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Advances in Sustainable Machining Processes and Technologies

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

Deadline for manuscript submissions: closed (30 September 2023) | Viewed by 5319

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Special Issue Editors

Dr. Azwan Iskandar Azmi

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Guest Editor

Department of Manufacturing, Faculty of Mechanical Engineering and Technology, Universiti Malaysia Perlis (UniMAP), Arau 026000, Perlis, Malaysia
Interests: machining and machinability of materials which include fibre reinforced polymer composites, Inconel 718, and Titanium Alloys, nano lubricant, tribology, and wear

Dr. Norshah Aizat Shuaib

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Guest Editor

Department of Manufacturing, Faculty of Mechanical Engineering and Technology, Universiti Malaysia Perlis (UniMAP), Arau 026000, Perlis, Malaysia
Interests: composite recycling; energy efficient machining; recycling; recycled material; life cycle assessment

Dr. Sikiru Oluwarotimi Ismail

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Guest Editor

Department of Engineering, School of Physics, Engineering and Computer Science, University of Hertfordshire, Hatfield AL10 9AB, Hertfordshire, England, UK
Interests: advanced machining processes (abrasive waterjet, electric discharge, etc.) and finishing technologies; materials and manufacturing (mechanical) engineering; process design and development/product innovation & technology transfer; innovative manufacturing/machining processes/ monitoring and optimisation; advanced and digital manufacturing/robots in manufacturing, among others; using experimental and numerical simulation/finite element/analytical modelling techniques
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Dr. Muhamad Nasir Murad

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Guest Editor

Department of Manufacturing, Faculty of Mechanical Engineering and Technology, Universiti Malaysia Perlis (UniMAP), Arau 026000, Perlis, Malaysia
Interests: machinability of difficult-to-cut materials namely Ti-6Al-4V, Inconel 718, NiTi, SS 316L and AZ91 alloy; biolubricant; nonolubricant and tribology

Special Issue Information

Dear Colleagues,

The advancement of technologies is a key factor in achieving zero carbon emission targets. With rapid development in such technologies, cutting-edge research has been directed towards the technical feasibilities. A holistic approach is essential in considering the sustainability aspects of the technologies. From this perspective, special attention has been continuously given towards the development or advancement of sustainable technological solutions for machining and other manufacturing processes.

Moreover, there are associated wastes of resources in the machining of engineering materials, such as metals, composites, and alloys. Such wastes include time, energy, and materials, among other vital resources. Therefore, there is a need to make the machining of materials more sustainable, as machinability is improved. Various technologies—processes and products—have been newly introduced to advance and enhance the sustainability of machining processes and technologies. These include the application of advanced or non-conventional machining (NCM), such as electron beam machining (EBM), abrasive/waterjet machining (A/WJM), ultrasonically assisted machining (UAM), laser beam machining (LBM), electrical/electron discharge machining (EDM), electrochemical machining (ECM) and other conventional and non-traditional/conventional machining processes.

Importantly, it is evident that sustainability becomes a key feature of future machining of various types of composites, metals, and alloys. Hence, the aim of this Special Issue is to follow the state-of-the-art of evolution of machining processes and technologies, publish original technical papers reflecting the most recent research and application results, and identify new challenges and ways forward to enhance the sustainability of machining and machinability of various materials. The Special Issue will focus on both conventional and advanced/NCM processes and technologies, but other relevant areas will also be considered. Papers covering important and timely topics are particularly sought for by this Special Issue.

This Special Issue aims to attract and disseminate high-quality and original research papers on the development or deployment of sustainable machining processes and technologies. Potential research areas include, but are not limited to:

Machining sustainability evaluation or assessment.
Sustainable machining performance via dry, MQL, cryogenic, internal cooling, and others.
Environmentally conscious machining processes.
Energy and resource utilization in machining processes.
Lifecycle assessment (LCA) in sustainable machining processes.
Waste minimization in machining processes.
Multi-disciplinary and integrated sustainable machining systems.

Dr. Azwan Iskandar Azmi
Dr. Norshah Aizat Shuaib
Dr. Sikiru Oluwarotimi Ismail
Dr. Muhamad Nasir Murad
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

machining
machinability
sustainability
manufacturing processes
zero carbon emission
low energy consumption
minimum waste

Published Papers (3 papers)

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Research

29 pages, 5314 KiB

Open AccessArticle

A Comparative Performance Investigation of Single- and Double-Nozzle Pulse Mode Minimum Quantity Lubrication Systems in Turning Super-Duplex Steel Using a Weighted Pugh Matrix Sustainable Approach

by Soumikh Roy, Ramanuj Kumar, Amlana Panda, Ashok Kumar Sahoo, Mohammad Rafighi and Diptikanta Das

Sustainability 2023, 15(20), 15160; https://doi.org/10.3390/su152015160 - 23 Oct 2023

Viewed by 1444

Abstract

This study investigates the performance comparison of machining of UNS S32750 super-duplex stainless steel under single- and double-nozzle pulse mode minimum quantity lubrication (MQL) conditions. The pulse mode MQL system delivers lubricant pulses at specific intervals. The Taguchi L₉ design, with three factors and their three levels, was taken to perform the CNC turning experiments under both single-nozzle and double-nozzle MQL cooling environments. The surface roughness (Ra), tool-flank wear (VB), tool-flank temperature (Tf), power consumption (Pc), and material removal rate (MRR) are evaluated and compared as performance indicators. In comparison to single-nozzle MQL, the responses of Ra, VB, Tf, and Pc were found to be decreased by 11.16%, 21.24%, 7.07%, and 3.16% under double-nozzle conditions, respectively, whereas MRR was found to be 18.37% higher under double-nozzle conditions. The MQL pulse time was found to be an important variable that affects Ra, VB, Tf, and MRR significantly. Under both cooling scenarios, common wears such as abrasion, built-up edges, adhesion, and notch wear are detected. Furthermore, the Pugh matrix-based sustainability evaluation results revealed that the double-nozzle MQL technique was superior to single-nozzle MQL, achieving improved sustainability for machining super-duplex stainless steel. Full article

(This article belongs to the Special Issue Advances in Sustainable Machining Processes and Technologies)

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18 pages, 2251 KiB

Open AccessArticle

Analysis of Carbon Footprints and Surface Quality in Green Cutting Environments for the Milling of AZ31 Magnesium Alloy

by Mohammad Kanan, Sadaf Zahoor, Muhammad Salman Habib, Sana Ehsan, Mudassar Rehman, Muhammad Shahzaib, Sajawal Ali Khan, Hassan Ali, Zaher Abusaq and Allam Hamdan

Sustainability 2023, 15(7), 6301; https://doi.org/10.3390/su15076301 - 06 Apr 2023

Cited by 7 | Viewed by 1473

Abstract

This investigation delves into the effectiveness of employing vegetable-based cutting fluids and nanoparticles in milling AZ31 magnesium alloy, as part of the pursuit of ecologically sustainable manufacturing practices. The study scrutinizes three different cutting environments: (i) dry cutting; (ii) minimum quantity lubrication (MQL) with rice bran oil as the base oil and turmeric oil as an additive; and (iii) MQL with rice bran oil as the base oil, and turmeric oil and kaolinite nanoparticles as additives. Fuzzy logic was implemented to develop the design of experiments and assess the impact of these cutting environments on carbon emissions, surface quality, and microhardness. Upon conducting an analysis of variance (ANOVA), it was determined that all the three input parameters (cutting environment, cutting speed, and feed) greatly affect carbon emissions. The third cutting environment (MQL + bio-oils + kaolinite) generated the lowest carbon emissions (average of 9.21 ppm) and surface roughness value (0.3 um). Confirmatory tests validated that the output parameters predicted using the multiobjective genetic algorithm aligned well with experimental values, thus affirming the algorithm’s robustness. Full article

(This article belongs to the Special Issue Advances in Sustainable Machining Processes and Technologies)

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14 pages, 10499 KiB

Open AccessArticle

Sustainable High-Speed Milling of Magnesium Alloy AZ91D in Dry and Cryogenic Conditions

by Nabil Jouini, Mohd Shahfizal Mohd Ruslan, Jaharah A. Ghani and Che Hassan Che Haron

Sustainability 2023, 15(4), 3760; https://doi.org/10.3390/su15043760 - 18 Feb 2023

Cited by 3 | Viewed by 1318

Abstract

Magnesium alloy AZ91D is used extensively in the automotive industry because of its high strength-to-weight ratio. Typically, components produced using the alloy are required to have good surface finish and to contribute to high productivity but require long cutting times. Cryogenic cooling is an environmentally friendly technology which has been proven to improve cutting tool life and surface finish. This paper presents an investigation on the effects of dry and cryogenic cutting conditions at a high cutting speed regime for milling of magnesium alloy. This study focused on a high-speed regime due to the chips of magnesium alloy being highly combustible and an effective means of decreasing the temperature in the cutting zone was of great concern. The machining experiment was carried out using uncoated carbide end milling utilizing a full factorial design (L16) with cutting speeds of 900 m/min and 1300 m/min, feed rate of 0.02 mm/tooth and 0.05 mm/tooth, axial depth of cut at 0.2 mm and 0.3 mm, and radial depth of cut at 10 mm and 40 mm. For dry machining, the longest tool life at flank wear (VBmax) of 0.21 mm was at 30 min, which was obtained at cutting speeds of 1300 m/min, feed rate of 0.02 mm/tooth, axial depth of cut at 0.2 mm, and radial depth of cut at 40 mm. Using this cutting condition, a mirror-like surface of 0.106 µm was produced. For machining under cryogenic condition at VBmax of 0.2 mm, the maximum tool life of 1864 min was achieved at a cutting speed of 900 m/min, feed rate of 0.02 mm/tooth, axial depth of cut of 0.3 mm, and radial depth of cut of 40 mm. Under this cutting condition, a lower surface finish of 0.091 µm was obtained. It can be concluded that the application of liquid nitrogen (LN2) is very effective in enhancing the tool life and in obtaining a better-machined surface, especially at a lower cutting speed of 900 m/min. A longer tool life and high-quality machined parts will significantly improve the productivity and cost savings in the related industry. Full article

(This article belongs to the Special Issue Advances in Sustainable Machining Processes and Technologies)

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