Manufacturing Engineering Report: Processes and Sustainability

This report delves into various aspects of manufacturing engineering. It begins by recommending and justifying the use of non-traditional machining processes like chemical milling in the aerospace industry, highlighting their advantages over traditional methods. The report then addresses sustainability issues within manufacturing, particularly focusing on environmental concerns related to vehicle emissions and the importance of sustainable practices. It emphasizes the need for proper engine ignition timing and stoichiometric air-fuel mixtures to reduce emissions and improve efficiency. Furthermore, the report explores the potential of 3D printing as the next industrial revolution, discussing its capacity for customized products and its impact on mass production. While acknowledging the advantages of mass production, the report highlights 3D printing's strengths in personalization and on-demand manufacturing. Finally, the report discusses the quality differences between super plastic and standard plastic materials, along with the defects associated with super plastics, such as cracking, and the factors that contribute to this phenomenon.

Manufacturing Engineering

TABLE OF CONTENTS
Part 1................................................................................................................................................3
Task 1...............................................................................................................................................3
1.1 Recommendation of non-traditional machining processes....................................................3
1.2 Justification of using non-traditional machining processes...................................................3
TASK 2............................................................................................................................................3
2.1 Sustainability issues...............................................................................................................3
2.2 Attention to manufacturing sustainability..............................................................................4
2.3 Address the manufacturing sustainability issue.....................................................................4
Task 3...............................................................................................................................................4
3.1 3-D printing- the next industrial revolution...........................................................................4
3.2 Can 3-D printing replace conventional process.....................................................................4
PART 3............................................................................................................................................5
TASK 1............................................................................................................................................5
1.1 Quality difference..................................................................................................................5
1.2 Defects in super plastic vs standard plastic............................................................................5
1.3 New material susceptible to cracking....................................................................................5
REFERENCES................................................................................................................................6
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PART 1
TASK 1
1.1 Recommendation of non-traditional machining processes
The traditional machining processes require hard work and time to complete the work.
Traditional machining processes uses very sharp cutting edged tools which can be very harmful
for the person working on that machine. To reduce the risk, many industries started using non
traditional machining processes that can be either mechanical, electrical, thermal or chemical
energy or sometimes it can be the combination of these energies. The risk is low because there is
no sharp cutting tool (Haapala and et.al., 2013).
In aerospace industry, it is recommended that the company should have Chemical
milling, which can be used in removing very small or shallow layers of particles which are
present of the large aircraft component.
1.2 Justification of using non-traditional machining processes
The process of Chemical milling uses a very strong acid and base solution which is used,
so that some unwanted particles of aluminum, titanium gets dissolved. The main aim of using
chemical machining is to reduce the weight of the component and at the same time increase its
efficiency. This process further provide a coating of the parts which prevent them from getting
dissolved apart from unwanted parts which will be removed. This process will give the fine
finishing, so that the Aero foil section of parts will be maintained. This will give the balance of
the parts. At the same time, the efficiency of the parts and the plane will be increased.
TASK 2
2.1 Sustainability issues
The major issue with this manufacturing system is the natural resources and emission
from the vehicle, which is causing harm to environment. VW manufactured the diesel cars which
is having defects in engines. Because their ignition timing was not proper, and this was giving
more carbon particles to the exhaust, and this is causing harm to the environment. The increase
in global warming is the main issue. The vehicles were not able to maintain the ecological
balance.
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2.2 Attention to manufacturing sustainability
The company should give attention to manufacturing sustainability in order to improve
the performance and to protect the environment. Vehicles, which are not sustainable are giving
more exhaust, emitting noxious substance to the environment, resulting increase in global
warming (Kreiger and Pearce, 2013). Manufacturing defects will give inconvenience to the
driver, as the engine will not run properly. It will take more fuel but will give less output. This
will decrease the efficiency of the vehicle as well.
2.3 Address the manufacturing sustainability issue
The manufacturer must make sure that, which ever type of engine they are using, be it a
two stroke or a four stroke, that engine must have proper ignition timing. The air fuel mixture
should be Stoichiometric, so that proper combustion should take place. This will give minimum
or no exhaust to the environment containing the carbon particles. Global warming will be
reduced, and up to negligible from that vehicle. The efficiency of the vehicle will also be
increased.
TASK 3
3.1 3-D printing- the next industrial revolution
3-D printing is the next level of manufacturing, because various types of customized
products can be manufactured, and on the same cost. It is making significant difference is many
areas which are included in production, like some products are of low quality and they are not
having standard manufacturing. In these cases 3-D printing is very helpful, because individual
can personalized the product, the way he wants (Conner and et.al., 2014). This is completely
destroying the mass production, where the products have to manufactured before selling. It is
possible that those products may cause some defect, and also the price range may vary. 3-D
printing is allowing everyone to manufacture any type of product, which are on demand and in
very affordable prize. The products can be changed very easily according to the needs and
demands of an individual.
3.2 Can 3-D printing replace conventional process
There is no doubt that, mass production is very ideal method for manufacturing ample
quantities of products, where the standard can be advantageous. The present 3-D printing can not
compete the qualities or the prices. But the major advantage of 3-D printing is personalization,
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on demand product and complexity in design. There are various industries like fashion,
aerospace, food are already started using advanced 3-D manufacturing. Another major impact of
3-D printing is that it can initiate completely new range and category of products. But due to it's
cost and other aspects, conventional manufacturing processes expected to remain the controlled
manufacturing process in many industries (Starosolski and et.al., 2014).
PART 3
TASK 1
1.1 Quality difference
The quality dimension may differ between the two materials used, because of the features
the super plastic is possessing. It is not suitable for rapid mass production and very soon starts
forming crack in the material. The cracking is due to the rapid heat and then rapid cooling. The
properties of super plastic is not able to withstand the pressure of cooling and after few weeks, it
will start forming crack.
1.2 Defects in super plastic vs standard plastic
The super plastic is having deformation when producing quickly and can not able to bear
the pressure applied to it. The standard plastic is having strong bonding between the ions and
very easily able to adopt the shape it required. The plasticity is more so it can withstand high
amount of pressure applied it.
1.3 New material susceptible to cracking
The new material is susceptible to cracking. Cracking occurs when complex molecules
like long chain hydrocarbon are broken down into simpler molecules. This happens when more
heat is given to the substance and in quick time. So the molecules will not be able to take that
heat and they will broke down into smaller molecules. Thus, it leads to cracking.
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REFERENCES
Books and Journals
Conner, B.P., and et.al., 2014. Making sense of 3-D printing: Creating a map of additive
manufacturing products and services. Additive Manufacturing. 1. pp.64-76.
Haapala, K.R., and et.al., 2013. A review of engineering research in sustainable manufacturing.
Journal of Manufacturing Science and Engineering. 135(4). p.041013.
Kreiger, M. and Pearce, J.M., 2013. Environmental life cycle analysis of distributed three-
dimensional printing and conventional manufacturing of polymer products. ACS
Sustainable Chemistry & Engineering. 1(12). pp.1511-1519.
Starosolski, Z.A., and et.al., 2014. Application of 3-D printing (rapid prototyping) for creating
physical models of pediatric orthopedic disorders. Pediatric radiology. 44(2). pp.216-
221.
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