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Finite Element Analysis and Models of Sustainable Manufacturing Processes
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Finite Element Analysis and Models of Sustainable Manufacturing Processes

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 October 2021) | Viewed by 14035

Special Issue Editors

Prof. Claudio Giardini

E-Mail Website1 Website2
Guest Editor
University of Bergamo, Italy
Interests: innovative sheet and tube metal processes; plastic deformation processes of metal; friction stir welding; cutting operations; process optimization; experimental and simulative analysis of forming processes
Prof. Gianluca D'Urso

E-Mail Website1 Website2
Guest Editor
University of Bergamo, Italy
Interests: friction stir welding; micromanufacturing (micro-EDM); experimental and simulative analysis of forming processes; cutting operations
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Attention to manufacturing process sustainability has recently gained much popularity in research and application communities in saving both rough material and energy consumptions. The use of simulative tools can give an important contribution in both the analysis of new processes from an energetic point of view and the forecast of the produced parts. In order to obtain reliable simulation results, it is also important to identify the flow stress laws and to study the physical properties of the recycled materials that can be very different from the nonrecycled ones.

This Special Issue aims to collect the research results dealing with the use of finite element analysis in studying new processes compliant with sustainable manufacturing requirements.

In particular, the potential topics include but are not limited to the use of Finite Element Analysis on:

  • New process proposal;
  • Study of conventional and innovative processes;
  • Reuse/recycling of materials:
    • Characteristics of the produced parts;
    • Study of characteristics of the recycled materials, tools, and fluids;
    • Optimization of the processes;
  • Estimation of:
    • Costs;
    • Production time;
    • Energy consumption;
    • Level of pollution/emission;
    • Environmental impact;
  • Study of the manufactured part behavior:
    • Mechanical properties of parts obtained with new processes vs. traditional processes;
    • Study and forecast of the material behavior.

The manufactured processes involved in this issue include but are not limited to:

  • Cutting and machining;
  • Micromachining;
  • Bulk forming;
  • Sheet forming;
  • Innovative sheet forming;
  • Tube forming;
  • Innovative tube forming;
  • Metal injection molding;
  • Additive manufacturing of metals and of polymers;
  • Other metal additive technologies;
  • Solid state joining technologies;
  • Any other new solution aimed to product/process sustainability.

In any case, the use of FEA must be considered as a tool for supporting the process and material study and the designer/technologist decisions.

Prof. Claudio Giardini
Prof. Gianluca D'Urso
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. Materials 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 2600 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

  • Finite Element Analysis—FEA
  • Process sustainability
  • Recycled material characteristics
  • Manufacturing processes
  • Process optimization
  • Energy consumption
  • Emissions
  • Innovative manufacturing processes
  • Characteristics of products obtained from recycled materials
  • Analytical or optimization models

Published Papers (7 papers)

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Editorial

Jump to: Research

2 pages, 166 KiB  
Editorial
Special Issue of Materials focusing on “Finite Element Analysis and Models of Sustainable Manufacturing Processes”
by Claudio Giardini and Gianluca D’Urso
Materials 2022, 15(3), 1116; https://doi.org/10.3390/ma15031116 - 31 Jan 2022
Viewed by 1292
Abstract
We believe that the chosen topic is nowadays extremely current and of great interest [...] Full article
(This article belongs to the Special Issue Finite Element Analysis and Models of Sustainable Manufacturing Processes)

Research

Jump to: Editorial

11 pages, 2726 KiB  
Article
Thermal Modeling of the Port on a Refining Furnace to Prevent Copper Infiltration and Slag Accretion
by Francisco José Jiménez-Espadafor Aguilar, José Antonio Vélez Godiño, Miguel Torres García, José María. Gallardo Fuentes and Eduardo Díaz Gutiérrez
Materials 2021, 14(22), 6978; https://doi.org/10.3390/ma14226978 - 18 Nov 2021
Cited by 2 | Viewed by 1147
Abstract
Fire refining of blister copper is a singular process at very high temperatures (~1400 K), which means the furnace is exposed to heavy thermal loads. The charge is directly heated by an internal burner. The impurities in the charge oxidize with the flux [...] Read more.
Fire refining of blister copper is a singular process at very high temperatures (~1400 K), which means the furnace is exposed to heavy thermal loads. The charge is directly heated by an internal burner. The impurities in the charge oxidize with the flux of hot gases, creating a slag layer on the top of the molten bath. This slag is periodically removed, which implies liquid metal flowing through the furnace port. To address its malfunction, a re-design of the furnace port is presented in this work. Due to the lack of previous technical information, the convective heat transfer coefficient between the slag and the furnace port was characterized through a combination of an experimental test and a three-dimensional transient model. Finally, the original design of the furnace port was analyzed and modifications were proposed, resulting in a reduction of the average temperature of the critical areas up to 300 K. This improvement prevents the anchoring of the accretion layer over the port plates and the steel plate from being attacked by the copper. Full article
(This article belongs to the Special Issue Finite Element Analysis and Models of Sustainable Manufacturing Processes)
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13 pages, 9412 KiB  
Article
Simulation of the Mechanical Behaviour of Metal Gyroids for Bone Tissue Application
by Fabrizia Caiazzo, Diego Gonzalo Guillen and Vittorio Alfieri
Materials 2021, 14(17), 4808; https://doi.org/10.3390/ma14174808 - 25 Aug 2021
Cited by 6 | Viewed by 1621
Abstract
Additive manufacturing is a valid solution to build complex geometries, including lightweight structures. Among these, gyroids offer a viable concept for bone tissue application, although many preliminary trials would be required to validate the design before actual implantation. In this frame, this study [...] Read more.
Additive manufacturing is a valid solution to build complex geometries, including lightweight structures. Among these, gyroids offer a viable concept for bone tissue application, although many preliminary trials would be required to validate the design before actual implantation. In this frame, this study is aimed at presenting the background and the steps to build a numerical simulation to extract the mechanical behaviour of the structure, thus reducing the experimental effort. The results of the simulation are compared to the actual outcome resulting from quasi-static compressive tests and the effectiveness of the model is measured with reference to similar studies presented in the literature about other lightweight structures. Full article
(This article belongs to the Special Issue Finite Element Analysis and Models of Sustainable Manufacturing Processes)
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22 pages, 12891 KiB  
Article
FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features
by Michele Lanzetta, Armin Gharibi, Marco Picchi Scardaoni and Claudia Vivaldi
Materials 2021, 14(14), 3789; https://doi.org/10.3390/ma14143789 - 06 Jul 2021
Cited by 4 | Viewed by 1675
Abstract
This paper explores the modeling of incipient cutting by Abaqus, LS-Dyna, and Ansys Finite Element Methods (FEMs), by comparing also experimentally the results on different material classes, including common aluminum and steel alloys and an acetal polymer. The target application is the sustainable [...] Read more.
This paper explores the modeling of incipient cutting by Abaqus, LS-Dyna, and Ansys Finite Element Methods (FEMs), by comparing also experimentally the results on different material classes, including common aluminum and steel alloys and an acetal polymer. The target application is the sustainable manufacturing of gecko adhesives by micromachining a durable mold for injection molding. The challenges posed by the mold shape include undercuts and sharp tips, which can be machined by a special diamond blade, which enters the material, forms a chip, and exits. An analytical model to predict the shape of the incipient chip and of the formed grove as a function of the material properties and of the cutting parameters is provided. The main scientific merit of the current work is to approach theoretically, numerically, and experimentally the very early phase of the cutting tool penetration for new sustainable machining and micro-machining processes. Full article
(This article belongs to the Special Issue Finite Element Analysis and Models of Sustainable Manufacturing Processes)
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17 pages, 10030 KiB  
Article
Redesign of a Piston for a Diesel Combustion Engine to Use Biodiesel Blends
by Jorge Israel Noriega Lozano, Juan Carlos Paredes Rojas, Beatriz Romero Ángeles, Guillermo Urriolagoitia Sosa, Belén Alejandra Contreras Mendoza, Christopher Rene Torres San Miguel, Georgiy Polupan and Guillermo Manuel Urriolagoitia Calderón
Materials 2021, 14(11), 2812; https://doi.org/10.3390/ma14112812 - 25 May 2021
Cited by 4 | Viewed by 2761
Abstract
Biofuels represent an energy option to mitigate polluting gases. However, technical problems must be solved, one of them is to improve the combustion process. In this study, the geometry of a piston head for a diesel engine was redesigned. The objective was to [...] Read more.
Biofuels represent an energy option to mitigate polluting gases. However, technical problems must be solved, one of them is to improve the combustion process. In this study, the geometry of a piston head for a diesel engine was redesigned. The objective was to improve the combustion process and reduce polluting emissions using biodiesel blends as the fuel. The methodology used was the mechanical engineering design process. A commercial piston (base piston) was selected as a reference model to assess the piston head’s redesign. Changes were applied to the profile of the piston head based on previous research and a new model was obtained. Both models were evaluated and analyzed using the finite element method, where the most relevant physical conditions were temperature and pressure. Numerical simulations in the base piston and the new piston redesign proposal presented similar behaviors and results. However, with the proposed piston, it was possible to reduce the effort and the material. The proposed piston profile presents adequate results and behaviors. In future, we suggest continuing conducting simulations and experimental tests to assess its performance. Full article
(This article belongs to the Special Issue Finite Element Analysis and Models of Sustainable Manufacturing Processes)
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17 pages, 4700 KiB  
Article
The Experimental Process Design of Artificial Lightweight Aggregates Using an Orthogonal Array Table and Analysis by Machine Learning
by Young Min Wie, Ki Gang Lee, Kang Hyuck Lee, Taehoon Ko and Kang Hoon Lee
Materials 2020, 13(23), 5570; https://doi.org/10.3390/ma13235570 - 07 Dec 2020
Cited by 9 | Viewed by 2327
Abstract
The purpose of this study is to experimentally design the drying, calcination, and sintering processes of artificial lightweight aggregates through the orthogonal array, to expand the data using the results, and to model the manufacturing process of lightweight aggregates through machine-learning techniques. The [...] Read more.
The purpose of this study is to experimentally design the drying, calcination, and sintering processes of artificial lightweight aggregates through the orthogonal array, to expand the data using the results, and to model the manufacturing process of lightweight aggregates through machine-learning techniques. The experimental design of the process consisted of L18(3661), which means that 36 × 61 data can be obtained in 18 experiments using an orthogonal array design. After the experiment, the data were expanded to 486 instances and trained by several machine-learning techniques such as linear regression, random forest, and support vector regression (SVR). We evaluated the predictive performance of machine-learning models by comparing predicted and actual values. As a result, the SVR showed the best performance for predicting measured values. This model also worked well for predictions of untested cases. Full article
(This article belongs to the Special Issue Finite Element Analysis and Models of Sustainable Manufacturing Processes)
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17 pages, 2096 KiB  
Article
Integrated Computational Material Design for PMC Manufacturing with Trapped Rubber
by Brina J. Blinzler, Pooria Khalili and Johan Ahlström
Materials 2020, 13(17), 3825; https://doi.org/10.3390/ma13173825 - 29 Aug 2020
Cited by 3 | Viewed by 2214
Abstract
As the use of continuous fiber polymer matrix composites expands into new fields, there is a growing need for more sustainable manufacturing processes. An integrated computational material design framework has been developed, which enables the design of tailored manufacturing systems for polymer matrix [...] Read more.
As the use of continuous fiber polymer matrix composites expands into new fields, there is a growing need for more sustainable manufacturing processes. An integrated computational material design framework has been developed, which enables the design of tailored manufacturing systems for polymer matrix composite materials as a sustainable alternative to achieving high-quality components in high-rate production. Trapped rubber processing achieves high pressures during polymer matrix composite processing, utilizing the thermally induced volume change of a nearly incompressible material inside a closed cavity mold. In this interdisciplinary study, the structural analysis, material science and manufacturing engineering perspectives are all combined to determine the mold mechanics, and the manufacturing process in a cohesive and iterative design loop. This study performs the coupled thermo-mechanical analysis required to simulate the transients involved in composite manufacturing and the results are compared with a previously developed test method. The internal surface pressure and temperatures are computed, compared with the experimental results, and the resulting design process is simulated. Overall, this approach maintains high-quality consolidation during curing while allowing for the possibility for custom distributions of pressures and temperatures. This can lead to more sustainable manufacturing by reducing energy consumption and improving throughput. Full article
(This article belongs to the Special Issue Finite Element Analysis and Models of Sustainable Manufacturing Processes)
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