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Processes
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Innovations in Manufacturing Processes and Systems for Sustainable Practices
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Innovations in Manufacturing Processes and Systems for Sustainable Practices

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 30 June 2024 | Viewed by 3261

Special Issue Editor

Dr. Raul D. S. G. Campilho

E-Mail Website
Guest Editor
Departamento de Engenharia Mecânica, Instituto Superior de Engenharia do Porto, 4200-072 Porto, Portugal
Interests: advanced manufacturing systems; automation and robotics; industrial design
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

As a fundamental pillar of industrial progress, manufacturing continues to undergo significant changes driven by technological advancements, societal demands and a growing emphasis on sustainability. Manufacturing systems, the backbone of production frameworks, have evolved significantly in response to the integration of cutting-edge technologies. The advent of Industry 4.0 has guided a new era characterized by the seamless fusion of digitalization, automation and robotics, and data exchange. Simultaneously, advancements in manufacturing processes have been fundamental in enhancing efficiency, precision and sustainability. From micro-nano-manufacturing to additive technologies such as 3D printing, researchers and practitioners are exploring innovative methods that redefine conventional manufacturing paradigms. Sustainability, a key concern in the industry, is a recurring theme to associate all these concepts with the legislation and societal-driven green practices, made possible by the integration of sustainability metrics, green manufacturing practices and novel approaches to process design. This Special Issue of the journal Processes aims to explore and present the latest findings on modern manufacturing, highlighting key trends that are shaping the future of this critical industry. The Special Issue invites contributions that delve into the described subjects, offering a nuanced understanding of how they contribute to the evolution of manufacturing methodologies. The aim is to present a holistic view of how manufacturing processes and systems can align with environmental and societal goals, fostering a more responsible and eco-conscious industry. To advance the state of the art and disseminate the recent advances in all manufacturing-related matters, this Special Issue intends to collate a significant number of contributions in this area through high-quality original or review works, subsequently promoting the issue’s dissemination via the open access system.

Dr. Raul D. S. G. Campilho
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • manufacturing systems
  • manufacturing processes
  • manufacturing technologies
  • automation
  • robotics
  • micro-nano-manufacturing
  • green manufacturing
  • sustainability
  • process design
  • new sustainable processes and supply chains
  • Industry 4.0
  • digitalization
  • data exchange
  • additive technologies (3D printing)

Published Papers (4 papers)

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Research

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17 pages, 3376 KiB  
Article
A Fuzzy Decision-Making Method for Green Design for Remanufacturability
by Yu Cai, Chao Ke and Qunjing Ji
Processes 2024, 12(5), 911; https://doi.org/10.3390/pr12050911 (registering DOI) - 29 Apr 2024
Viewed by 45
Abstract
Designs for remanufacturing (DfRem) consider the remanufacturability of the product in the early stages of product design, which can greatly increase the reusability of the products. However, product design schemes lack reasonable evaluation indicators for remanufacturability, and the decision-makers of the design scheme [...] Read more.
Designs for remanufacturing (DfRem) consider the remanufacturability of the product in the early stages of product design, which can greatly increase the reusability of the products. However, product design schemes lack reasonable evaluation indicators for remanufacturability, and the decision-makers of the design scheme have subjective preferences and vague hesitation. These result in inaccurate decision making on DfRem schemes that will affect the successful implementation of product remanufacturing. In order to improve the accuracy of the DfRem scheme decision, a fuzzy decision-making method for green design for remanufacturability is proposed. Firstly, an evaluation indicator system for green design schemes was established that takes into account remanufacturability, reliability, cost, and the environment, and the entropy weighting method is used to quantify and weigh the design scheme evaluation indicators. Then, the hesitation fuzzy set is applied to construct the set of evaluations and the optimal design scheme is selected by applying the comprehensive evaluation method. Finally, the feasibility of the above method is verified by using the green design of an injection mold as an example, and the results show that the above method is able to make accurate and effective design scheme decisions. This method has been implemented in a prototype system using Visual Studio 2022 and Microsoft SQL Server2022. The results show that the fuzzy decision-making system is accurate and effective for rapidly generating a rational green design scheme for remanufacturability. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
18 pages, 4734 KiB  
Article
Implementations of Digital Transformation and Digital Twins: Exploring the Factory of the Future
by Ramin Rahmani, Cristiano Jesus and Sérgio I. Lopes
Processes 2024, 12(4), 787; https://doi.org/10.3390/pr12040787 - 14 Apr 2024
Viewed by 559
Abstract
In the era of rapid technological advancement and evolving industrial landscapes, embracing the concept of the factory of the future (FoF) is crucial for companies seeking to optimize efficiency, enhance productivity, and stay sustainable. This case study explores the concept of the FoF [...] Read more.
In the era of rapid technological advancement and evolving industrial landscapes, embracing the concept of the factory of the future (FoF) is crucial for companies seeking to optimize efficiency, enhance productivity, and stay sustainable. This case study explores the concept of the FoF and its role in driving the energy transition and digital transformation within the automotive sector. By embracing advancements in technology and innovation, these factories aim to establish a smart, sustainable, inclusive, and resilient growth framework. The shift towards hybrid and electric vehicles necessitates significant adjustments in vehicle components and production processes. To achieve this, the adoption of lighter materials becomes imperative, and new technologies such as additive manufacturing (AM) and artificial intelligence (AI) are being adopted, facilitating enhanced efficiency and innovation within the factory environment. An important aspect of this paradigm involves the development and utilization of a modular, affordable, safe human–robot interaction and highly performant intelligent robot. The introduction of this intelligent robot aims to foster a higher degree of automation and efficiency through collaborative human–robot environments on the factory floor and production lines, specifically tailored to the automotive sector. By combining the strengths of human and robotic capabilities, the future factory aims to revolutionize manufacturing processes, ultimately driving the automotive industry towards a more sustainable and technologically advanced future. This study explores the implementation of automation and the initial strides toward transitioning from Industry 4.0 to 5.0, focusing on three recognized, large, and automotive companies operating in the north of Portugal. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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30 pages, 12317 KiB  
Article
Fabrication and Characterisation of Sustainable 3D-Printed Parts Using Post-Consumer PLA Plastic and Virgin PLA Blends
by Mohammad Raquibul Hasan, Ian J. Davies, Alokesh Paramanik, Michele John and Wahidul K. Biswas
Processes 2024, 12(4), 760; https://doi.org/10.3390/pr12040760 - 09 Apr 2024
Viewed by 501
Abstract
Sustainable manufacturing practices are becoming increasingly necessary due to the growing concerns regarding climate change and resource scarcity. Consequently, material recycling technologies have gradually become preferred over conventional processes. This study aimed to recycle waste polylactic acid (PLA) from household-disposed cups and lids [...] Read more.
Sustainable manufacturing practices are becoming increasingly necessary due to the growing concerns regarding climate change and resource scarcity. Consequently, material recycling technologies have gradually become preferred over conventional processes. This study aimed to recycle waste polylactic acid (PLA) from household-disposed cups and lids to create 3D-printed parts and promote sustainable manufacturing practices. To achieve this, the current study utilised virgin and post-consumer PLA (PC-PLA) (sourced from household waste) blends. The PC-PLA wastes were shredded and sorted by size with the aid of a washing step, resulting in a filament with a 1.70 ± 0.5 mm diameter without fragmentation or dissolution. A 50:50 wt.% blend of virgin PLA (vPLA) and PC-PLA was selected as the standard recycling percentage based on previous research and resource conservation goals. The study investigated the impact of three 3D printing parameters (layer height (LH), infill density (I), and nozzle temperature (NT)) on the quality of 3D-printed parts using a three-level L9 Taguchi orthogonal array. The findings revealed that blending PC-PLA with vPLA led to significant improvements in tensile, flexural, and impact strengths by 18.40%, 8%, and 9.15%, respectively, compared to those of recycled PLA (rPLA). This conclusion was supported by the investigation of the fracture surface area, which revealed fractographic features associated with printing parameters, such as plastic deformation and interfilament debonding. An ANOVA analysis revealed a positive influence of a greater layer height and high nozzle temperature on mechanical properties. Subsequently, the optimal printing parameters (LH: 0.3 mm, I: 100%, and NT: 215 °C) were determined using the S/N ratio, and a confirmation test using the optimum printing parameters exhibited a strong correlation with the statistically predicted outcomes. Finally, the study used optimum printing parameters to fabricate 100% PC-PLA 3D-printed parts, demonstrating their potential for low-strength applications. The findings suggest that employing vPLA and PC-PLA blended filaments for fabricating 3D-printed components presents an effective means of promoting plastic recycling within a closed-loop recycling system and achieving a circular economy. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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Review

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28 pages, 7430 KiB  
Review
Dry Machining Techniques for Sustainability in Metal Cutting: A Review
by Shailendra Pawanr and Kapil Gupta
Processes 2024, 12(2), 417; https://doi.org/10.3390/pr12020417 - 19 Feb 2024
Viewed by 887
Abstract
Dry machining has gained significant importance in the last few years due to its promising contribution towards sustainability. This review study introduces dry machining, presents its benefits, and summarizes the recent technological developments that can facilitate dry machining. It aims to provide a [...] Read more.
Dry machining has gained significant importance in the last few years due to its promising contribution towards sustainability. This review study introduces dry machining, presents its benefits, and summarizes the recent technological developments that can facilitate dry machining. It aims to provide a concise overview of the current state of the art in dry machining to promote sustainability. This article synthesizes and emphasizes the useful information from the existing literature, and summarizes the methods and tools used to implement it. It also identifies some of the major problems and challenges and their potential solutions to make dry machining more viable and efficient. It concludes with some future research directions important for the scholars and researchers to establish the field further. From this review study, the major findings are: (1) tools with textures or patterns can enhance the cutting performance of dry machining for various materials, (2) tool coating is an effective way to lower the tool cost in dry machining and can achieve the required functionality for the cutting tool without affecting its core properties, (3) Alumina-based mixed ceramic tools with SiC whiskers have better fracture toughness, thermal shock resistance, and self-crack healing properties, (4) one effective method to improve the dry cutting of engineering materials is to apply external energy sources to assist the dry machining process, (5) by using microwave sintering, cutting tools with finer microstructures and higher densities can be produced, which improve their hardness, wear resistance, and thermal stability to perform well in dry machining conditions. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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