Abstract

3D printing is predicted to grow and underpin distributed manufacture of customized and geometrically complex products. At this early stage of technology development it is timely to consider and optimize the resource efficiency of these layered manufacturing technologies. In this work, the direct electrical energy demand in one of the most popular technologies, fused deposition modelling was studied and a generic model for direct energy demand in layered manufacture proposed. To explore the variability of energy demand according to…
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Abstract

Energy modelling for mechanical machining processes is essential for energy labelling of machined products and as a foundation for selecting optimum cutting conditions that meet economic objectives while reducing energy demand and CO2 footprint. Electrical energy demand in machining can be modelled in two parts: ‘Basic Energy’ demand by the machine tool and ‘Tip Energy’ for actual material removal. A significant amount of research and energy evaluation is based on the use of average specific energy values…
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Abstract

Nitronic 33 steel alloys are metallic alloys that exhibit characteristics such as high strength-to-weight ratio, outstanding corrosion and erosion resistant properties, and the ability to withstand cryogenic conditions and elevated temperatures. These characteristics of Nitronic 33 steel alloys make it popular in the fabrication of chemical processing, pollution control, aerospace equipment, and for steam and autoclave applications. Nitronic 33 steel alloy is classified as difficult-to-cut materials because of its high nitrogen content and the capability to form martensite as…
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Abstract

Electricity consumptions have attracted global interest in recent times. This is attributable to the increasing technological advancement and new machines and materials development hence, an urgent global call for energy efficiency and sustainable manufacture. The electricity consumption in the manufacturing sector especially at the process level stages is an increasing trend. This is partly due to the energy demand of the auxiliary units and machine features incorporated into the machine tools at the design and manufacturing stages and…
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ABSTRACT

The research work aimed to investigate the effect of machine modules and auxiliary units on the power and energy consumption for machine tools. The total electrical current consumption of machine modules and NC codes was measured. The power demand was evaluated and analyzed statistically to define the significance of machine events on power and energy consumption. The paper provides valuable information on the impact of machine modules, auxiliary units and motion states on the energy demand budget…
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Abstract

The global trend for energy consumption as a foundational requirement for economic and social development is an increasing one. Electricity consumption is proportional to the CO2 emitted at the process level and especially for machining processes. The electrical energy demand during machining can be categorized and modelled as basic energy (energy demand by the machine tool while operating

at zero load) and tip energy (energy for actual material removal–cutting). The tool tip energy is evaluated from the specific…
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Abstract

This work aimed to develop an expert fault diagnostic system for the repair and maintenance of bulldozer work equipment faults. An Expert System, ES is one of the many quick and efficient repairs and maintenance strategy that can be used on these machines. ES is a C# computer based programming software that can be adopted to extend the life span of equipments and reduce the cost of human expert for their repairs. In this work, an expert system was…
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.Abstract

Limited availability of natural resources and the negative environmental burden of industrial processes are driving environmental awareness and resource efficiency improvements in manufacturing. Issues of concern in mechanical machining arise from the significant use of electrical energy and oil-based coolants/lubricants. Process innovation through high speed machining has enabled manufacturing cycle times to be reduced and in some cases promoted dry machining or the use of minimum quantity lubrication. However, the environmental assessment of these innovations has hardly…
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Abstract

It is envisaged and expected that professional engineers, process and product developers plays an active role in the sustainable development of manufacturing activities to overcome the global challenges of depletion of natural resources, environmental pollution and damage to the ecosystems. This however calls for the necessity of the industry to adapt and improve on the various manufacturing processes employed for their products not only to keep up with global competition by reducing its variable costs, but also for the…
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Abstract

The Injection molding machine is one of the commonly used machines for the production of domestic and industrial plastic products, which differ in sizes, shapes, complexities, and applications. Inadequate pressure load to push the molten plastic pellets through to filling the mold during the molding processes is one of the problems reported in literature. Hydraulic pressure to force the melt into the mold is initiated from the hydraulic pump to the main spindle that often results to product…
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Abstract

This research works investigate the structural stress analysis of car seat height screw adjuster in the driver’s side to investigate design failure and to determine the optimum life and necessary factor of safety measures of the chair. In this analysis, parameter and dimension were adjusted during Dynamic simulation and static stress analysis in order to confirm the seat reliability, durability and average weight it can withstand during the use phase. Finite element analysis was carried out on the carriage…
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Abstract

The CNC router can be adapted for drilling and engraving operations based on the imagination and creative skills of the operator. A CNC router consists of three main parts: a mechanical setup that can move in X, Y and Z directions, a driving circuitry which includes the stepper motor and a software program that controls the operation of the system. Although, CNC router is commonly and commercially available, the emphasis is to increase the understanding and encourage developing countries…
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Abstract

In a developing company or industry where there is availability of machines to keep the industry running effectively, a need always arise to consider the accessories and the spare parts which will enhance the production planning and also affects the economic growth of the company positively. An optimum model is developed to control the limited available budget that will be optimally allotted to accessories, spare parts and miscellaneous costs. This study considered the strategic decisions for budgeting, developed mathematical…
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Abstract

The advent of 3D printers has been embraced globally within few years of its emergence. The surge in the acceptability of rapid manufacturing RM strategy can be attributed to the depletion and cost of natural resources, waste reduction and sustainability criterion of manufactured parts. This rapidly evolving 3D printing technologies is predicted to grow exponentially especially for the manufacture of customized and geometrically complex products. Therefore, it is appropriate to consider and optimize the resource efficiency of 3D printing…
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Abstract

The automatic sorting system has been reported to be complex and a global problem. This is because of the inability of sorting machines to incorporate flexibility in their design concept. This research therefore designed and developed an automated sorting object of a conveyor belt. The developed automated sorting machine is able to incorporate flexibility and separate species of non-ferrous metal objects and at the same time move objects automatically to the basket as defined by the regulation of…
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Abstract

A Smart Clamping Force Control (SCFC) is adapted to hold sensitive workpiece using magnetic proximity switch during a machining operation on the CNC machine tool. It has been ascertained that work-holding of different workpiece materials and shapes during machining operation is one of the problems encountered during CNC milling machining operations. This work proposes a novel clamping strategy for workpieces with the aid of SCFC. The purpose of the study is to adjust the forward movement of the clamp…
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Abstract

In mechanical machining operations, process mechanisms and machining efficiency can be characterized by the cutting tool geometry, process parameters and workpiece materials. These variables are vital parameters to evaluating the specific cutting energy demand as indication to sustainable manufacture. In today's manufacturing environment, where minimum production cost is required to maximize profits, optimum performance of manufactured component is one of the pre-requisite to consumer's continuous patronage. The optimum performance of product especially in machining can be linked to…
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The sustainability criterion in the manufacturing industries is imperative, especially in the automobile industries. Currently, efforts are being made by the industries to mitigate CO2 emission by the total vehicle weight optimization, machine utilization and resource efficiency. In lieu of this, it is important to understudy the manufacturing machines adopted in the automobile industries. One of such machine is the hot stamping machine that is used for about 35% of the manufacturing operations within the automobile industries. Therefore,…
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Abstract

Mechanical machining processes are common manufacturing strategies to re-shape materials to desired specification. The mechanistic approach has revealed the mechanics of the machining  processes with various parameters determined. The aim of this work is to investigate the  impact of swept angle optimization and their influence on the specific cutting energy in milling AISI 1045 steel alloy. This is achieved by varying the step over at different feed rate values in order to determine the optimization criterion…
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Abstract

Manufacturing sustainability and minimal environmental impacts of machining processes could be achieved by embracing energy demand reduction strategies. These may include the use of more efficient machine tool components (such as drives and pumps) and reduction in weights of materials being moved by the feed drive (machine table, vice, and workpiece material). However, it has not been defined in literature that energy saving approaches could be identified by studying the influence of toolpath strategies and machine tool…
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Abstract:

We have seen that reserves are those quantities of petroleum claimed to be commercially recoverable by application of development projects to known accumulations under defined conditions and it must satisfy four criteria which must be: discovered through one or more exploratory wells, recoverable using existing technology, commercially viable and remaining in the ground. These conditions have actually be met by some oil producing countries but how long will they rely on it to maintain a stable economic growth and…
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Abstract

Many engines have been destroyed as a result of the constant use of wrong petroleum products on them. This paper attempts to educate people on the need to know the right fuel for different engines in the developing countries. Using the wrong fuel on an engine has always resulted from the adulteration of petroleum products by our major and independent marketers of these products in the developing countries so as to maximize profit at the expense of these engines. A lot…
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Abstract :

A domestic passive solar crop dryer for agricultural applications and purposes has been successfully designed and constructed. The dryer is an integral or direct mode type made from locally available materials such as plywood, plane glass, aluminium sheets, hardwood, mild steel, paints, etc. the dimensions of the dryer is 0.7m × 0.5m × 0.7m / 0.5m (length × width × height). The maximum temperature of the dryer recorded was 82°C and the corresponding ambient temperature was 30°C. The dryer was used to…
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Abstract

The techno-economic effects of diesel-kerosene blends on the operation of a direct ignition (DI) diesel engine were investigated using a stationary LD 20-D !issan diesel engine. Standard experimental procedures were adopted. The values of pressure data of all petroleum fuel blends were higher when compared with that obtained when the engine was run on diesel fuel. However, due to the deterioration of combustion process caused by too much kerosene at 40% kerosene mixing, pressure data for 30% kerosene blend were higher…
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Limited availability of natural resources and the negative environmental burden of industrial processes are driving environmental awareness and resource efficiency improvements in manufacturing. Issues of concern in mechanical machining arise from the significant use of electrical energy and oil-based coolants/lubricants. Process innovation through high speed machining has enabled manufacturing cycle times to be reduced and in some cases promoted dry machining or the use of minimum quantity lubrication. However, the environmental assessment of these innovations has hardly been…
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In the past, the cutting conditions that meet the economic and environmental objectives of the specified manufacturing process were selected based on minimum tooling cost and/or minimum electrical energy criterion. However, detailed modelling of electrical energy based on tool life and cost criterion has not been addressed. In this study, machining tests were conducted to develop a cost model which includes machining energy, and to assess the impact of the extended tool life model with regards to selection…
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This paper presents an approach to analytically determine the most energy efficient toolpath strategy in mechanical machining. This was achieved by evaluating the electrical energy requirement of the NC codes generated for the zag, zigzag, and rectangular contour toolpath strategies. The analytical method was validated by performing pocket milling on AISI 1018 steel with the considered toolpaths using a 3-axis Takisawa Mac-V3 milling machine. The rectangular contour toolpath was the most efficient in terms of the electrical energy…
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The aim of this research was to contribute towards the development of a new mathematical model and logic for predicting direct electrical energy requirements in machining toolpaths. This model will track the visibility and process dependence of energy and hence carbon footprint in machining process. This study includes a critical review of similar existing models and their limitations. The effect that machine modules, auxiliary units and machine codes have on power and energy consumption during machining was studied…
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Energy demand reduction is a grand challenge for manufacturing sustainability in order to reduce the escalating cost of energy and to cut down on the carbon footprint of manufacturing processes. The direct electrical energy requirements in manufacturing and machining in particular can be modelled from the basic energy required by the machine tool and the energy for actual material removal (tip energy). However, energy centric modelling of manufacturing processes is in its infancy and related material processing data is limited…
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3D printing can spur manufacturing rebirth in Nigeria and the World in general. There are many areas where 3D printing is creating significant change, particularly in designing and prototyping of new products, in the arts, and in visualizing abstract concepts. This is a step change from conventional manufacturing processes to rapid prototyping and layer manufacturing. This report has defined rapid prototyping, rapid manufacturing and the current technologies available to fabricate 3D components. In addition to this, it provides…
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Rubbing and ploughing increase the tool tip energy demand in machining. An efficient set of cutting conditions would direct the energy into material shearing and hence selecting the efficient set is a value adding activity. In this work, a side milling tests were conducted on a milling machine tool to investigate the specific ploughing energy on AISI 1045 steel alloy, titanium 6Ale4V alloy and aluminium AW6082-T6 alloy materials. The relationship between the cutter swept angle and the specific…
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Abstract:

Oil reserve is defined as an estimate of how much oil can ultimately be recovered. This broad definition is also called oil in place. It includes undiscovered or "yet to find" reserves. It's based on the probability of finding reserves in certain geological areas. It also assumes that new types of technology will make it economically feasible to extract the oil. Nigeria oil and gas reserves have increased to 37 billion barrels. It can also be said…
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Abstract

The environmental impact of conventional machining processes as influenced by the consumption of electrical energy resources is one of the contributing factors to global warming potentials and pollution. This is as a result of CO2 emission in the manufacturing process. Mechanical machining is one of the most commonly used processes and a major electrical energy consumer in manufacturing sector. In this paper, a framework is presented to validate the energy consumption model previously proposed using the computer…
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Abstract

Electromagnetic devices have become increasingly important within the manufacturing industries and their applications ranges from memory devices, semiconductors to medical and bio-mechatronics (i.e. in the testing of medicines and observation of human internal organs). However, due to high cost and availability, the equipment capable of measuring the magnetic field of humane treatment and observations are difficult to acquire. This work is carried out to develop resources that can be widely adopted for the purpose of presenting science…
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Abstract

The aim of this work is to determine the influence of cutting edge radius on the specific cutting energy and surface finish in a mechanical machining process. This was achieved by assessing the direct electrical energy demand during side milling of aluminium AW6082-T6 alloy and AISI 1018 steel in a dry cutting environment using three different cutting tool inserts. The specific energy coefficient was evaluated as an index of the sustainable milling process. The surface finish of…
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Abstract

This study presents an approach for determining energy efficient toolpaths using numerical control (NC)-based energy demand software. To achieve this, NC programmes were generated for the true spiral, rectangular spiral, and square contour toolpaths from HyperMill, a commercially available Computer-Aided Manufacturing (CAM) software for performing pocket milling of AISI 1018 steel on a 3-axis CNC milling machine. These programmes were uploaded as input on the graphical user interface (GUI) of the NC code-based energy demand software. The…
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Abstract

The change of an object's position with respect to time and a reference point is usually adopted to determine its velocity. This is usually a function of time. Velocity can be deduced in terms of its speed and direction of motion. It is an important concept in the description of kinematics and mechanics of bodies which entails the definitions of the bodies magnitude and direction. This project is one of the teaching series of smart technology development…
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Abstract

The optimization of electrical energy demand is an important objective function in machining science. This ensue minimum cost and specific energy demand of manufacturing processes. Mechanical machining as one of the major manufacturing processes consumed on average 38 TWh of electrical energy. This generated on average 16 million tones of CO2 emitted to the environment in the UK in 2012. Since carbon dioxide emission is attributable to electrical energy consumption, urgent action is required at all levels…
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Abstract

Toolpath orientations and axes weights have been identified as some of the parameters that could influence the electrical energy consumption and sustainable machining objectives. However, power evaluations of the machine tool axes when carrying different weights and in different toolpath trajectories have not been fully implemented for energy management in machining processes. This work proposes a framework for determining optimum toolpath orientations by conducting a comparative study and individualization analysis of axes weights for electrical power consumption…
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Abstract

Mechanical machining processes are common manufacturing strategies to re-shape materials to desired specification. The mechanistic approach has revealed the mechanics of the machining  processes with various parameters determined. The aim of this work is to investigate the  impact of swept angle optimization and their influence on the specific cutting energy in milling AISI 1045 steel alloy. This is achieved by varying the step over at different feed rate values in order to determine the optimization criterion for…
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 Abstract

Mechanical machining processes are common manufacturing strategies to re-shape materials to desired specification. The mechanistic approach has revealed the mechanics of the machining  processes with various parameters determined. The aim of this work is to investigate the  impact of swept angle optimization and their influence on the specific cutting energy in milling AISI 1045 steel alloy. This is achieved by varying the step over at different feed rate values in order to determine the optimization criterion for…
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Machines designed to operate in marine environment are generally vulnerable to failure by corrosion. It is therefore imperative
that the corrosion susceptibility of such facilities is evaluated with a view to establishing mechanism for its mitigation. In this
study, the corrosion behaviour of as-cast and retrogression-reagion (RRA) specimens of aluminum alloy containing 0.4–2.0
percent magnesium additions in NaCl, FeCl3, and EXCO solutions was investigated. The corrosion simulation processes involved
gravimetric and electrochemical techniques. Results show substantial inducement…
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