Progress Toward Modeling and Optimization of Sustainable Machining Processes

Abstract

The topic of sustainable machining has in recent times emerged as a significant and impactful area of research focus as it directly deals with environmental health and protection, economic growth and prosperity and societal wellbeing with greater human health and safety. More specifically, sustainable machining at product, process and system levels deals with reducing negative environmental impact; offering improved energy and resource efficiency; generating minimum quantity of wastes; providing operational safety; and offering improved personal health. This paper summarizes recent efforts by the world research community in sustainable machining with a systematic approach for the analysis of machining processes that are broadly defined and classified as sustainable, beginning with dry machining, and then near-dry (also known as MQL, minimum quantity lubrication) and cryogenic machining processes. The paper also extends its analysis to hybrid mode of sustainable machining which effectively combines cryogenic and MQL machining processes for improved machining productivity, performance and sustainability. While a significant part of this paper presents a summary of recent experimental analysis, the progress being made in modeling and optimization has also been discussed in the paper. In particular, major challenges involved in model development for practical implementation, with a view to selecting optimum cutting conditions and cutting tools, are primarily discussed in the paper. The need for continued modeling efforts for achieving deployable optimized conditions for sustainable machining is highly recognized, and further research is urged in numerous fronts integrating the various convergent disciplines such as materials, mechanics, computational sciences, economics, environmental sciences, etc.

Manufacturing of a natural fiber/glass fiber hybrid reinforced polymer composite (PxGyEz) for high flexural strength: an optimization approach

“…Using such methods in conducting analytical analyses, several researchers in various disciplines have met advanced design criteria [43][44][45]. These modeling and optimization strategies have addressed the issues in physical complexity that are commonly faced in scientific and engineering research [44,46]. Material scientists have been experimenting with computational approaches to enhance the mechanical characteristics of composite materials reinforced with natural fibers, mostly to replace synthetic fibers owing to concerns about sustainability and the environment.…”

Sustainable Manufacturing Technologies: A Systematic Review of Latest Trends and Themes

“…Manufacturing process technology innovations, such as sustainable machining [77,78], sustainable lubrication and nanofluids [148], sustainable additive manufacturing [117], sustainable welding [120], sustainable casting [129], and sustainable metal forming [167], are also of paramount importance for SM and will act as "the nuts and bolts" in our journey towards SM.…”

“…It was noteworthy that a ma tion (approximately 50%) of the SM technology research focalised in sustainable ing technologies [74,75], including Alvarez et al [76], Uhlmann et al [77], and Ja al. [78], who documented various sustainable machining and engineering so Welding is an impactful manufacturing process for sustainability [79,80], and it w tified as the second most popular SM technology research area, with 14%. Additi ufacturing as a highly emerging research stream [81] was established as the th theme (13%), with various sustainability aspects of this promising manufacturi nology receiving attention.…”

“…The articles were categorised into the sustainable manufacturing technology area studied, and findings are demonstrated in Figure 7. It was noteworthy that a major portion (approximately 50%) of the SM technology research focalised in sustainable machining technologies [74,75], including Alvarez et al [76], Uhlmann et al [77], and Jawahir et al [78], who documented various sustainable machining and engineering solutions. Welding is an impactful manufacturing process for sustainability [79,80], and it was identified as the second most popular SM technology research area, with 14%.…”

Manufacturing Parameters Optimization and Modeling of PxGyEz Hybrid Composite for High Flexural Strength Using Taguchi Robust Experimental Design Technique and General Regression Analysis

“…Advanced design requirements have been achieved by different researchers in various fields by applying these computational methods in carrying out analytical studies (Shalf, 2020;Abdulqadir et al, 2021;Mulenga et al 2021). The challenges in physical complexities which are normally encountered in science and engineering research have been addressed by these modeling and optimization techniques (Jawahir et al, 2020;Mulengaet al, 2021). In the field of materials, researchers have been exploring these computational techniques to optimize the mechanical characteristics of these composite materials which are reinforced with natural fibers mostly to potentially replace synthetic fibers because of sustainability issues and environmental aspects.…”