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The purpose of this study is to compare the environmental impacts of two additive manufacturing machines to a traditional computer numerical control (CNC) milling machine to determine which method is the most sustainable.

A life-cycle assessment (LCA) was performed, comparing a Haas VF0 CNC mill to two methods of additive manufacturing: a Dimension 1200BST FDM and an Objet Connex 350 “inkjet”/“polyjet”. The LCA’s functional unit was the manufacturing of two specific parts in acrylonitrile butadiene styrene (ABS) plastic or similar polymer, as required by the machines. The scope was cradle to grave, including embodied impacts, transportation, energy used during manufacturing, energy used while idling and in standby, material used in final parts, waste material generated, cutting fluid for CNC, and disposal. Several scenarios were considered, all scored using the ReCiPe Endpoint H and IMPACT 2002+ methodologies.

Results showed that the sustainability of additive manufacturing vs CNC machining depends primarily on the per cent utilization of each machine. Higher utilization both reduces idling energy use and amortizes the embodied impacts of each machine. For both three-dimensional (3D) printers, electricity use is always the dominant impact, but for CNC at maximum utilization, material waste became dominant, and cutting fluid was roughly on par with electricity use. At both high and low utilization, the fused deposition modeling (FDM) machine had the lowest ecological impacts per part. The inkjet machine sometimes performed better and sometimes worse than CNC, depending on idle time/energy and on process parameters.

The study only compared additive manufacturing in plastic, and did not include other additive manufacturing technologies, such as selective laser sintering or stereolithography. It also does not include post-processing that might bring the surface finish of FDM parts up to the quality of inkjet or CNC parts.

Designers and engineers seeking to minimize the environmental impacts of their prototypes should share high-utilization machines, and are advised to use FDM machines over CNC mills or polyjet machines if they provide sufficient quality of surface finish.

This is the first paper quantitatively comparing the environmental impacts of additive manufacturing with traditional machining. It also provides a more comprehensive measurement of environmental impacts than most studies of either milling or additive manufacturing alone – it includes not merely CO₂ emissions or waste but also acidification, eutrophication, human toxicity, ecotoxicity and other impact categories. Designers, engineers and job shop managers may use the results to guide sourcing or purchasing decisions related to rapid prototyping.

Training centers and labs offer many applications suitable for beginners who want to know how to set and operate a computer numerical control (CNC) milling machine. However, few applications address a basic understanding of the machining process founded on mathematical principals in line with new high-speed and high-precision machining technologies. The purpose of this paper is to present a complex mechanism in a simplified way, explaining the subject at an elementary level.

The authors have developed an application of the CNC milling machine in a Matlab/Simulink package, obtaining the appropriate parameters mathematically. The project developed an analytical method using Matlab code to test the step response (the actual cutting force) under various parameters to ensure comparability of the designed model. The analytical results are in line with the developed model. The Matlab/Simulink user interface allows the application to better explain machining for educational purposes. Furthermore, by combining this mathematical model and the fuzzy controller, the high-speed constant-force milling control model has a user interface for data entry. The addition of two kinds of fuzzy controllers (look-up table and Mamdani) achieve a more educational environment compared with existing models.

The developed technique can be used in CNC milling machine centers and laboratories. For virtual training purposes, this paper provides a two-stage educational model, giving students the necessary feedback on what they have learned at each stage from the beginning use of the CNC milling machine, with and without the controller. The system also offers to track the step-response analysis method. This method overcomes the shortage of milling processes modeled by the traditional transfer function, which more accurately establishes the relationship between cutting force and cutting parameters.

This technique can be used in the CNC machine centers and laboratory for teaching beginner students and trainees. Real data from the workshop had been used.

The earlier versions of this manuscript were presented in: JVE International LTD. Vibroengineering Procedia. +2017. 14.; IEEE 4th International Conference on Information Science and Control Engineering (ICISCE) +2017.

The objective of CNC machining is to produce mechanical parts with designed quality most efficiently. To generate CNC tool paths for machining a sculptured part using a three‐axis CNC machine, surface geometry, cutter shape and size, as well as tool path interval and direction need to be considered. In this work, the relation between the direction of a tool motion and cutting efficiency is studied. A new measure of cutting efficiency in three‐axis CNC milling – the length of effective cutting edge (ECE) is introduced. The ECE length is mathematically proven to reach its maximum when the tool cuts a sculptured surface along its steepest tangent direction at the cutter contact point. The steepest tangent direction is thus proven to be the most efficient tool feed direction in three‐axis sculptured part machining. The study identifies tool feed direction as a new control parameter in CNC tool path planning, and forms the foundation for further research on three‐axis tool path generation of sculptured parts.

Electrospark deposition (ESD) attracts special attention from scientists and engineers because of its unique advantages. However, the ESD process has been carried out by hand up to the present. This prevents ESD from preparing complex curve/surface coatings owing to manual operation characteristics. To meet the coating precise preparation requirements for a lot of parts with complex surface from various industrial fields, this paper aims to obtain a new automatic ESD equipment, process and preparation methodology for complex surface coatings.

By designing a special deposition holder and re-programming programmable machine controller, an ESD power supply and a computer numerical control milling machine are integrated to obtain an electrospark-computer integrated deposition system (ES-CIDS). Then, based on the ES-CIDS, a new ESD process, named electrospark-computer numerical control deposition (ES-CNCD) is developed. Furthermore, complex surface coatings are depicted using non-uniform rational B-spline mathematical model and modeled in a special software developed via MATLAB. Finally, deposition programs for a complex coating are generated using golden section interpolation method, and transferred to and executed by the ES-CIDS to accomplish the preparation of the complex surface coating.

This paper demonstrates that it is possible and feasible to prepare complex surface coatings via an automatic ESD process (namely, ES-CNCD) precisely.

This paper can make automatic ESD process get more attention from scientific researchers and engineers, and promote the research of the ES-CNCD process/equipment.

The ES-CNCD process can be used in the manufacturing of complex surface coatings, and in the remanufacturing of complex shape parts.

The ES-CIDS/ES-CNCD can promote the development of related equipment and technology, and bring opportunities and employment to ESD industry.

This work prepares complex surface coatings precisely for the first time using a new automatic ESD process (ES-CNCD), which has wide application prospects in various industries.

Sound design, planning and monitoring is critical to the operational and financial success of today′s sophisticated manufacturing and non‐manufacturing systems. Owing to their increasing complexity, discrete‐event simulation is becoming the most acceptable tool to aid planning the design and management of production and operations. This growing acceptance has led to the development of many simulators. Two fundamental criteria enable assessment of the suitability of these simulations in complex environments. First, the sophistication of their modelling capability to handle a wide range of problematic situations and second, ease of use. These two considerations, however, tend to conflict; resulting in flexible simulators being difficult to use and vice versa. DSSL II is an advanced simulation methodology with a well defined and user‐friendly modelling strategy. It has been devised to offer a versatile approach in modelling today′s sophisticated systems and policies. Features incorporated include a schematic modelling concept to represent the operational logic of systems, a set of software modules and an associated logical structure. Using the logical structure, the modules are combined to transform the concept of the schematic model into a representative computer program. Using DSSL II, models of manufacturing and non‐manufacturing systems are constructed readily to provide accurate and trustworthy answers to essential “what‐if” questions posed by decision makers, to determine which out of several scenarios would be the most appropriate. The purpose of this paper is to present the concepts and techniques employed by DSSL II. A simple case study and an example of a real industrial application are given in order to demonstrate its features and potential.

Rapid prototyping (RP) techniques are being increasingly used to manufacture injection molding and die casting core and cavity sets, known as tools, and for other tooling‐related parts, such as EDM electrodes. This paper presents a STL‐based finish machining technique for tools and parts made using RP techniques in order to achieve the tight tolerance and surface finish requirements necessary for tooling applications. Rotate, scale, translate and offset algorithms are used to pre‐process the 3D model prior to its manufacture. A machining strategy of adaptive raster milling of the surface, plus hole drilling and sharp edge contour machining, is developed to finish the parts and tools after fabrication using RP. Finally, a benchmark part was designed and fabricated using the above‐mentioned strategies and the results show the effectiveness of the developed software.

In milling process the surface roughness and delamination are the most important performance characteristics, which are influenced by many factors like fibre orientation angle, helix angle, feed rate and spindle speed. The selection of these parameters at optimum level plays a vital role in getting minimum surface roughness and delamination factor. The purpose of this paper is to present multi-objective optimisation of Computer Numerical Control milling parameters using Grey-Taguchi method to get minimum surface roughness and delamination factor in machining of glass fibre reinforced plastics (GFRP) composites used in automotive, aircraft and manufacture of space ships.

The experiments are designed and conducted based on Taguchi's L₂₇ orthogonal array by taking fibre orientation angle, helix angle, feed rate and spindle speed at three levels and responses are surface roughness and delamination factor. Taguchi's signal-to-noise (S/N) ratio are determined based on their performance characteristics. A Grey relation grade is obtained by using S/N ratio. Based on Grey relational grade value, optimum levels of parameters have been identified by using response table and response graph.

Optimum levels of parameters for GFRP composites have been identified by using response table and response graph and the significant contributions of controlling parameters are estimated using analysis of variance.

The combined effect of fibre orientation angle and helix angle during milling of GFRP composites using Grey relational analysis has not been previously attempted for analysis.

Glass fibre reinforced plastics (GFRP) contain two phases of materials with drastically distinguished mechanical and thermal properties, which brings in complicated interactions between the matrix and the reinforcement during machining. Surface quality and dimensional precision will greatly affect parts during their useful life especially in cases where the components will be in contact with other elements or materials during their useful life. The purpose of this paper is to discuss the application of the Taguchi method with fuzzy logic to optimise the machining parameters for machining of GFRP composites with multiple characteristics.

The machining tests were performed on a CNC milling machine using solid carbide (K10) End mill cutting tool with three different helix angles. Experiments were planned using Taguchi’s orthogonal array with the cutting conditions prefixed.

The machining parameters, namely, helix angle of the end mill cutter, spindle speed, feed rate, depth of cut, and work piece fibre orientation (specially applied to the GFRP composites) were optimised with considerations of multiple response characteristics, including machining force, material removal rate, and delamination. The results from confirmation runs indicated that the determined optimal combination of machining parameters improved the performance of the machining process.

Multi-response optimisation of machinability behaviour of GFRP composites using fuzzy logic has not been attempted previously.

We investigate the effects of technological capabilities on firms’ survival chances during market-fusing technological change. Our context is the matured U.S. machine tool industry. During the period of our study, 1975 through 1995, a drastic shift in demand conditions prompted the buyers of machine tools to demand more versatile products to improve their productivity. The advent of microprocessors enabled manufacturers to meet these demands by combining the functions of previously distinctive products. As a result, market segments fused and machine tool manufacturers in once disparate product categories came into direct competition with one another. We propose that incumbents with broader component and architectural capabilities will be better able to adapt to and hence survive market-fusing technological change. Our results, based on a panel data set of U.S. machine tool incumbents, support the value of broad component capabilities but reveal no adaptive advantage of architectural capabilities.

This paper aims to present a friction stir molding (FSM) method for the rapid manufacturing of metal tooling. The method uses additive and subtractive techniques to sequentially friction stir bond and then mill slabs of metal. Mold tooling is grown in a bottom-up fashion, overcoming machining accessibility problems typically associated with deep cavity tooling.

To test the feasibility of FSM in building functional molds, a layer addition procedure that combines friction stir spot welding (FSSW) with an initial glue application and clamping for slabs of AA6061-T651 was investigated. Additionally, FSSW parameters and the mechanical behavior of test mold materials, including shear strength and hardness, were studied. Further, scanning electron microscopy (SEM)/elemental map analysis (EDS) of the spot weld zones was carried out to understand the effect of FSSW on the glue materials and to study potential mixing of glue with the plate materials in the welded zone.

The results indicate that FSM provides good layer stacking without gaps when slabs are pre-processed through sand blasting, moistening, uniform clamping and FSSW using a tapered pin tool. The tensile shear strength results revealed that the welded spots were able to withstand cutting forces during machining stages; however, FSSW was found to cause hardness reduction among spot zones because of over-aging. The SEM/EDS results showed that glue was not mixed with slab materials in spot zones. The proposed process was able to build a test tooling sample successfully using AA6061-T651 plates welded and machined on a three-axis computer numerical control (CNC) mill.

The proposed FSM process is a new process presented by the authors, developed for the rapid manufacturing of metal tooling. The method uses additive and subtractive techniques to sequentially friction stir bond and then mill slabs of metal. The use of FSSW process for materials addition is an original contribution that enables automatic process planning for this new process.