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Sustainable and Advanced Remanufacturing Processes

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A special issue of Sustainability (ISSN 2071-1050). This special issue belongs to the section "Sustainable Chemical Engineering and Technology".

Deadline for manuscript submissions: closed (30 September 2022) | Viewed by 46742

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Special Issue Editors

Dr. Chander Prakash

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Guest Editor

Department of Industrial Engineering, School of Mechanical Engineering, Lovely Professional University, Punjab 144411, India
Interests: biomaterials; sustainable manufacturing; surface engineering
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Dr. Sunpreet Singh

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Guest Editor

Department of Mechanical Engineering, National University of Singapore, Singapore 119077, Singapore
Interests: additive manufacturing; sustainable manufacturing; implants
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Prof. Dr. Seeram Ramakrishna

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Department of Mechanical Engineering, National University of Singapore, Singapore 119077, Singapore
Interests: circular economy; sustainability; energy; biomaterials; nanofibers
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Dr. Alokesh Pramanik

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Guest Editor

Department of Mechanical Engineering, Curtin University, GPO Box U1987, Perth, WA 6845, Australia
Interests: machining processes; CAD/CAM; digital manufacturing
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Prof. Dr. Hongyu Zheng

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Department of Mechanical Engineering, Shandong University of Technology, Zibo 255000, Shandong, China
Interests: laser materials processing; micro/nano processing; surface texturing; sustainbale manufacturing

Prof. Dr. Yongling (Linda) Wu

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Guest Editor

Department of Mechanical Engineering, Shandong University of Technology, Zibo 255000, Shandong, China
Interests: surface engineering; nanomaterials; sustainbale materials; advanced manufacturing

Special Issue Information

Dear Colleagues,

The increasing demand for advanced manufacturing processes for function is making an impact on the Earth’s resources, and its industrial practices are producing negative impacts on the environment, such as carbon footprints, energy resources, waste, etc. The trend of advanced manufacturing coincides with the acceleration of innovations in sustainable techniques. Sustainable development is a globally recognized mandate and it includes green or environment-friendly manufacturing practices. Sustainability also depends upon the 6 Rs of materials (reuse, recycle, redesign, remanufacture, reduce, recover) and manufacturing processes can play an important role in maintaining a homeostasis-balanced environment.

The scope of the proposed Special Issue includes sustainable and advanced manufacturing processes. We welcome high quality research papers presenting new trends in the study of manufacturing processes and materials with a sustainable approach. The Guest Editors (GEs) welcome literature reviews, research papers, and case studies that include but are not restricted to the following areas:

Assessing affordability-based design methodologies that consider environmental factors for advanced manufacturing
Implementing design for remanufacturing, recycling, and recovery
Methods for assessing sustainability in manufacturing (e.g., life cycle assessment, material flow analysis, carbon footprint of manufacturing processes) and their impact on plant performance
Focusing exclusively on sustainable materials, the 6 Rs, lifecycle engineering, and life cycle assessment
Highlighting issues related to materials recovery, and circular economy, keeping in mind IR 4.0
Materials/energy/resource utilisation factors, waste minimisation/management
Use of new sustainable materials in processes (e.g., bio-lubricants) and their impact on environment and plant performance
Case studies and comparison of manufacturing processes based on their sustainability
Implementing real-time energy efficiency assessment of components and systems
Optimizing the design and advanced manufacturing processes for optimizing energy and material efficiency
Optimizing process technologies for transforming scrap into reusable raw materials
Optimizing process planning and process scheduling for advanced manufacturing, especially in the context of low fossil-carbon and sustainability dimensions
Optimizing manufacturing systems under multiple sustainability criteria, such as economic feasibility, fossil-carbon emissions, and energy consumption
Monitoring and reducing the fossil-carbon energy footprints in advanced manufacturing process planning and production scheduling
Cleaner production using different cooling-lubrication conditions
Additive manufacturing/3D Printing towards zero waste manufacturing
Eco-friendly machining

Dr. Chander Prakash
Dr. Sunpreet Singh
Prof. Dr. Seeram Ramakrishna
Dr. Alokesh Pramanik
Prof. Dr. Hongyu Zheng
Prof. Dr. Yongling (Linda) Wu
Guest Editors

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. Sustainability is an international peer-reviewed open access semimonthly 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

Advanced Sustainable Manufacturing
Re-manufacturing
Life Cycle Assement
recycling
fossil-carbon emissions
energy consumption
waste management
Eco-friendly machining

Published Papers (8 papers)

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Research

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23 pages, 2604 KiB

Open AccessArticle

MgO Nano-Catalyzed Biodiesel Production from Waste Coconut Oil and Fish Oil Using Response Surface Methodology and Grasshopper Optimization

by Impha Yalagudige Dharmegowda, Lakshmidevamma Madarakallu Muniyappa, Parameshwara Siddalingaiah, Ajith Bintravalli Suresh, Manjunath Patel Gowdru Chandrashekarappa and Chander Prakash

Sustainability 2022, 14(18), 11132; https://doi.org/10.3390/su141811132 - 06 Sep 2022

Cited by 12 | Viewed by 2312

Abstract

In India, a densely populated country, fossil fuel depletion affects the energy sector that fulfils the industrial and human needs. Concerning greenhouse gas emissions and pollutants, and sustainability, there is a great demand to search for alternate feedstocks to produce alternate fuels at a low cost. The present work focuses on waste coconut and fish oil as potential inexpensive feedstock for biodiesel production. Two-stage transesterification processes for biodiesel production from hybrid oils mixed in a 1:1 volume ratio by employing solid nano-catalyst Magnesium Oxide (MgO). Response surface methodology (RSM) was used to analyze the effects of the physics of transesterification variables, such as methanol-to-oil molar ratio (M:O), MgO catalyst concentration (MgO CC), and reaction temperature (RT), on biodiesel yield, based on experimental data gathered in accordance with the matrices of central composite design (CCD). MgO CC showed the highest contribution, followed by M:O and RT, to maximize biodiesel yield. All interaction factors showed a significant effect except the M:O with RT. Grasshopper optimization algorithm (GOA) determined optimal conditions (M:O: 10.65; MgO CC: 1.977 wt.%; RT: 80 °C) based on empirical equations, resulting in maximum biodiesel yield conversion experimentally equal to 96.8%. The physical stability of the MgO nano-catalyst and reactivity up to 5 successive cycles can yield 91.5% biodiesel yield, demonstrating its reusability for sustainable biodiesel production at low cost. The optimized biodiesel yield showed better physicochemical properties (tested according to ASTM D6751-15C) to use practically in diesel engines. Full article

(This article belongs to the Special Issue Sustainable and Advanced Remanufacturing Processes)

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24 pages, 4967 KiB

Open AccessArticle

Development of GGBS-Based Geopolymer Concrete Incorporated with Polypropylene Fibers as Sustainable Materials

by Gaurav Thakur, Yatendra Singh, Rajesh Singh, Chander Prakash, Kuldeep K. Saxena, Alokesh Pramanik, Animesh Basak and Shankar Subramaniam

Sustainability 2022, 14(17), 10639; https://doi.org/10.3390/su141710639 - 26 Aug 2022

Cited by 7 | Viewed by 2479

Abstract

Geopolymer concrete, because of its less embodied energy as compared to conventional cement concrete, has paved the way for achieving sustainable development goals. In this study, an effort was made to optimize its quality characteristics or responses, namely, workability, and the compressive and flexural strengths of Ground Granulated Blast-furnace Slag (GGBS)-based geopolymer concrete incorporated with polypropylene (PP) fibers by Taguchi’s method. A three-factor and three-level design of experiments was adopted with the three factors and their corresponding levels as alkali ratio (NaOH:Na₂SiO₃) (1:1.5 (8 M NaOH); 1:2 (10 M NaOH); 1:2.5 (12 M NaOH)), percentage of GGBS (80%, 90%, and 100%) and PP fibers (1.5%, 2%, and 2.5%). M25 was taken as the control mix for gauging and comparing the results. Nine mixes were obtained using an L9 orthogonal array, and an analysis was performed. The analysis revealed the optimum levels as 1:2 (10 molar) alkali ratio, 80% GGBS, and 2% PP fibers for workability; 1:2 (10 molar) alkali ratio, 80% GGBS, and 2.5% PP fibers for compressive strength; and 1:2 (10 molar) alkali ratio, 80% GGBS, and 1.5% PP fibers for flexural strength. The percentage of GGBS was found to be the most effective parameter for all three responses. The analysis also revealed the ranks of all the factors in terms of significance in determining the three responses. ANOVA conducted on the results validated the reliability of the results obtained by Taguchi’s method. The optimized results were further verified by confirmation tests. The confirmation tests revealed the compressive and flexural strengths to be quite close to the strengths of the control mix. Thus, optimum mixes with comparable strengths were successfully achieved by replacing cement with GGBS and thereby providing a better path for sustainable development. Full article

(This article belongs to the Special Issue Sustainable and Advanced Remanufacturing Processes)

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18 pages, 3333 KiB

Open AccessEditor’s ChoiceArticle

A Review on Global E-Waste Management: Urban Mining towards a Sustainable Future and Circular Economy

by Venkatesha Murthy and Seeram Ramakrishna

Sustainability 2022, 14(2), 647; https://doi.org/10.3390/su14020647 - 07 Jan 2022

Cited by 94 | Viewed by 16269

Abstract

The trending need for smarter electrical and electronic equipment (EEE) is surging globally by the year and is giving rise to huge amounts of outdated EEE going into landfills. This has caused enormous threats to our environment and the health of living beings due to its unsustainable ways of collection, treatment and disposal of waste EEE or E-waste. With increasing E-waste, the formal sectors lack infrastructure, technology and expertise required to collect and process the E-waste in an environmentally sound manner. This article is intended to bring out the global best practices in the field of E-waste management, to shed light on the importance of policy implementation, technology requirement and social awareness to arrive at a sustainable and circular economy. Although about 71% of the world’s populace has incorporated E-waste legislation, there is a need to enforce and implement a common legal framework across the globe. The article explains the gap created among the stakeholders and their knowledge on the roles and responsibilities towards a legalized E-waste management. It further explains the lack of awareness on extended producer responsibility (EPR) and producer responsibility schemes. Despite various legislations in force, numerous illegal practices such as acid leaching, open incineration, illegal dumping carried out by the informal sector are causing harm to the environment, natural resources and the safety of unorganized and unskilled labor. The article discusses the crucial need for awareness amongst stakeholders, consumer behavior and the global challenges and opportunities in this field to achieve a low-carbon, circular economy. To conclude, the article highlights the importance of common legal framework, EPR and licenses, transformation of the informal sector, benchmark technologies, responsibilities of various stakeholders and entrepreneurial opportunities to enhance the formal capacity. The article wholly advocates for transparency, accountability and traceability in the E-waste recycling chain, thus creating a greener environment and protecting our planet and natural resources for future generations. Full article

(This article belongs to the Special Issue Sustainable and Advanced Remanufacturing Processes)

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16 pages, 2329 KiB

Open AccessArticle

Sustainability Analysis of a ZnO-NaCl-Based Capacitor Using Accelerated Life Testing and an Intelligent Modeling Approach

by Pardeep Kumar Sharma, Cherry Bhargava and Ketan Kotecha

Sustainability 2021, 13(19), 10736; https://doi.org/10.3390/su131910736 - 27 Sep 2021

Cited by 7 | Viewed by 1722

Abstract

From small toys to satellites, capacitors play a vital role as an energy storage element, filtering or controlling other critical tasks. This research paper focuses on estimating the remaining useful life of a nanocomposite-based fabricated capacitor using various experimental and artificial intelligence techniques. Accelerated life testing is used to explore the sustainability and remaining useful life of the fabricated capacitor. The acceleration factors affecting the health of capacitors are investigated, and experiments are designed using Taguchi’s approach. The remaining useful lifetime of the fabricated capacitor is calculated using a statistical technique, i.e., regression analysis using Minitab 18.1 software. An expert model is designed using artificial neural networks (ANN), which warns the user of any upcoming faults and failures. The average remaining useful life of the fabricated capacitor, using accelerated life testing, regression, and artificial neural network, is reported as 13,724.3 h, 14,515.9 h, and 14,247.1 h, respectively. A comparison analysis is conducted, and performance metrics are analyzed to opt for the most efficient technique for the prediction of the remaining useful life of the fabricated capacitor, which confirms 93.83% accuracy using the statistical method and 95.82% accuracy using artificial neural networks. The root mean square error (RMSE) of regression and artificial neural networks is found to be 0.102 and 0.167, respectively, which validates the consistency of the reliability methods. Full article

(This article belongs to the Special Issue Sustainable and Advanced Remanufacturing Processes)

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49 pages, 11893 KiB

Open AccessArticle

Sustainable Development of Smart Manufacturing Driven by the Digital Twin Framework: A Statistical Analysis

by Vivek Warke, Satish Kumar, Arunkumar Bongale and Ketan Kotecha

Sustainability 2021, 13(18), 10139; https://doi.org/10.3390/su131810139 - 10 Sep 2021

Cited by 39 | Viewed by 5580

Abstract

The Fourth Industrial Revolution drives industries from traditional manufacturing to the smart manufacturing approach. In this transformation, existing equipment, processes, or devices are retrofitted with some sensors and other cyber-physical systems (CPS), and adapted towards digital production, which is a blend of critical enabling technologies. In the current scenario of Industry 4.0, industries are shaping themselves towards the development of customized and cost-effective processes to satisfy customer needs with the aid of a digital twin framework, which enables the user to monitor, simulate, control, optimize, and identify defects and trends within, ongoing process, and reduces the chances of human prone errors. This paper intends to make an appraisal of the literature on the digital twin (DT) framework in the domain of smart manufacturing with the aid of critical enabling technologies such as data-driven systems, machine learning and artificial intelligence, and deep learning. This paper also focuses on the concept, evolution, and background of digital twin and the benefits and challenges involved in its implementation. The Scopus and Web of Science databases from 2016 to 2021 were considered for the bibliometric analysis and used to study and analyze the articles that fall within the research theme. For the systematic bibliometric analysis, a novel approach known as Proknow-C was employed, including a series of procedures for article selection and filtration from the existing databases to get the most appropriate articles aligned with the research theme. Additionally, the authors performed statistical and network analyses on the articles within the research theme to identify the most prominent research areas, journal/conference, and authors in the field of a digital twin. This study identifies the current scenarios, possible research gaps, challenges in implementing DT, case studies and future research goals within the research theme. Full article

(This article belongs to the Special Issue Sustainable and Advanced Remanufacturing Processes)

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22 pages, 2872 KiB

Open AccessArticle

Environmental, Economical and Technological Analysis of MQL-Assisted Machining of Al-Mg-Zr Alloy Using PCD Tool

by Md. Rezaul Karim, Juairiya Binte Tariq, Shah Murtoza Morshed, Sabbir Hossain Shawon, Abir Hasan, Chander Prakash, Sunpreet Singh, Raman Kumar, Yadaiah Nirsanametla and Catalin I. Pruncu

Sustainability 2021, 13(13), 7321; https://doi.org/10.3390/su13137321 - 30 Jun 2021

Cited by 30 | Viewed by 3999

Abstract

Clean technological machining operations can improve traditional methods’ environmental, economic, and technical viability, resulting in sustainability, compatibility, and human-centered machining. This, this work focuses on sustainable machining of Al-Mg-Zr alloy with minimum quantity lubricant (MQL)-assisted machining using a polycrystalline diamond (PCD) tool. The effect of various process parameters on the surface roughness and cutting temperature were analyzed. The Taguchi L₂₅ orthogonal array-based experimental design has been utilized. Experiments have been carried out in the MQL environment, and pressure was maintained at 8 bar. The multiple responses were optimized using desirability function analysis (DFA). Analysis of variance (ANOVA) shows that cutting speed and depth of cut are the most prominent factors for surface roughness and cutting temperature. Therefore, the DFA suggested that, to attain reasonable response values, a lower to moderate value of depth of cut, cutting speed and feed rate are appreciable. An artificial neural network (ANN) model with four different learning algorithms was used to predict the surface roughness and temperature. Apart from this, to address the sustainability aspect, life cycle assessment (LCA) of MQL-assisted and dry machining has been carried out. Energy consumption, CO₂ emissions, and processing time have been determined for MQL-assisted and dry machining. The results showed that MQL-machining required a very nominal amount of cutting fluid, which produced a smaller carbon footprint. Moreover, very little energy consumption is required in MQL-machining to achieve high material removal and very low tool change. Full article

(This article belongs to the Special Issue Sustainable and Advanced Remanufacturing Processes)

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Review

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20 pages, 8473 KiB

Open AccessReview

Cloud Manufacturing, Internet of Things-Assisted Manufacturing and 3D Printing Technology: Reliable Tools for Sustainable Construction

by Rajesh Singh, Anita Gehlot, Shaik Vaseem Akram, Lovi Raj Gupta, Manoj Kumar Jena, Chander Prakash, Sunpreet Singh and Raman Kumar

Sustainability 2021, 13(13), 7327; https://doi.org/10.3390/su13137327 - 30 Jun 2021

Cited by 52 | Viewed by 6695

Abstract

The United Nations (UN) 2030 agenda on sustainable development goals (SDGs) encourages us to implement sustainable infrastructure and services for confronting challenges such as large energy consumption, solid waste generation, depletion of water resources and emission of greenhouse gases in the construction industry. Therefore, to overcome challenges and establishing sustainable construction, there is a requirement to integrate information technology with innovative manufacturing processes and materials science. Moreover, the wide implementation of three-dimensional printing (3DP) technology in constructing monuments, artistic objects, and residential buildings has gained attention. The integration of the Internet of Things (IoT), cloud manufacturing (CM), and 3DP allows us to digitalize the construction for providing reliable and digitalized features to the users. In this review article, we discuss the opportunities and challenges of implementing the IoT, CM, and 3D printing (3DP) technologies in building constructions for achieving sustainability. The recent convergence research of cloud development and 3D printing (3DP) are being explored in the article by categorizing them into multiple sections including 3D printing resource access technology, 3D printing cloud platform (3D–PCP) service architectures, 3D printing service optimized configuration technology, 3D printing service evaluation technology, and 3D service control and monitoring technology. This paper also examines and analyzes the limitations of existing research and, moreover, the article provides key recommendations such as automation with robotics, predictive analytics in 3DP, eco-friendly 3DP, and 5G technology-based IoT-based CM for future enhancements. Full article

(This article belongs to the Special Issue Sustainable and Advanced Remanufacturing Processes)

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30 pages, 9244 KiB

Open AccessReview

Bibliometric Analysis of Specific Energy Consumption (SEC) in Machining Operations: A Sustainable Response

by Raman Kumar, Sehijpal Singh, Ardamanbir Singh Sidhu and Catalin I. Pruncu

Sustainability 2021, 13(10), 5617; https://doi.org/10.3390/su13105617 - 18 May 2021

Cited by 46 | Viewed by 5030

Abstract

This paper’s persistence is to make an inclusive analysis of 268 documents about specific energy consumption (SEC) in machining operations from 2001 to 2020 in the Scopus database. A systematic approach collects information on SEC documents’ primary data; their types, publications, citations, and predictions are presented. The VOSviewer 1.1.16 and Biblioshiny 2.0 software are used for visualization analysis to show the progress standing of SEC publications. The selection criteria of documents are set for citation analysis. The ranks are assigned to the most prolific and dominant authors, sources, articles, countries, and organizations based on the total citations, number of documents, average total citation, and total link strength. The author-keywords, index-keywords, and text data content analysis has been conducted to find the hotspots and progress trend in SEC in machining operations. The most prolific and dominant article, source, author, organization, and country are Anderson et al. “Laser-assisted machining of Inconel 718 with an economic analysis”, the Int J Mach Tools Manuf, Shin Y.C., form Purdue University Singapore, and United States, respectively, based on total citations as per defined criteria. The author keywords “specific cutting energy” and “surface roughness” dominate the machining operations SEC. SEC’s implication in machining operations review and bibliometric analysis is to deliver an inclusive perception for the scholars working in this field. It is the primary paper that utilizes bibliometric research to analyze the SEC in machining operations publications expansively. It is valuable for scholars to grasp the hotspots in this field in time and help the researchers in the SEC exploration arena rapidly comprehend the expansion status and trend. Full article

(This article belongs to the Special Issue Sustainable and Advanced Remanufacturing Processes)

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