Product and Process Innovation for Modeling of Sustainable Machining Processes

  • I. S. Jawahir
  • A. D. Jayal
Conference paper

Abstract

Sustainability is recognized as the driver for innovation. However, there is a critical need for improved sustainability evaluation methods, as well as for improved predictive models and optimization methods, to aid decision-making and selection of novel product and process designs for sustainable manufacturing. In the case of machining, increased awareness of the need for sustainability in manufacturing operations has led to significant research in advancing with new and more sustainable processes such as dry, near-dry and cryogenic machining. This paper presents an overview of product and process sustainability evaluation methods and modeling techniques, including analytical, empirical and computational methods, as well as optimization procedures, developed for predicting the performance of sustainable machining processes and major sustainability elements in machined products. The paper also highlights the technological challenges involved, and the future work needed, in developing comprehensive predictive models and optimization techniques for sustainable machining.

Keywords

Sustainable manufacturing Machining Modeling Products Processes 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    ITA, U.S. Dept. of Commerce, 2007, How Does Commerce Define Sustainable Manufacturing?, Available: http://www.trade.gov/competitiveness/sustainablemanufacturing/how_doc_defines_SM.asp.
  2. 2.
    National Council for Advanced Manufacturing (NACFAM), 2009, Sustainable Manufacturing, Available: http://nacfam02.dev.web.sba.com/PolicyInitiatives/SustainableManufacturing/tabid/64/Default.aspx.
  3. 3.
    Graedel, T.E., Streamlined life-cycle assessment, 1998, Prentice-Hall, New Jersey, USA.Google Scholar
  4. 4.
    Jaafar, I.H., Venkatachalam, A., Joshi, K., Ungureanu, A.C., De Silva, N., Dillon, Jr., O.W., Rouch, K.E., Jawahir, I.S., 2007, Product design for sustainability: a new assessment methodology and case studies, Hdbk. Env. Conscious Mech. Des., (Ed.: M. Kutz), John Wiley & Sons, 25–65.Google Scholar
  5. 5.
    Joshi, K., Venkatachalam, A., Jawahir, I.S., 2006, A new methodology for transforming 3R concept into 6R concept for improved product sustainability, IV Global Conf. Sust. Prod. Dev. & LCE, São Carlos, Brazil.Google Scholar
  6. 6.
    Silva, N.D., Jawahir, I.S., Dillon, O.W., Russell, M., 2009, A New Comprehensive Methodology for the Evaluation of Product Sustainability at the Design and Development Stage of Consumer Electronic Products, Int. J. Sust. Manuf., 1/3, 251–264.Google Scholar
  7. 7.
    Jawahir, I.S., Dillon, Jr., O.W., 2007, Sustainable manufacturing processes: new challenges for developing predictive models and optimization techniques, 1st Int. Conf. Sust. Manuf. (SM1), Montreal, Canada, 1–19.Google Scholar
  8. 8.
    Gupta, A., Vangari, R., Jayal, A.D., Jawahir, I.S., 2010, Priority Evaluation of Product Metrics for Sustainable Manufacturing, Proc. 20th CIRP Des. Conf., Nantes, France.Google Scholar
  9. 9.
    Granados, S., Jawahir, I.S., Fernandez, J., 2009, A comprehensive criterion for sustainability evaluation of machining processes, 7th Global Conf. Sust. Manuf., IIT Madras, Chennai, India, 385–391.Google Scholar
  10. 10.
    Wanigarathne, P.C., Liew, J., Wang, X., Dillon, Jr., O.W., Jawahir, I.S., 2004, Assessment of process sustainability for product manufacture in machining operations, Global Conf. Sust. Prod. Dev. & LCE, Berlin, Germany, 305–312.Google Scholar
  11. 11.
    Klocke, F., Eisenblatter, G., 1997, Dry Cutting, Annals of the CIRP, 46(2), 519–526.CrossRefGoogle Scholar
  12. 12.
    Weinert, K., Inasaki, I., Sutherland, J.W., Wakabayashi, T., 2004, Dry machining and minimum quantity lubrication, Annals of the CIRP, 53(2), 511–537.CrossRefGoogle Scholar
  13. 13.
    Pusavec, F., 2010, Modeling and characterization of sustainable cryogenic machining, PhD Dissert., University of Ljubljana, Ljubljana, Slovenia.Google Scholar
  14. 14.
    Redetzky, M., Balaji, A.K., Jawahir, I.S., 1999, Predictive modeling of cutting forces and chip flow in machining with nose radius tools, 2nd CIRP Int. Wksp. Modeling of Machining Operations, Nantes, France, 160–180.Google Scholar
  15. 15.
    Ghosh, R., Redetzky, M., Balaji, A.K., Jawahir, I.S., 1996, The equivalent toolface (ET) approach for modeling chip curl in machining with grooved tools, CSME Forum, 702–711.Google Scholar
  16. 16.
    Ghosh, R., Dillon, O.W., Jawahir, I.S., 1998, An investigation of 3D curled chip in machining – part 1: A mechanics-based analytical model, Mach. Sci. & Tech., 2(1), 91–116.CrossRefGoogle Scholar
  17. 17.
    Wang, X., Jawahir, I.S., 2007, Recent advances in plasticity applications in metal machining: slip-line models for machining with rounded cutting edge restricted contact grooved tools, Int. J. Machining & Machinability of Materials, 2(3), 347–360.CrossRefGoogle Scholar
  18. 18.
    Oxley, P.L.B., 1989, Mechanics of machining: an analytical approach to assessing machinability, Ellis Horwood.Google Scholar
  19. 19.
    Ee, K.C., Dillon, Jr., O.W., Jawahir, I.S., 2005, Finite element modeling of residual stresses in machining induced by cutting tool with a finite edge radius, Int. J. Mech. Sci., 47, 1611–1628.MATHCrossRefGoogle Scholar
  20. 20.
    Wanigarathne, P.C., 2006, Experimental and analytical modeling of near-dry turning operations with coated grooved tools for improved sustainability, PhD Dissert., Univ. of Kentucky.Google Scholar
  21. 21.
    Umbrello, D., Jayal, A. D., Caruso, S., Dillon, O. W., Jawahir, I. S., 2010, Modeling of white and dark layer formation in hard machining of AISI 52100 steel, Mach. Sci. & Tech., 14(1), pp. 128–147.CrossRefGoogle Scholar
  22. 22.
    Wang, X., Jawahir, I.S., 2005, Optimization of multi-pass turning operations using genetic algorithms for the selection of cutting conditions and cutting tools with tool-wear effect, Int. J. Prod. Res., 43(17), 3543–3559.MATHCrossRefGoogle Scholar
  23. 23.
    Da, Z.J. and Jawahir, I.S., 1998, Optimal chip control in turning operations, Int. Sem. Improving Mach. Tool Perf., San Sebastian, Spain, Vol. II, pp. 607–618.Google Scholar
  24. 24.
    Jawahir, I.S., 1990, On the controllability of chip breaking cycles and modes of chip breaking in metal machining, Annals of the CIRP, 39(1), 47–51.CrossRefGoogle Scholar
  25. 25.
    Jawahir, I.S., Li, P.X., Ghosh, R., Exner, E.L., 1995, A new parametric approach for the assessment of comprehensive tool-wear in coated grooved tools, Annals of the CIRP, 45(1), 49–54.CrossRefGoogle Scholar
  26. 26.
    Jawahir, I.S., Fang, X.D., Li, P.X., Ghosh, R., 1997, Method of assessing tool-life in grooved tools, US patent: 5,689,062.Google Scholar
  27. 27.
    Um, J.-Y., Chow, L.C., Jawahir, I.S., 1995, An experimental investigation of the application of the spray cooling method in stainless steel machining, ASME-IMECE, MED, 2(1), 165–178.Google Scholar
  28. 28.
    Marksberry, P., Jawahir, I.S., 2008, A comprehensive tool-life performance model in near-dry machining for sustainable manufacturing, Int. J. Mach. Tools & Manuf., 48(7–8), 878–886.CrossRefGoogle Scholar
  29. 29.
    Kardekar, A., 2005, Modeling and optimization of machining performance measures in face milling of automotive aluminum alloy A380 under different lubrication/cooling conditions for sustainable manufacturing, MS Thesis, Univ. of Kentucky.Google Scholar
  30. 30.
    Hong, Z., Hong, S.Y., 1992, Cryogenic properties of some cutting tool materials, J. Mat. Eng. & Perf., 1(5), 705–714.CrossRefGoogle Scholar
  31. 31.
    Zurecki, Z., Ghosh, R., Frey, J.H., 2003, Investigation of white layers formed in conventional and cryogenic hard turning of steels, Proc. ASME IMECE2003-42313.Google Scholar
  32. 32.
    Outeiro, J.C., Kandibanda, R., Pina, J.C., Dillon Jr., O.W., Jawahir, I.S., 2010, Size-effects and surface integrity in machining and their influence on product sustainability, Int. J. Sust. Manuf., 2(1), 112–126.Google Scholar

Copyright information

© Springer-Verlag Berlin Heidelberg 2011

Authors and Affiliations

  • I. S. Jawahir
    • 1
  • A. D. Jayal
    • 1
  1. 1.Institute for Sustainable ManufacturingUniversity of KentuckyLexingtonUSA

Personalised recommendations