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Open Access
Article
Publication date: 14 June 2021

Vennan Sibanda, Khumbulani Mpofu and John Trimble

In manufacturing, dedicated machine tools and flexible machine tools are failing to satisfy the ever-changing manufacturing demands of short life cycles and dynamic nature of…

1917

Abstract

Purpose

In manufacturing, dedicated machine tools and flexible machine tools are failing to satisfy the ever-changing manufacturing demands of short life cycles and dynamic nature of products. These machines are limited when new product designs are introduced. The solution lies in developing responsive machines that can be adjusted or be changed functionally when these change requirements arise. These machines are reconfigurable machines which are becoming the new focus, as they rapidly respond to product variety and volume changes. A sheet metal working machine known as a reconfigurable guillotine shear and bending press machine (RGS&BPM) has been developed. The purpose of this paper is to present a methodology, function-oriented design approach (FODA), which was developed for the design of the RGS&BPM.

Design/methodology/approach

The design of the machine is based on the six principles of reconfigurable manufacturing systems (RMSs), namely, modularity, scalability integrability, convertibility, diagnosability and customisability. The methodology seeks to optimise the design process of the RGS&BPM through a design of modules that make up the machine, enable its conversion and reconfiguration. The FODA is focussed on function identification to select the operational function required. Two main functions are recognised for the machine, these being cutting and bending; hence, the design revolves around these two and reconfigurability.

Findings

The developed design methodology was tested in the design of a prototype for the reconfigurable guillotine shear and bending press machine. The prototype is currently being manufactured and will be subjected to functional tests once completed. This paper is being presented not only to present the methodology by to show and highlight its practical applicability, as the prototype manufacturers have been enthusiastic about this new approach.

Research limitations/implications

The research was limited to the design methodology for the RGS&BPM, the machine which has been designed to completion using this methodology, with prototype being manufactured.

Practical implications

This study presents critical steps and considerations in the development of reconfigurable machines. The main thrust being to explore the best possibility of developing the machines with dual functionality that will assist in availing the technology to manufacturer. As the machine has been development, the success of the design can be directly attributed to the FODA methodology, among other contributing factors. It also highlights the significance of the principles of RMS in reconfigurable machine design.

Social implications

The RGS&BM machine is an answer for the small-to-medium enterprises (SMEs), as the machine replaces two machines with one, and the methodology ensures its affordable design. It contributes immensely to the machine availability by eliminating trial and error approaches.

Originality/value

This study presents a new approach to the design of reconfigurable dual machines using principles of RMS. As the targeted market is the SME, it is not limited to that as any entrepreneur may use the machine to their advantage. The design methodology presented contributes to the body of knowledge in dual reconfigurable machine tool design.

Details

Journal of Engineering, Design and Technology , vol. 19 no. 6
Type: Research Article
ISSN: 1726-0531

Keywords

Open Access
Article
Publication date: 15 March 2022

Mehrshad Mehrpouya, Daniel Tuma, Tom Vaneker, Mohamadreza Afrasiabi, Markus Bambach and Ian Gibson

This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It…

6595

Abstract

Purpose

This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It reviews the emerging technologies in PBF multimaterial printing and summarizes the latest simulation approaches for modeling them. The topic of “multimaterial PBF techniques” is still very new, undeveloped, and of interest to academia and industry on many levels.

Design/methodology/approach

This is a review paper. The study approach was to carefully search for and investigate notable works and peer-reviewed publications concerning multimaterial three-dimensional printing using PBF techniques. The current methodologies, as well as their advantages and disadvantages, are cross-compared through a systematic review.

Findings

The results show that the development of multimaterial PBF techniques is still in its infancy as many fundamental “research” questions have yet to be addressed before production. Experimentation has many limitations and is costly; therefore, modeling and simulation can be very helpful and is, of course, possible; however, it is heavily dependent on the material data and computational power, so it needs further development in future studies.

Originality/value

This work investigates the multimaterial PBF techniques and discusses the novel printing methods with practical examples. Our literature survey revealed that the number of accounts on the predictive modeling of stresses and optimizing laser scan strategies in multimaterial PBF is low with a (very) limited range of applications. To facilitate future developments in this direction, the key information of the simulation efforts and the state-of-the-art computational models of multimaterial PBF are provided.

Details

Rapid Prototyping Journal, vol. 28 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Open Access
Article
Publication date: 20 March 2024

Guijian Xiao, Tangming Zhang, Yi He, Zihan Zheng and Jingzhe Wang

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding…

Abstract

Purpose

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding and polishing of additive titanium alloy blades to ensure the surface integrity and machining accuracy of the blades.

Design/methodology/approach

At present, robot grinding and polishing are mainstream processing methods in blade automatic processing. This review systematically summarizes the processing characteristics and processing methods of additive manufacturing (AM) titanium alloy blades. On the one hand, the unique manufacturing process and thermal effect of AM have created the unique processing characteristics of additive titanium alloy blades. On the other hand, the robot grinding and polishing process needs to incorporate the material removal model into the traditional processing flow according to the processing characteristics of the additive titanium alloy.

Findings

Robot belt grinding can solve the processing problem of additive titanium alloy blades. The complex surface of the blade generates a robot grinding trajectory through trajectory planning. The trajectory planning of the robot profoundly affects the machining accuracy and surface quality of the blade. Subsequent research is needed to solve the problems of high machining accuracy of blade profiles, complex surface material removal models and uneven distribution of blade machining allowance. In the process parameters of the robot, the grinding parameters, trajectory planning and error compensation affect the surface quality of the blade through the material removal method, grinding force and grinding temperature. The machining accuracy of the blade surface is affected by robot vibration and stiffness.

Originality/value

This review systematically summarizes the processing characteristics and processing methods of aviation titanium alloy blades manufactured by AM. Combined with the material properties of additive titanium alloy, it provides a new idea for robot grinding and polishing of aviation titanium alloy blades manufactured by AM.

Details

Journal of Intelligent Manufacturing and Special Equipment, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2633-6596

Keywords

Open Access
Article
Publication date: 3 February 2020

Jørgen Blindheim, Christer W. Elverum, Torgeir Welo and Martin Steinert

This paper proposes the combination of rapid prototyping and physical modelling as a set-based concept evaluation method in the early stage of new product development.

3711

Abstract

Purpose

This paper proposes the combination of rapid prototyping and physical modelling as a set-based concept evaluation method in the early stage of new product development.

Design/methodology/approach

The concept evaluation method is applied in a case study of a new metal additive manufacturing process for aluminium, where a set of four extruder concepts has been modelled and evaluated. Rapid prototyping was used to produce plastic models of the different designs, and plasticine feedstock material was used to physically model the metal flow during operation. Finally, the selected concept has been verified in full-scale for processing of aluminium feedstock material.

Findings

The proposed method led to several valuable insights on critical factors that were unknown at the outset of the development project. Overall, these insights enabled concept exploration and concept selection that led to a substantially better solution than the original design.

Research limitations/implications

This method can be applied for other projects where numerical approaches are not applicable or capable, and where the costs or time required for producing full-scale prototypes are high.

Practical implications

Employing this method can enable a more thorough exploration of the design space, allowing new solutions to be discovered.

Originality/value

The proposed method allows a design team to test and evaluate multiple concepts at lower cost and time than what is usually required to produce full-scale prototypes. It is, therefore, concluded to be a valuable design strategy for the early development stages of complex products or technologies.

Details

Journal of Engineering, Design and Technology , vol. 18 no. 5
Type: Research Article
ISSN: 1726-0531

Keywords

Open Access
Article
Publication date: 29 February 2024

Guanchen Liu, Dongdong Xu, Zifu Shen, Hongjie Xu and Liang Ding

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous…

Abstract

Purpose

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Design/methodology/approach

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

Findings

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

Originality/value

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

Details

Journal of Intelligent Manufacturing and Special Equipment, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2633-6596

Keywords

Open Access
Article
Publication date: 2 June 2020

Kamaruzzaman Yunus, M.A. Zuraidah and Akbar John

This study aims to examine the metal pollution in coastal sediment in the Peninsular Malaysia.

10896

Abstract

Purpose

This study aims to examine the metal pollution in coastal sediment in the Peninsular Malaysia.

Design/methodology/approach

Approximately 141 published studies were screened from 1,285 documents and reviewed to determine the existing pollution status in the coastal areas of Peninsular Malaysia and the metals under review were Pb, Hg, Cd, Ar, Cu, Zn, Cr and Ni. Sources of pollutants and their effect on biological systems, marine organisms and human health were addressed in this review as well as recommendation of heavy metal removal or remedies in short. Emphasis is placed on marine pollution, particularly on the toxic metal accumulation in biota.

Findings

This study has revealed the different concentrations of pollutants, low, moderately, and chronically contaminated areas from heavy metals and the consequences to aquatic ecosystem and indirectly to human health, since an increasing in the coastal developments in Peninsular Malaysia.

Originality/value

This study has revealed the different concentrations of pollutants, low, moderately, and chronically contaminated areas from heavy metals and the consequences to aquatic ecosystem and indirectly to human health, since an increasing in the coastal developments in Peninsular Malaysia.

Details

Ecofeminism and Climate Change, vol. 1 no. 1
Type: Research Article
ISSN: 2633-4062

Keywords

Open Access
Article
Publication date: 10 December 2021

Pingan Zhu, Chao Zhang and Jun Zou

The purpose of the work is to provide a comprehensive review of the digital image correlation (DIC) technique for those who are interested in performing the DIC technique in the…

Abstract

Purpose

The purpose of the work is to provide a comprehensive review of the digital image correlation (DIC) technique for those who are interested in performing the DIC technique in the area of manufacturing.

Design/methodology/approach

No methodology was used because the paper is a review article.

Findings

no fundings.

Originality/value

Herein, the historical development, main strengths and measurement setup of DIC are introduced. Subsequently, the basic principles of the DIC technique are outlined in detail. The analysis of measurement accuracy associated with experimental factors and correlation algorithms is discussed and some useful recommendations for reducing measurement errors are also offered. Then, the utilization of DIC in different manufacturing fields (e.g. cutting, welding, forming and additive manufacturing) is summarized. Finally, the current challenges and prospects of DIC in intelligent manufacturing are discussed.

Details

Journal of Intelligent Manufacturing and Special Equipment, vol. 2 no. 2
Type: Research Article
ISSN: 2633-6596

Keywords

Open Access
Article
Publication date: 17 July 2023

Kanza Abid, Zafar Iqbal Shams, Muhammad Suleman Tahir and Arif Zubair

The presence of heavy metals in milk causes many acute and chronic physiological dysfunctions in human organs. The present study aims to investigate the heavy metals in cow's and…

1044

Abstract

Purpose

The presence of heavy metals in milk causes many acute and chronic physiological dysfunctions in human organs. The present study aims to investigate the heavy metals in cow's and buffalo's milk of two major cities, Karachi and Gujranwala, Pakistan to estimate metal intake by humans from this source.

Design/methodology/approach

In total, 48 milk samples from 2 cities were drawn from animals' udder to avoid contamination. Each sample was digested with nitric acid at 105 oC (degree Celsius) on a pre-heated electric hot plate to investigate the metals by atomic absorption spectroscopy (flame type). Air-acetylene technique analyzed chromium, cadmium and lead, and the hydride method analyzed arsenic in the milk samples.

Findings

The results revealed the highest mean lead concentration (19.65 ± 43.86 ppb) in the milk samples, followed by chromium (2.10 ± 2.33 ppb) and arsenic (0.48 ± 0.73 ppb). Cadmium was not detected in any sample, assuming cadmium's occurrence was below the detection level. The concentrations of all the metals in the samples of the two cities do not differ statistically. Lead concentrations in the buffalo's milk were higher than in cow's milk (p < 0.05). However, the concentrations of arsenic and chromium between buffalo's and cow's milk do not differ statistically. The present study reveals a lower level of metals in the milk than those conducted elsewhere. The mean concentrations of all the metals met the World Health Organization's (WHO) safety guidelines (1993).

Research limitations/implications

Although cadmium causes toxicity in the human body, cadmium could not be measured because cadmium's concentration was below the detection level, which is 1 ppb.

Practical implications

This study will help reduce the toxic metals in our environment, and the sources of heavy metals, particularly from the industrial sector could be identified. The feed and water consumed by the milking animals could be carefully used for feeding them.

Social implications

This study will help reduce the diseases and malfunction of human organs and organ systems since these heavy metals cause toxicity and carcinogenicity in humans. Arsenic and chromium cause cancer while lead causes encephalopathy (a brain disease).

Originality/value

The study reports heavy metal concentrations in the two attributes of four independent variables of raw milk samples that were scarcely reported from Pakistan.

Details

Arab Gulf Journal of Scientific Research, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1985-9899

Keywords

Open Access
Article
Publication date: 27 April 2020

Mojtaba Izadi, Aidin Farzaneh, Mazher Mohammed, Ian Gibson and Bernard Rolfe

This paper aims to present a comprehensive review of the laser engineered net shaping (LENS) process in an attempt to provide the reader with a deep understanding of the…

11435

Abstract

Purpose

This paper aims to present a comprehensive review of the laser engineered net shaping (LENS) process in an attempt to provide the reader with a deep understanding of the controllable and fixed build parameters of metallic parts. The authors discuss the effect and interplay between process parameters, including: laser power, scan speed and powder feed rate. Further, the authors show the interplay between process parameters is pivotal in achieving the desired microstructure, macrostructure, geometrical accuracy and mechanical properties.

Design/methodology/approach

In this manuscript, the authors review current research examining the process inputs and their influences on the final product when manufacturing with the LENS process. The authors also discuss how these parameters relate to important build aspects such as melt-pool dimensions, the volume of porosity and geometry accuracy.

Findings

The authors conclude that studies have greatly enriched the understanding of the LENS build process, however, much studies remains to be done. Importantly, the authors reveal that to date there are a number of detailed theoretical models that predict the end properties of deposition, however, much more study is necessary to allow for reasonable prediction of the build process for standard industrial parts, based on the synchronistic behavior of the input parameters.

Originality/value

This paper intends to raise questions about the possible research areas that could potentially promote the effectiveness of this LENS technology.

Details

Rapid Prototyping Journal, vol. 26 no. 6
Type: Research Article
ISSN: 1355-2546

Keywords

Open Access
Article
Publication date: 14 September 2015

Aristotelis Naniopoulos, Panagiotis Tsalis, Eleni Papanikolaou, Alexandra Kalliagra and Charitomeni Kourmpeti

Access to culture is a fundamental right of people with disabilities and a significant aspect in the development of accessible tourism. A visit to a monument provides an authentic…

2208

Abstract

Purpose

Access to culture is a fundamental right of people with disabilities and a significant aspect in the development of accessible tourism. A visit to a monument provides an authentic experience which cannot be substituted by any representation. However, any interventions to improve accessibility should be made carefully, so as not to alter the monument’s character, or damage it visually or structurally. The paper aims to discuss these issues.

Design/methodology/approach

A theoretical approach model was defined in the PROSPELASIS project for the improvement of accessibility in monuments which was applied in Byzantine monuments of Thessaloniki. This approach contains the following steps: evaluation of existing accessibility level; definition of alternative solutions; creation of final studies, approval by archaeological authorities and implementation of interventions.

Findings

In six major Byzantine monuments significant improvements were realized which include: installation of two lifts and creation of a new staircase at Acheiropoietos; creation of a metal bridge, a new staircase and installation of a lift at Rotunda; opening of the secondary gate and creation of a ramp at the Heptapyrgion fortress; creation of an accessible toilet at the Saint Demetrios church; installation in the six monuments of a WiFi system providing text and audible information as well as information in Greek and International Sign Language; creation of two tactile models; creation of a “cultural route” connecting three major Byzantine monuments.

Originality/value

For the first time, to the knowledge, a set of interventions has been realized in Byzantine monuments focusing on various categories of people with disabilities, i.e. motor, visual, hearing and cognitive.

Details

Journal of Tourism Futures, vol. 1 no. 3
Type: Research Article
ISSN: 2055-5911

Keywords

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