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1

Analysis of Wire Rolling Processes Using Convolutional Neural Networks

Capelin Matheus, Martinez Gustavo A.S., Xin Yutao, Siqueira Adriano F., Qian Wei-Liang

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no 2

103--114

EN

This study leverages machine learning to analyze the cross-sectional profiles of materials subjected to wire-rolling processes, focusing on the specific stages of these processes and the characteristics of the resulting microstructural profiles. The convolutional neural network (CNN), a potent tool for visual feature analysis and learning, is utilized to explore the properties and impacts of the cold plastic deformation technique. Specifically, CNNs are constructed and trained using 6400 image segments, each with a resolution of 120x90 pixels. The chosen architecture incorporates convolutional layers intercalated with polling layers and the “relu” activation function. The results, intriguingly, are derived from the observation of only a minuscule cropped fraction of the material’s cross-sectional profile. Following calibration and training of two distinct neural networks, we achieve training and validation accuracies of 97.4%/97% and 79%/75%, respectively. These accuracies correspond to identifying the cropped image’s location and the number of passes applied to the material. Further improvements in accuracy are reported upon integrating the two networks using a multiple-output setup, with the overall training and validation accuracies slightly increasing to 98.9%/79.4% and 94.6%/78.1%, respectively, for the two features. The study emphasizes the pivotal role of specific architectural elements, such as the rescaling parameter of the augmentation process, in attaining a satisfactory prediction rate. Lastly, we delve into the potential implications of our findings, which shed light on the potential of machine learning techniques in refining our understanding of wire-rolling processes and guiding the development of more efficient and sustainable manufacturing practices.

2

The role of green competencies for the sustainability manufacturing grow: preliminary research

Graczyk-Kucharska Magdalena

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2022

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z. 159

105--117

EN

Purpose: The EU’s guidelines exert an important influence on companies aiming to accelerate the implementation of green measures and minimise their negative environmental impacts. The objective of this paper is to define the key categories of green organisations and green competences whose development can accelerate the implementation of green processes in companies. Design/methodology/approach: Based on the literature review, a semi-structured qualitative research questionnaire was developed and a pilot study was conducted on four large manufacturing companies. Findings: A list of categories of activities linked to green organisations was developed and key components of green competences were defined. It was shown that performance-related managerial competences are the most important components of green competences for the companies. It was also pointed out that the categories that are the components of green 19 organisations are important and that the degree to which they are met has been increasing over time in recent years. Research limitations/implications: The pilot study was conducted with middle and senior 22 level representatives of four manufacturing companies. Its conclusions will be used to continue the research with a larger sample. Practical implications: The results of the study will allow companies to better adapt to the challenges of sustainability and green organisations. Key green competences and an emphasis on their development in the companies will allow more green organisation areas to be achieved more quickly. Social implications: The development of green organisations has a direct influence on minimising the negative environmental impacts and thereby improving the quality of life for everyone in society. Originality/value: Based on the analysis of the literature, it can be stated that there is no clear definition of green organisations while the variety of measures and their nomenclature in the area of sustainability is extensive. Research in that area contributes to the development of the science of management and quality and represents an important new field of research. This paper is meant for researchers and practitioners as well as HR representatives who work with the issue of green competences and green organisations.

3

Production and characterization of natural clay‑free green building brick materials using water treatment sludge and oak wood ash

Harja Maria, Gencel Osman, Sari Ahmet, Sutcu Mucahit, Erdogmus Ertugrul, Hekimoglu Gokhan

Archives of Civil and Mechanical Engineering

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2022

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Vol. 22, no. 2

art. no. e79, 1--14

EN

The experimental study investigates the feasibility of using two extensively waste (wastewater treatment sludge and oak wood ash) as raw materials in the manufacture of clay-free bricks. The wastes were characterized by particle-size distribution, chemical composition (EDX), X-ray diffraction (XRD), thermal analysis, and scanning electron microscopy (SEM). The oak wood ash replaced the water treatment sludge in different amounts (10-30 wt.%) in brick manufacture. The properties of clay-free green building brick were compared with the conventional bricks (obtained by standard methods). The properties depended of waste proportion. The 30 wt.% oak wood ash content achieved increase apparent porosity, with direct effect over water absorption and decreasing compressive strength. By replacing the water treatment sludge with oak wood ash, the CaO content increased, with negative effect over efflorescence on the surface; however, for 30 wt.% oak wood ash is below the imposed limits. Amounts of heavy metals in the leachates of fired samples are observed below the specified limits of the EPA (Environment Protection Authority). Additionally, the clay-free green bricks showed properties similar to the commercial bricks and improved thermal conductivity. The bricks containing 80 wt.% wastewater treatment sludge and 20 wt.% oak wood ash fulfilled standard requirements for clay masonry materials.

4

Sustainable manufacturing: re-contouring of laser cladding restored parts by machining method with cutting energy management

Zhang Peirong, Du Jin, Zhou Tingting, Su Guosheng, Huang Weimin, Liu Zhanqiang

Archives of Civil and Mechanical Engineering

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2020

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Vol. 20, no. 2

167--176

EN

Laser cladding has been commonly utilized for restoring high value-added parts. However, the poor surface quality becomes key technological barrier which restricts its widespread applications. In the paper, re-contouring strategies by machining method are explored for minimal energy consumption as well as required surface roughness. Firstly, the effect of structural characteristics of the laser-cladded workpiece on specific cutting energy was explored by means of layer-by-layer turning and orthogonal cutting. Results indicated that the specific cutting energy increased, and the machining chatter/vibration exacerbated with decreasing coating thickness under fixed cutting parameters. The reason can be summarized as a result of the effect of elastoplastic deformation behavior across the interface. Then, the influences of depth of cut and feed on specific cutting energy in finish turning were addressed. Results indicated that the specific cutting energy reduced with increasing depth of cut and feed in the form of power functions. In addition, energy efficiency decreased with an increase in uncut chip thickness and cutting speed. On basis of this work, large feed and low cutting speed with the adoption of wiper inserts were recommended for minimizing energy consumption within surface roughness requirement.

5

Wpływ technologii otrzymywania gniazd w formach wtryskowych na efektywność przetwarzania tworzyw

Pepliński K.

Polimery

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2018

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T. 63, nr 9

633--639

PL

Analizowano wpływ technologii wytwarzania gniazd form wtryskowych – ubytkowej (CM) i addytywnej (AM) – na jakość otrzymanych form, jakość wytworów uzyskanych z ich wykorzystaniem, efektywność przetwarzania i szkodliwość oddziaływania środowiskowego zarówno produktów, jak i procesów wytwarzania form/przetwarzania tworzyw polimerowych. Oceny dokonano na podstawie wartości wskaźników stanów postulowanych odpowiadających modelom matematycznym efektywności ekonomicznej, energetycznej i ekologicznej procesu, a także szkodliwości środowiskowej produktu i procesu przetwarzania tworzyw, opartych na badaniach doświadczalnych w warunkach rzeczywistych.

EN

The influence of injection mold manufacturing methods – cutting (CM) and additive (AM) – on the quality of obtained molds and parts produced from them, processing efficiency and harmfulness of environmental impact of the products and mold making/plastic processing methods was investigated. The assessment was made on the basis of the indicator values for postulated states corresponding to the mathematical models of the economic, energy and ecological process efficiency as well as the environmental harmfulness of the product and plastic processing method based on experimental research under real conditions.

6

The concept of using FMEA method for sustainable manufacturing

Hąbek P.

Systemy Wspomagania w Inżynierii Produkcji

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2017

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Vol. 6, iss. 4

49--55

EN

Sustainable manufacturing is to ensure that cost-effective manufacturing processes do not endanger the environment, are implemented in a way that is safe for life and health of employees and the public. The question then arises of how to improve manufacturing processes to make them more sustainable? Such a question cannot be answered unequivocally. The author draws attention to the possibility of using for that purpose FMEA (Failure Mode and Effects Analysis) method, which aims to identify potential defects in the process/product and then eliminate them or minimize the risks associated with them. In the article it will be proposed modification of this method for using it in the process of sustainable manufacturing.

PL

Zrównoważone wytwarzanie polega na zapewnianiu, że opłacalne ekonomicznie procesy wytwórcze nie zagrażają środowisku naturalnemu, są realizowane w sposób bezpieczny dla zdrowia i życia pracowników oraz społeczeństwa. Powstaje zatem pytanie w jaki sposób usprawniać procesy wytwarzania aby uczynić je bardziej zrównoważonymi? Na tak postawione pytanie nie sposób odpowiedzieć jednoznacznie. Autorka artykułu zwraca uwagę na możliwość wykorzystania w tym celu metody FMEA (Failure Mode and Effects Analysis), której celem jest identyfikowanie potencjalnych wad produktu/procesu, a następnie ich eliminowanie lub minimalizowanie ryzyka z nimi związanego. W artykule zaproponowana zostanie modyfikacja tej metody dla zastosowania jej w procesie zrównoważonego wytwarzania.

7

Maintenance in sustainable manufacturing

Stuchly V., Jasiulewicz-Kaczmarek M.

LogForum

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2014

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Vol. 10, no. 3

273--284

EN

Background: Sustainable development is about reaching a balance between economic, social, and environmental goals, as well as people's participation in the planning process in order to gain their input and support. For a company, sustainable development means adoption of such business strategy and actions that contribute to satisfying present needs of company and stakeholders, as well as simultaneous protection, maintenance and strengthening of human and environmental potential which will be needed in the future. This new approach forces manufacturing companies to change their previous management paradigms. New management paradigm should include new issues and develop innovative methods, practices and technologies striving for solving problem of shortages of resources, softening environment overload and enabling development of environment-friendly lifecycle of products. Hence, its realization requires updating existing production models as they are based on previously accepted paradigm of unlimited resources and unlimited regeneration capabilities. Maintenance plays a crucial role because of its impact on availability, reliability, quality and life cycle cost, thus it should be one of the main pillars of new business running model. Material and methods: The following paper is a result of research on the literature and observation of practices undertaken by a company within maintenance area. Results and conclusions: The main message is that considering sustainable manufacturing requires considerable expanding range of analysis and focusing on supporting processes. Maintenance offers numerous opportunities of decreasing influence of business processes on natural environment and more efficient resources utilization. The goal of maintenance processes realizing sustainable development strategy is increased profitability of exploitation and optimization of total lifecycle cost without disturbing safety and environmental issues.

PL

Wstęp: Zrównoważony rozwój opiera się osiąganiu równowagi pomiędzy celami ekonomicznymi, społecznymi i ekologicznymi i na udziale ludzi w planowanie procesu tak, by zdobyć ich zaangażowanie i wsparcie. Dla przedsiębiorstwa, zrównoważony rozwój oznacza przyjęcie takiej strategii biznesowej i realizacja takich działań, które przyczyniają się do zaspokajania bieżących potrzeb przedsiębiorstwa i stron zainteresowanych, przy jednoczesnej ochronie, utrzymaniu i wzmacnianiu potencjału ludzkiego i środowiskowego, który potrzebny będzie w przyszłości. To nowe podejście zmusza przedsiębiorstwa produkcyjne do zmiany uprzednio stosowanych przez nie paradygmatów zarządzania. Nowy paradygmat produkcji musi uwzględnić nowe zagadnienia i rozwijać innowacyjne metody, praktyki i technologie, na rzecz rozwiązania światowych niedoborów zasobów i złagodzenia nadmiernego obciążenia środowiska, umożliwiając przyjazny środowisku cykl życia produktów. Jego realizacja natomiast, wymaga aktualizacji obecnych modeli produkcji, opartych na starym paradygmacie nieograniczonych zasobów i nieograniczonej zdolności do regeneracji. Utrzymanie ruchu odgrywa kluczową rolę ze względu na swój wpływ na dostępność, niezawodność, jakość i koszt w całym cyklu życia wyrobu, zatem powinno być jednym z głównych filarów nowego modelu prowadzenia biznesu. Wyniki i wnioski: głównym przesłaniem niniejszego artykułu jest stwierdzenie, że aby rozważać koncepcję zrównoważonej produkcji musimy znacznie rozszerzyć granicę analiz i skierować uwagę na procesy wsparcia. Utrzymanie ruchu oferuje wiele możliwości zmniejszenia wpływu na środowisko naturalne i bardziej efektywne wykorzystanie zasobów. Celem bowiem procesów utrzymania ruchu w przedsiębiorstwie realizującym strategię zrównoważonego rozwoju jest zwiększenie efektywności eksploatacji i optymalizacja całkowitego kosztu cyklu życia wyrobu bez naruszania bezpieczeństwa i kwestii dotyczących środowiska.

8

Companies’ responsibility for sustainable development. Sustainable production patterns in small and medium - sized enterprises

Hąbek P.

Systemy Wspomagania w Inżynierii Produkcji

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2012

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z. 1 (1)

97--105

PL

W artykule poruszona została problematyka zmiany wzorców produkcji na sprzyjające realizacji zasad zrównoważonego rozwoju. W pierwszej części artykułu omówiono wkład, jaki przedsiębiorstwa wnoszą w zrównoważony rozwój poprzez implementację koncepcji społecznej odpowiedzialności (CSR), a w jej ramach idei zrównoważonego wytwarzania. W drugiej części artykułu przedstawiono wybrane wskaźniki wdrażania zrównoważonych wzorców produkcji w sektorze małych i średnich przedsiębiorstw w Polsce, odnosząc je do sytuacji panującej w Unii Europejskiej.

9

Energy and carbon footprint analysis for machiningtitanium Ti-6Al-4V alloy

Rajemi M. F., Mativenga P. T., Jaffery S. I.

Journal of Machine Engineering

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2009

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Vol. 9, No. 1

103--112

EN

Titanium alloys are increasingly being used in manufacturing especially in aerospace industries. The environmental impact of using this material is rarely discussed especially with regards to energy consumption and its contribution to carbon emissions. The poor machinability of titanium leads to lower material removal rate and longer machining time. Coupled with high carbon footprints encountered, in extracting this material from ore, it is clear that the environmental impact of using this material needs to be optimised. In the research reported here, cutting tests were undertaken on a lathe and milling machine using unified cutting conditions. The associated energy and carbon footprints were analysed and discussed with emphasis on high speed machining. The paper clearly shows the impact of process choice and cutting speed on environmental footprints as a key performance measure in sustainable manufacturing.

10

Achievements of sustainable manufacturing by machining

Kopac J.

Journal of Achievements in Materials and Manufacturing Engineering

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2009

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Vol. 34, nr 2

180-187

EN

Purpose: Manufacturing industry is under increasing pressure of global competition, stricter environmental legislation and supply-chain demand for improved sustainability performance. The latter can be achieved through changes in products, processes and systems which are related to the sustainability issues. Sustainability in manufacturing is an appropriate approach; however it is still unified to a higher production rate and benefit. To encounter this problem academic, scientific, cultural and human organizations have to find the way, on a highest level of decision; maybe to rise the sustainability over production growth. This paper also presents some results from modelling and optimization of sustainable machining of Inconel 718. High temperature alloys, such as Nickel and Titanium alloys, pose significant difficulty in machining, due to their unique thermo-mechanical properties. Design/methodology/approach: In the paper are presented and evaluated two sustainable machining alternatives: cryogenic machining and high pressure assisted machining in comparison to conventional machining. The sustainability performance measures refer to environmental impact, energy consumption, safety, personal health, waste management and costs. The sustainability evaluation is supported with machining experiments on high-temperature Ni-alloy (Inconel 718). It is shown that tooling costs are presenting the major contribution to the overall production costs, when hard-to-machine materials are machined, what is contradictory with previous analysis. Findings: As a result, it is shown that sustainable machining alternatives offer economic, environmental and social performance improvement in comparison to conventional machining. The results of the experimental part show that appropriate cooling/lubrication application can provide improved overall machining performance while satisfying sustainable issues in terms of enhanced machined surface quality, tool-life, chip breakability, power consumption and increasing productivity. Research limitations/implications: The Faculty of Mechanical Engineering in Ljubljana, Slovenia is implementing two new cutting strategies for the machining of a special material – Inconel. The first one is cryogenic machining and the second is material cutting by assistance of high pressure jet cooling lubrication. Both machining strategy are in rang of sustainable manufacturing. The implications of processes like those are not only nature friendly, but also modern spirit for producers and users of products. Originality/value: Paper present the technical description of two modern machining processes, the comparison of them and benefit, advantages and disantvantages. Really new is the strategy and opinion of spirit, which can be included in product over sustainable manufacturing processes.