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Evolutionary Manufacturing, Design and Operational Practices for Resource and Environmental Sustainability. Edition No. 1

  • Book

  • 544 Pages
  • August 2024
  • John Wiley and Sons Ltd
  • ID: 5914257
This book highlights the important use of digital technologies and the latest developments in mechanical and industrial engineering to enhance environmental and resource sustainability.

Sustainable Development Goals (SDGs) have as their overarching objective the reduction or eradication of a wide range of global problems, including, but not limited to poverty, climate change, environmental degradation, and inequality. Digital technologies (DTs) have the potential to be exploited to meet the goals associated with the circular economy (CE) and sustainable development. Additive manufacturing (AM), cyber-physical systems (CPS), and blockchain technology are examples of DT-enabled technologies that are helpful for businesses that seek to shift to a circular economic model.

With the remanufacturing of products, applications that make use of virtual reality and augmented reality, in addition to the Internet of Things, simplify the construction of strategic decision models that reduce time and expense while simultaneously increasing productivity. In addition, the utilization of big data analytics helps businesses discover previously undisclosed trends and unlock numerous opportunities for environmental and resource sustainability. Employing analytics makes it feasible to collect helpful information regarding the socio-environmental impact of a product, as well as consumption factors over the entirety of a product’s life cycle.

This book contains 44 comprehensive chapters and is divided into five parts. Part 1 delves deeply into sustainable operational practices and supply chain management. The impact that digital technology-enabled operational techniques have on product life cycles is investigated, as well as the design of efficient remanufacturing processes, environmentally friendly logistics and warehousing practices, sustainable designs for distributed energy supply systems, and efficient recycling procedures.

Part 2 provides a perspective on advanced materials and developments for sustainable manufacturing. The chapters in this section address sustainable material development and its application in the circular economy concept. Included here is an in-depth exploration of cutting-edge technology for synthesis, processing, fabrication, process optimization, testing, and performance evaluation of advanced materials. Part 3 covers sustainable manufacturing practices and looks at the problems faced by the industry when using digital technologies in their operations, as well as the possible benefits.

Part 4 examines sustainable innovation in mechanical design. It addresses all aspects of mechanical design that contribute to sustainable innovation for nation-building. Part 5 delves into heat transfer and fluid flow concepts for sustainable product development and applications. The chapters explain how to construct sustainable energy systems by reducing the total amount of energy that is utilized, enhancing the efficiency of the process of energy conversion, and making use of sources of energy that are renewable.

Audience

This book has a wide audience in academic institutions and engineers in a variety of manufacturing industries. It will also appeal to economists and policymakers working on the circular economy, clean tech investors, industrial decision-makers, and environmental professionals.

Table of Contents

Preface xxiii

Part 1: Sustainable Operational Practices and Supply Chain Management 1

1 Financial Impacts of COVID-19: A Special Emphasis on the Sustainability of Indian Banking Sectors and Stock Markets 3
Pradeep Reddy K., Venkateswarlu Chandu, Ch. Sahyaja, Shifaly, Elia Thagaram, Amala Gangula and Debesh Mishra

1.1 Introduction 4

1.2 Research Methodology 5

1.3 Literature 5

1.4 Conclusion 8

2 Dynamic Load Frequency Control of Microgrids with Diverse Distributed Energy Resources 11
Mathew Pua, Ashish Kr. Luhach and Joseph Fisher

2.1 Introduction 12

2.2 PV Modeling 12

2.3 Grid Modeling 17

2.4 Mathematical Model of PV-Grid System 27

2.5 Conclusion 28

3 Analysis of Microgrids with Diverse Distributed Energy Resources Using Genetic Algorithm 31
Mathew Pua, Ashish Kr. Luhach and Joseph Fisher

3.1 Introduction 32

3.2 Mathematical Model of PV-Grid System 33

3.3 Results and Discussion 35

3.4 Results Obtained at Dynamic State Using Proposed GA-Optimized PID Controller 41

3.5 Conclusion 47

4 Comparison of Solar Power Forecasting Using RNN-Dense and LSTM-Dense Neural Network 49
Sushree Samikshya Pattanaik, Ashwin Kumar Sahoo and Rajesh Panda

4.1 Introduction 50

4.2 Related Work 50

4.3 Machine Learning 51

4.4 Methodology 52

4.5 Results 56

4.6 Conclusion 59

5 Organizational Opportunities Through Digital - and Social-Media Marketing for Sustainable Businesses 61
Pradeep Reddy K., Venkateswarlu Chandu, Ch. Sahyaja, Shifaly, Elia Thagaram, Amala Gangula, Debesh Mishra and Sibabrata Mohanty

5.1 Introduction 62

5.2 Methodology 63

5.3 Literature 63

5.4 Challenges in DSMM 66

5.5 Conclusion 67

6 Design of Innovative and User-Friendly Household PET Plastic Bottle Shredder to Promote Green Economy 71
McKurai Minig, Christopher Bubuwau and Aezeden Mohamed

6.1 Introduction 71

6.2 Literature Review 72

6.3 Methodology 73

6.4 Results and Discussion 75

6.5 Conclusion and Recommendation 78

Part 2: Prospective of Advanced Materials and Development for Sustainable Manufacturing 81

7 Sacrificial Anodes and Environmental Effects 83
Noel Martin and Aezeden Mohamed

7.1 Introduction 84

7.2 Literature Review 91

7.3 Methodology 94

7.4 Recommendation 101

7.5 Conclusion 102

8 Experimental Investigation of Steel and Porous Al Foam LM Vehicle Leaf Spring By Using Mechanical and Computer Method 107
K. Manickaraj, R. Ramamoorthi, Karuppasamy R., S. Kannan and B. Vijayaprakash

8.1 Introduction 108

8.2 Manufacture of Al Foam 108

8.3 Tests for Deflection 108

8.4 Results and Discussion 111

8.5 Conclusion 111

9 Effect on Mechanical and Physical Properties of Microwave-Sintered Alumina Nanocomposite on Addition of ZrO2 and MgO 113
K.L. Meena, Shaik Mozammil and Eklavya Koshta

9.1 Introduction 114

9.2 Investigation Procedure 115

9.3 Results and Discussion 117

9.4 Conclusions 120

10 Pull Test Analysis of Friction Welding Samples on Boiler Grade Materials With the Assistance of Taguchi and ANOVA 125
A. Daniel Das and S. Manivannan

10.1 Introduction 126

10.2 Experimental Investigation 126

10.3 Discussion on Results 128

10.4 Conclusions 132

11 A Review of Natural Biofiber-Reinforced Polymer Matrix Composites 135
K. Manickaraj, R. Ramamoorthi, Karuppasamy R., K. R. Sakthivel and B. Vijayaprakash

11.1 Introduction 136

11.2 Biofibers in Manufacturing 136

11.3 Composites Made of Natural Biofibers 137

11.4 Natural Fibers Treatment 137

11.5 Selecting A Matrix 138

11.6 Mechanical Characteristics of Composites 138

11.7 Conclusion 139

12 Evaluation of Hot Corrosion and High Temperature Oxidation on GTA Weldments of Nb-Controlled INCONEL 718 143
A. Daniel Das and S. Manivannan

12.1 Introduction 144

12.2 Experimental Procedure 144

12.3 Results and Discussion 146

13 Review on "Fused Deposition Modeling" Process Parameters and Their Influence on Material Properties: A Sustainable Approach 153
Deepak J., Adarsha H., A. Pattanaik and Ramkumar N.P.

13.1 Introduction 154

13.2 Process Parameters 154

13.3 Properties Affected by Different Process Parameters 157

13.4 Conclusions 160

14 Numerical Investigation of Combustion Characteristics for Soybean Biodiesel Depending on Variable Compression Ratios by Using Diesel RK Software 163
Abdullah Lattouf Hussein Juma, M. K. Parida and H. Joardar

14.1 Introduction 164

14.2 Physical Properties of Biodiesel 165

14.3 Production of Biodiesel 167

14.4 Diesel-RK Software 168

14.5 Results and Discussion 169

14.6 Conclusion 173

15 Property Evaluation of Coconut Shell Ash-Reinforced Aluminum Composite Made by Squeeze Casting 177
P. Paranthaman, Debabrata Barik, R. Arul Murugan and N. Sathiesh Kumar

15.1 Introduction 177

15.2 Materials and Methods 179

15.3 Results and Discussion 180

15.4 Conclusion 182

16 Synthesis and Characterization of AZ91 Magnesium Alloy-Alumina/Ceria Composite Coating By Thermal Spray Technique 185
Adarsha H., Ashutosh Pattanaik, S. C. Sharma and Bikash Ranjan Moharana

16.1 Introduction 186

16.2 Selection of Materials and Methods 187

16.3 Results and Discussions 188

16.4 Conclusions 190

17 Sustainable Corrosion Prevention System of Steel Structures 193
Noel Martin and Aezeden Mohamed

17.1 Introduction 194

17.2 Sustainable Sacrificial Anodes 194

17.3 Impressed Current Cathodic Protection System 197

17.4 Test Results from Idubada SACP Terminal (PNG) 198

17.5 Wewak Sacrificial Anodes CP 200

17.6 Conclusion 202

18 Design of a Binary Distillation Column to Increase the Naphthalene Yield in Tar Distillation Plant of a Steel Plant 203
Rudra Narayan Mohapatro, Ranjita Swain, Sunita Routray and PrabhakarSethi

18.1 Introduction 204

18.2 Material Method 205

18.3 Results and Discussion 207

18.4 Results and Discussion by Using Software 211

18.5 Conclusion 216

18.6 References 216

19 Machining of Ni-Based Super Alloy with Coated and Uncoated Tools in a Sustainable Machining Environment 217
Pravatnalini Chhotaray and Bikash Chandra Behera

19.1 Introduction 217

19.2 Materials and Methods 218

19.3 Results and Discussion 219

19.4 Conclusion 221

Part 3: Sustainable Manufacturing Practices 223

20 The New Age of Manufacturing from Concept to Creation: Innovative World of 3D Printing 225
Sunil Kumar Panda, Kali Charan Rath and Sujit Mishra

20.1 Introduction 226

20.2 Additive Manufacturing Technology 226

20.3 3D Printing Method 234

20.4 Role of 3D Printing in Industry 4.0 240

20.5 Conclusion 242

21 Optimization of EDM Process Parameters with Fuzzy Logic Technique for SS-316 Steel and Investigation of Microstructural Characteristics of EDM Machining Surface 245
G. Sridevi, Kali Charan Rath, Sujit Mishra, Santosh Patro and P. Srinivasa Rao

21.1 Introduction 246

21.2 Investigational Setup 247

21.3 Fuzzy Modeling 249

21.4 Results and Discussion 251

21.5 Microstructural Characterization of Machining Surface 254

21.6 Conclusions 255

22 Comparison Evaluation of Machining Characteristics of Hypereutectic Aluminium-20%Silicon with Uncoated, PVD, and CVD Coated Inserts 257
Arunkumar D. T., Ashutosh Pattanaik, K. G. Basavakumar and P. S. Raghvendra Rao

22.1 Introduction 258

22.2 Materials and Methodology 259

22.3 Results and Discussion 261

22.4 Conclusions 264

23 A Review of TIG Welding Processes: Experimentation and Finite Element Analysis for Sustainable Operational Practices 267
Anish K. Raj, Bikash Ranjan Moharana and Kalinga Simant Bal

23.1 Introduction 268

23.2 Joining of Metals by TIG Welding Process 269

23.3 Joining of Metals by Pulsed-TIG (P-TIG) Welding Process 271

23.4 Case Study: Experimental Investigation 272

23.5 Conclusions 277

24 Strategic Implementation of Reliability Centered Maintenance with Development of a Framework of an Indian Manufacturing Industry 281
Hiranmoy Samanta, Pradip Kumar Talapatra and Kamal Golui

24.1 Introduction 282

24.2 Literature Review 282

24.3 How the Concept of RCM was Generated (Background) 282

24.4 Various Definitions of RCM 283

24.5 Objectives of RCM 283

24.6 Components of RCM 284

24.7 RCM Principles 285

24.8 RCM Methodology 286

24.9 Step-by-Step Analysis of Reliability-Centered Maintenance 287

24.10 Maintenance Analysis Process for Machines 288

24.11 Evaluations of the Machines 288

24.12 Conclusion 289

Part 4: Sustainable Innovation in Mechanical Design 291

25 Bending Behavior of Multi-Layered Ionic Polymer Metal Composite Actuator in Time Domain 293
Dillip Kumar Biswal, Ashutosh Biswal and Bikash Ranjan Moharana

25.1 Introduction 294

25.2 Bending Behavior of Fabricated Ag-IPMC 295

25.3 Fabricated Ag-IPMC Modeling 298

25.4 Results and Discussion 299

25.5 Conclusion 301

26 Experimental Approach for Analyzing the Algorithm with Camera on Distracted Driving Algorithms by Using Image Recognition Models 303
Brijesh S. Patil and Divya Midhunchakkaravarthy

26.1 Introduction 303

26.2 Methodology 305

26.3 Working Approach 306

26.4 Experimental Approach 308

26.5 Conclusion 312

27 Techno-Economic and Feasibility Analysis of a Mixed Mode Solar Dryer 315
Deepak C. N. and A. K. Behura

27.1 Introduction 316

27.2 Materials and Methods 317

27.3 Thermal Energy Storage Integration 321

27.4 Results and Discussion 322

27.5 Conclusion 323

28 Fabrication of Four-Wheel Steering With Three-Mode Operation 325
Jayapradha P., Arun Prakash J. and Debabrata Barik

28.1 Introduction 326

28.2 Result and Discussion 327

28.3 Working Principle 332

28.4 Conclusion 332

Part 5: Heat Transfer and Fluid Flow Concept for Sustainable Product Development and Their Application 335

29 Effectiveness of Solar Still Combining Thermocol Insulation with Locally Accessible Heat Storage Materials: An Experimental Approach 337
Saurav Sahoo and Dillip Kumar Biswal

29.1 Introduction 338

29.2 Experimental Investigation 340

29.3 Results and Discussion 341

30 Estimation of Cooling Load of Air Cooling System for a Hospital Room 347
Saurav Sharma, Amit Kumar, Shrikant Vidya, Pramod Kumar and Md. Maroof

30.1 Introduction 348

30.2 Analysis and Evaluation 350

30.3 Results and Discussion 352

30.4 Conclusion 352

31 Numerical Investigation of Small-Scale Model of a Blast Furnace for Laminar and Turbulent Regimes 355
Shafiq Mohamad, Sachindra Kumar Rout, Neruda Barakat, Jnana Ranjan Senapati and Sunil Kumar Sarangi

31.1 Introduction 356

31.2 Literature Review 356

31.3 Geometry Investigation and Quantitative Evaluation 358

31.4 Findings and Discussion 360

31.5 Conclusions 363

32 A Critical Review on Blood Flow Modeling: Relevance to Rheology, Numerical and Computational Methods 365
Hiranmoy Samanta, Binoy Mandal, Abhijit Majumder, Srrejit Roy Chowdhury and Gulshan Kumar

32.1 Introduction 365

32.2 Constitutive Models of Blood 367

32.3 Mathematical Modeling of Blood Flow Simulation 369

32.4 Conclusions 376

33 Research Trends and Perspectives of Thermal Management of Photovoltaic/Thermal (PV/T) System: Bibliometric Analysis 379
Mukul Kant Paliwal, Sanjeev Jakhar and Vikrant Sharma

33.1 Introduction 380

33.2 Methodology 381

33.3 Results 383

33.4 Discussions 388

33.5 Conclusions 388

34 Waste Cooking Oil Biodiesel Synthesis and Emission Comparison Study of Diesel and Biodiesel as Fuel for Cleaner Environment 391
N. Sathiesh Kumar and Debabrata Barik

34.1 Introduction 392

34.2 Materials and Methods 393

34.3 Preparation of Catalyst 393

34.4 Process of Biodiesel Synthesis 394

34.5 Engine Testing 394

34.6 Exhaust Gas Analyzer 394

34.7 Results and Discussion 395

34.8 Conclusion 397

35 Dynamic Modeling of Solar Parabolic Trough Collector--A Review 401
Subham Show, Binayak Pattanayak and Subhrajit Ray

35.1 Introduction 402

35.2 Methodology 402

35.3 Receiver Numerical Model 403

35.4 Simulation Software 405

35.5 Conclusions and Future Scope 406

36 Minimizing the Surface Temperature of Heat Sink in Electronic Components for Sustainability 409
P. Ragupathi and Debabrata Barik

36.1 Introduction 410

36.2 Methodology 411

36.3 Results and Discussion 415

36.4 Conclusion 416

37 An Investigation of Heat Transfer Performance of a Novel Three-Fluid Heat Exchanger Proposed for Household Heating Systems 419
Belal Almasri and Taraprasad Mohapatra

37.1 Introduction 420

37.2 Materials and Methods 421

37.3 Results and Discussion 423

37.4 Conclusions 427

38 Cooling Load Calculations for a Mosque Using HAP Software: A Case Study 431
Naved Khan, Mohd. Yasar, Shrikant Vidya, Pramod Kumar and Haridwar Narayan

Abbreviations 431

38.1 Introduction 431

38.2 Methodology & Analysis 433

38.3 Results and Discussion 436

38.4 Conclusion 437

39 Challenges and Future Prospects of Hydrogen Fuel Cell Technology: An Overview 441
Arbab Nafees, Shrikant Vidya, Lavepreet Singh, Md. Nasar Equbal and Priyanka Agrawal

39.1 Introduction 442

39.2 Principle of a Fuel Cell 442

39.3 Challenges and Issues 444

39.4 Solving Global Warming 445

39.5 Alternative Fuels 445

39.6 Advanced Ultra-Super Critical Technology (AUSC) 447

39.7 Energy Technology and Climate Change 447

39.8 Renewable Statistics 448

39.9 Carbon Economy 449

39.10 Carbon Footprint 450

39.11 Conclusions and Future Scope 450

40 Adsorption Kinetics Assessment of CO2 Capture in an Adsorber Bed Under Atmospheric Conditions 453
P. Eswar Babu and B. Kiran Naik

40.1 Introduction 454

40.2 Numerical Model 457

40.3 Algorithm 459

40.4 Performance Characteristics of CO2 Capture 460

40.5 Model Validation 461

40.6 Results and Discussion 462

40.7 Conclusions 464

41 Numerical Analysis of a Nature-Inspired Insulation Method for Building Applications 467
Belal Almasri and Taraprasad Mohapatra

41.1 Introduction 468

41.2 Numerical Simulations 470

41.3 Results and Discussion 472

41.4 Conclusions 477

42 Numerical Study of the Unsteady Flow in Simplified and Realistic Bifurcation Arterial Models 481
Hiranmoy Samanta, Kamal Golui, Sk. Tarif Ali and Debajit Saha

42.1 Introduction 481

42.2 Literature Review 482

42.3 Mathematical Modeling of Blood Flow 482

42.4 Results and Discussion 489

42.5 Conclusions 491

43 Study of Natural Convection From a Vertical Wall with Extended Surfaces 495
Sachindra kumar Rout, Ahmad Khadim Hussein, Kamalakanta Muduli, S. K. Asif Uddin, Ayush Kumar Chinara, Dibya Ranjan Mahalik, Roshan Prasad Mallia and Rahul Kumar Sahu

43.1 Introduction 496

43.2 Problem Description 498

43.3 Numerical Procedure 498

43.4 Results 499

43.5 Impact of Radius of Fin to Spacing of Fin Ratio on Nusselt Number 499

43.6 Impact of Rayleigh Numbers on Temperature Contours 500

43.7 Impact of Rayleigh Numbers on Temperature Flow Fields 500

43.8 Conclusions 501

44 Impact of Natural Convection Heat Transfer on the Efficiency of Various Heat Dissipating Devices and Heat Sinks--A Review 503
B. Dash, J. Nanda, S.K. Rout and J.R. Senapati

Nomenclature 503

44.1 Introduction 503

44.2 Literature Review 504

44.3 Numerical Simulation Data Interpretation 506

44.4 Impact of Buoyancy 507

44.5 Conclusion 507

References 507

Index 511

Authors

Kamalakanta Muduli Papua New Guinea University of Technology, Papua New Guinea. Sachindra Kumar Rout CV Raman Global University in Bhubaneswar, India. Sunil Sarangi Indian Institute of Technology in Bhubaneswar, India. Sardar M. N. Islam Victoria University, Australia. Aezeden Mohamed Papua New Guinea University of Technology, Papua New Guinea.