Sustainable Manufacturing Processes

1st Edition - October 8, 2022
Imprint: Academic Press
Editors: R. Ganesh Narayanan, Jay S. Gunasekera
Language: English
Paperback ISBN:
9 7 8 - 0 - 3 2 3 - 9 9 9 9 0 - 8
eBook ISBN:
9 7 8 - 0 - 3 2 3 - 9 8 3 1 7 - 4

Sustainable Manufacturing Processes provides best practice advice on sustainable manufacturing methods, with examples from industry as well as important supporting theory. I… Read more

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Sustainable Manufacturing Processes provides best practice advice on sustainable manufacturing methods, with examples from industry as well as important supporting theory. In the current manufacturing industry, processes and materials are developed with close reference to sustainability issues, with an outward look to optimum production efficiency and reduced environmental impact. Important topics such as the use of renewable energy, reduction of material waste and recycling, reduction in energy and water consumption, and reduction in emissions are all discussed, along with broad coverage of deformation and joining technologies, computational techniques, and computer-aided engineering. In addition, a wide range of traditional and innovative manufacturing technologies are covered, including friction stir welding, incremental forming, abrasive water jet machining, laser beam machining, sustainable foundry, porous material fabrication by powder metallurgy, laser and additive manufacturing, and thermoelectric and thermomagnetic energy harvesting.

Cover image
Title page
Table of Contents
Copyright
Dedication
Contributors
About the editors
Foreword
Preface
Acknowledgment
Chapter 1. Introduction to sustainable manufacturing processes
1.1. Definition and importance
1.2. Manufacturing processes and sustainability implementation
1.3. Sustainability assessment
1.4. Computer-aided analyses and sustainable manufacturing
1.5. Industry 4.0 and sustainable manufacturing
1.6. Education for sustainability development
1.7. Summary
Chapter 2. Sustainability in foundry and metal casting industry
2.1. Introduction
2.2. What are foundry and metal casting processes?
2.3. Environmental issues in foundry and metal casting
2.4. Sustainability indicators for the foundry and metal casting industry
2.5. Concepts, technologies, management practices, and systems for sustainability assessment in the foundry and metal casting
2.6. IoT and Industry 4.0 in the foundry and metal casting
2.7. Summary
2.8. Disclosure
Chapter 3. Sustainable manufacturing: material forming and joining
3.1. Need for sustainable material forming
3.2. Extrusion and forging
3.3. Rolling and wire drawing
3.4. Sheet stamping
3.5. Flexible tooling
3.6. Green lubrication
3.7. Laser-based manufacturing
3.8. Need for sustainable joining processes
3.9. Sustainable fusion and solid-state welding processes
3.10. Mechanical joining
3.11. Adhesive bonding
3.12. Hybrid joining
3.13. Inclusive manufacturing
3.14. Summary
Chapter 4. Sustainable manufacturing strategies in machining
4.1. Need for sustainable machining
4.2. Sustainable characteristics in machining
4.3. Sustainable machining techniques
4.4. Role of sustainable machining techniques in conventional machining processes
4.5. Sustainable nonconventional machining processes
4.6. Summary of recent developments, challenges, and future prospects
Chapter 5. Materials development for sustainable manufacturing
5.1. Introduction
5.2. Need for development of materials
5.3. Classification of materials development
5.4. Microstructural modification of traditional materials
5.5. Optimization of material processing conditions
5.6. Material workability and microstructural control during deformation processes
5.7. Material processing maps
5.8. Role of activation energy
5.9. Role of stability
5.10. Increasing productivity of aluminum extrusion industry case study
5.11. Effects of prior processing history on workpiece behavior case study
5.12. Processing windows for different forms of Al-2024 materials case study
5.13. Stainless steel forging microstructure and property control case study
5.14. Summary
Chapter 6. Sustainable product development process
6.1. Innovation and product development
6.2. Product innovation strategy
6.3. Product life cycle
6.4. Product development process
6.5. Stage gate processes
6.6. NPD organization
6.7. Decision making process
6.8. Program release and launch
6.9. Proactive feedback mechanism and lessons learnt
6.10. Design processes, tools, and design for sustainability
6.11. Sustainability in remanufacturing
6.12. End of life design
6.13. Future outlook and direction
Chapter 7. A case study on sustainable manufacture of Ti–6Al–4V ultralightweight structurally porous metallic materials by powder metallurgy route
7.1. Introduction
7.2. ANTARES interface
7.3. Dynamic material model processing map
7.4. Summary
Chapter 8. Waste energy harvesting in sustainable manufacturing
8.1. Introduction
8.2. Piezoelectric technology in sustainable manufacturing
8.3. Thermoelectric technology in sustainable manufacturing
8.4. Other energy harvesting technologies in sustainable manufacturing
8.5. Conclusion
Chapter 9. Sustainability performance evaluation in manufacturing: theoretical and practical perspectives
9.1. Literature and state of art
9.2. Methodology
9.3. Case study
9.4. Results
9.5. Summary and recommendations
Chapter 10. Additive manufacturing including laser-based manufacturing
10.1. Introduction and basic principles
10.2. Vat photopolymerization process (SLA)
10.3. Powder bed fusion process (PBF)
10.4. Extrusion-based process (FDM or FFF)
10.5. Jetting-based process (material jetting (MJ) and binder jetting (BJ))
10.6. Sheet lamination process (SL)
10.7. Directed energy deposition process (DED)
10.8. Hybrid manufacturing
10.9. Post-treatment processes
10.10. Sustainability issues in AM
10.11. Summary and future outlook
Chapter 11. Computer integrated sustainable manufacturing
11.1. Introduction to computer integrated manufacturing
11.2. CAD/CAM/CAE in sustainable manufacturing
11.3. CAE in sustainable manufacturing
Index

R. Ganesh Narayanan

Dr. R. Ganesh Narayanan is a Professor at the Department of Mechanical Engineering, Indian Institute of Technology (IIT) Guwahati, India. He received his Ph.D. from the IIT Bombay, India. His research areas of interest include Metal Forming and Joining. He has contributed many research articles in reputed journals and international conferences. He has edited several titles including: ‘Strengthening and Joining by Plastic Deformation’ published by Springer Singapore, ‘Advances in Material Forming and Joining’ published by Springer India, and ‘Metal Forming Technology and Process Modeling’ published by McGraw Hill Education, India. He has also edited several special journal issues including: Advances in Computational Methods in Manufacturing in the International Journal of Mechatronics and Manufacturing Systems, and Numerical Simulations in Manufacturing in the Journal of Machining and Forming Technologies. He has organized three international conferences at IIT Guwahati, namely the International Conference on Computational Methods in Manufacturing (ICCMM) in 2011, the 5th International and 26th All India Manufacturing Technology, Design and Research (AIMTDR) Conference in 2014 and the 2nd International Conference on Computational Methods in Manufacturing (ICCMM) in 2019. He has also organized a GIAN course on ‘Green Material Forming and Joining’ at IIT Guwahati in 2016.

Affiliations and expertise

Professor, Department of Mechanical Engineering, Indian Institute of Technology (IIT), Guwahati, India

Jay S. Gunasekera

Jay Gunasekera is an Adjunct Professor in the Department of Mechanical Engineering of the University of Delaware, USA. He was previously the chair of the department of Mechanical Engineering at Ohio University, a Director of the SME/NAMRI board of the Society of Manufacturing Engineers, and North American editor of Elsevier’s Journal of Materials Processing Technology. He has undertaken research and consulting projects for the United States Air Force, General Electric, Pratt & Whitney, General Motors and a large number of manufacturing companies in the US. Dr. Gunasekera has published over 150 technical publications in refereed journals and conferences. He was awarded the highest doctorate (D.Sc.) Degree by the University of London in 1991 for his contribution in research and publications in the field of manufacturing engineering. He was made a Fellow of the City & Guilds of London, which is the highest honor conferred by that institution. He is a Fellow of SME & FRSA, past Fellow of IMechE, IProdE & IEE. .

Affiliations and expertise

Adjunct Professor, Department of Mechanical Engineering, University of Delaware, Newark, DE, USA

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