för tvåledsramar blir densamma som för fackverk/balk/pelar-system och därför är ett likvärdigt alternativ som stomsystem.En viktig slutsats från projektet är att tvåledsramar används mycket mer sällan än fackverk/balk/pelar-system som stomsystem i lätta hallbyggnader i Sverige på grund av att kostnaderna blir mycket högre med tvåledsramar och att det är ett mer komplicerat system i beräkningsarbetet. De viktigaste slutsatserna från jämförelsestudien går att sammafatta som följande: Tvåledsramar är dyrare att använda. Tvåledsramar är ett mer komplicerat system beräkningsmässigt. Traditionen av att använda tvåledsramar finns inte och därför används inte systemet.

Non-Participatory Poverty

In a capitalistic market society, all individuals should have an equal opportunity to participate, with varying extents, in consumerism. Democracy entitles one to political participation but people have come to value consumer participation as having more importance as shopping and the exchange of goods and services have become an important part of everyday living. Yet not everyone can participate in consumerism and they end up suffering, especially the children living in poverty. These children internalize the message that since they cannot participate in a society based on material consumption, they cannot belong. Poverty not only causes individuals to experience their lives differently, but also affects the development of one’s physical, cognitive, social, and emotional identity. Many of the consequences of poverty have been scrutinized and studied to try to explain the experiences of such children. What has not been closely examined however is the relationship between the inability to participate in a consumer society and the bodily being, thoughts, actions, and feelings of impoverished children. I will discuss how these effects of poverty result in the inability of children to participate in society.

Tamanho de amostra e estimativa de custo em levantamento epidemiológico de cárie dentária

This study aimed to analyze how the prevalence and the distribution of dental caries influence the sample size in epidemiological surveys, and how much are the costs. Secondary data of oral health surveys in 12-year-old schoolchildren from Bauru in 1976, 1984, 1990, 1994, and 2001, and from Piracicaba in 2001 and 2005 were studied. Sample sizes were estimated taking into account the mean DMFT and standard deviation of each survey, establishing sampling errors of 1%, 2%, 5%, and 10%. Costs were estimated considering permanent material, consumption material and human resources. The sample size in both towns needed to be increased, ranging from 119 in 1976 to 1,118 in 2001 in Bauru, and from 954 in 2001 to 1,252 in 2005 in Piracicaba, when a sampling error of 10% was considered. The cost of dental caries surveys was verified considering different sampling errors. This cost depends on how acceptable is the margin of difference between the true mean and the one found in the survey. In conclusion, the reduction in the prevalence of dental caries has determined the need for increase in sample size and in costs for conducting the surveys.

Efeito do genótipo e do teor protéico da dieta na resistência de cordeiros à hemoncose experimental

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)