A B S T R A C T This paper aims to provide a systematic overview of the state of the art in energy and resource efficiency increasing methods and techniques in the domain of discrete part manufacturing, with attention for the effectiveness of the available options. For this purpose a structured approach, distinguishing different system scale levels, is applied: starting from a unit process focus, respectively the multi-machine, factory, multi-facility and supply chain levels are covered. Determined by the research contributions reported in literature, the de facto focus of the paper is mainly on energy related aspects of manufacturing. Significant opportunities for systematic efficiency improving measures are identified and summarized in this area. 2012 CIRP.

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Towards Energy and Resource Efficient Manufacturing: A Processes and Systems Approach

Outstanding mechanical and physical properties like high thermal resistance, high hardness and chemical stability have encouraged use of structural ceramics in several applications. The brittle and hard nature of these ceramics makes them difficult to machine using conventional techniques and damage caused to the surface while machining affects efficiency of components. Laser machining has recently emerged as a potential technique for attaining high material removal rates. This review paper aims at presenting the state of the art in the field of laser machining of structural ceramics and emphasizes on experimental and computational approaches in understanding physical nature of the complex phenomena.

Laser machining of structural ceramics—A review

A nanofluid minimum quantity lubrication with addition of one kind of nanoparticle has several limitations, such as grinding of difficult-to-cutting materials Hybrid nanoparticles integrate the properties of two or more kinds of nanoparticles, thus having better lubrication and heat transfer performances than single nanoparticle additives However, the use of hybrid nanoparticles in nanofluid minimum quantity lubrication grinding has not been reported This study aims to determine whether hybrid nanoparticles have better lubrication performance than pure nanoparticle A hybrid nanofluid consisting of MoS2 nanoparticles with good lubrication effect and CNTs with high heat conductivity coefficient is investigated The effects of the hybrid nanofluid on grinding force, coefficient of friction, and workpiece surface quality for Ni-based alloy grinding are analyzed Results show that the MoS2/CNT hybrid nanoparticles achieve better lubrication effect than single nanoparticles The optimal MoS2/CNT mixing ratio and nanofluid concentration are 2:1 and 6 wt%, respectively

Experimental Evaluation of the Lubrication Performance of MoS2/CNT Nanofluid for Minimal Quantity Lubrication in Ni-based Alloy Grinding

Dispersing mechanism and tribological performance of vegetable oil-based CNT nanofluids with different surfactants

Effects of Minimum Quantity Lubrication (MQL) in machining processes using conventional and nanofluid based cutting fluids: A comprehensive review

Cooling and lubrication are very critical to ensure workpiece quality in grinding due to the high friction and intense heat generation involved in the process. Liquid lubricants have traditionally been used in flood form or minimum quantity lubrication (MQL), raising however, major environmental and economic concerns. The focus of this study is to evaluate the performance of graphite nanoplatelets as a lubricant in surface grinding. The role of graphite's characteristics such as form, size and concentration; and the effect of the carrying medium and the graphite's application method are determined based on an experimental study. The results indicate that graphite nanoplatelets significantly reduce the grinding forces, specific energy, and improve surface finish during surface grinding of hardened D-2 tool steel. A comparison with results obtained in conventional MQL grinding is also provided. The proper selection of graphite, carrying medium and application method can lead to a low cost, nontoxic and simple alternative to solid lubrication or MQL grinding.

An investigation of graphite nanoplatelets as lubricant in grinding

Laser-assisted mechanical micromachining (LAMM) is a micro-cutting method that employs highly localized thermal softening of the material by continuous wave laser irradiation focused in front of a miniature cutting tool However, since it is a heat-assisted process, it can induce a detrimental heat-affected zone (HAZ) in the part This paper focuses on characterization and prediction of the HAZ produced in a LAMM-based micro-grooving process The heat-affected zone generated by laser heating of H-13 mold steel (42 HRC) at different laser scanning speeds is analyzed for changes in microstructure and microhardness A 3-D transient finite element model for a moving Gaussian laser heat source is developed to predict the temperature distribution in the workpiece material The model prediction error is found to be in the 5–15% range with most values falling within 10% of the measured temperatures The predicted temperature distribution is correlated with the HAZ and a critical temperature range (840–890 °C) corresponding to the maximum depth of the HAZ is identified using a combination of metallography, hardness testing, and thermal modeling

Matthew J. Alberts

Papers

An investigation of graphite nanoplatelets as lubricant in grinding

Characterization and prediction of the heat-affected zone in a laser-assisted mechanical micromachining process

Predicting chatter using machine learning and acoustic signals from low-cost microphones