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Processes
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Low-Carbon Design and Manufacturing Processes
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Low-Carbon Design and Manufacturing Processes

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 15 December 2024 | Viewed by 14964

Special Issue Editors

Prof. Dr. Zhigang Jiang

E-Mail Website
Guest Editor
Department of Industrial Engineering, School of Mechanical Automation, Wuhan University of Science and Technology, Wuhan 430081, China
Interests: green manufacturing and remanufacturing; energy efficient manufacturing; low carbon design and manufacturing
Special Issues, Collections and Topics in MDPI journals
Dr. Yan Wang

E-Mail Website
Guest Editor
School of Computing, Engineering and Mathematics, University of Brighton, Brighton BN2 4GJ, UK
Interests: intelligent and sustainable manufacturing; sustainable design; remanufacturing; process and operation management; computer-aided design and manufacturing
Special Issues, Collections and Topics in MDPI journals
Dr. Chao Ke

E-Mail
Guest Editor Assistant
School of Mechanical Automation, Wuhan University of Science and Technology, Wuhan 430081, China
Interests: green manufacturing and remanufacturing; intelligent design; low carbon design
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

With the introduction of Industry 5.0 and the Chinese dual carbon goal, low-carbon manufacturing has become the focus of widespread global attention. The carbon emissions in the product development process are mainly generated during the manufacturing process, which includes mechanical processing, energy and material consumption, logistics, etc. These have a significant negative impact on the ecological environment; therefore, there is an urgent need to optimize production processes, logistics, and workshop scheduling to reduce carbon emissions in the manufacturing process. Moreover, low-carbon design is a vital step in achieving efficient energy usage and emission reductions in manufacturing systems. Indeed, a reasonable product design scheme can help reduce carbon emissions during the manufacturing process. For reducing manufacturing carbon emissions and to promote the implementation of the dual carbon goals, it is necessary to conduct in-depth research on low-carbon design and low-carbon manufacturing.

The goal of this Research Topic is to explore scientific models, methods and technologies that demonstrate both solid theoretical development and practical importance in order to implement low-carbon design and manufacturing. The central theme of the proposed Research Topic is on the low-carbon design and manufacturing processes, where information technology-based modelling, analysis, control and optimization are the focus areas, with broad aspects and issues also being explored. Topics to be covered include, but are not limited to, the following:

  • Low-carbon product design method
  • Low-carbon manufacturing
  • Low-carbon manufacturing process planning
  • Low-carbon workshop scheduling
  • Low-carbon design method for remanufacturing
  • Low-carbon remanufacturing process planning
  • Low-carbon logistics
  • Low-carbon reverse supply chain

Prof. Dr. Zhigang Jiang
Dr. Yan Wang
Guest Editors

Dr. Chao Ke
Guest Editor Assistant

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. Processes is an international peer-reviewed open access monthly 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

  • low-carbon design
  • manufacturing process
  • remanufacturing process
  • low-carbon logistics
  • low-carbon reverse supply chain

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Published Papers (10 papers)

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Research

16 pages, 5675 KiB  
Article
Development of Replica Molding Processes for Hypervariable Microstructural Components
by Yung-Jin Weng, Yu-Zhe Gao and Yu-Ming Chen
Processes 2024, 12(9), 1968; https://doi.org/10.3390/pr12091968 - 13 Sep 2024
Viewed by 3064
Abstract
The current study investigates the development of a replica molding process for hypervariable microstructures. Initially, the mold deformation theory for these hypervariable microstructures was derived. Based on this theory, a metal material with magnetic properties was selected as the structural material to create [...] Read more.
The current study investigates the development of a replica molding process for hypervariable microstructures. Initially, the mold deformation theory for these hypervariable microstructures was derived. Based on this theory, a metal material with magnetic properties was selected as the structural material to create a negative Poisson’s ratio (NPR) geometric structure. The experimental results, obtained by fabricating the NPR geometric mold layer with a metal material with adjustable magnetic properties and controlling microstructure deformation indirectly, validate the deformation theory and its predictions. These results demonstrate that the developed molding process, integrated with the magnetic NPR regulation system, exhibits excellent stability and replication capability. In this study, at the zero height (z = 0) position on the interface between the NPR geometric structure layer and the Polydimethylsiloxane (PDMS), the variation becomes more pronounced with increasing distance from the center of the microstructure. Furthermore, the tendency of the function curve varies accordingly. The primary cause is the lack of constraints on the free ends of both sides and the excessive constraints on the intermediate parts. Under the conditions in this study, the maximum ratio of its influence on the radial diameter thickness was 2.1%. This innovative process facilitates the rapid imprinting of microstructural components and offers the advantage of efficient molding. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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18 pages, 1703 KiB  
Article
A Decision Tree-Based Method for Evaluating the Remanufacturability of Used Parts
by Shuhua Chen, Jian Hao, Yanxiang Chen and Zhongyuan Yang
Processes 2024, 12(6), 1220; https://doi.org/10.3390/pr12061220 - 14 Jun 2024
Viewed by 865
Abstract
Assessing the remanufacturability of used parts is a crucial basis for determining their value and optimal utilization methods. Due to the uncertain quality of used parts and the varying processing capacity of enterprises, coupled with the continuous expansion of the scale of the [...] Read more.
Assessing the remanufacturability of used parts is a crucial basis for determining their value and optimal utilization methods. Due to the uncertain quality of used parts and the varying processing capacity of enterprises, coupled with the continuous expansion of the scale of the remanufacturing industry, the traditional weighted-analysis model, which considers all indicators at the same level, is inefficient for decision-making. In order to evaluate the remanufacturability of used parts more efficiently, a decision tree-based method is proposed, which hierarchically processes the evaluation criteria to enhance decision-making efficiency and adaptability. First, using a data platform, the remaining value of used parts reflected in the failure degree is analyzed and predicted, with the aid of artificial neural networks and the Weibull model, providing an initial remanufacturability assessment. Then, remanufacturability is assessed sequentially from the technical, economic, and environmental feasibility aspects, based on the enterprise’s processing capabilities. Finally, the effectiveness of the proposed method is validated through a case study on the remanufacturing of used blades. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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34 pages, 58259 KiB  
Article
Observation of Gap Phenomena and Development Processing Technology for ECDM of Sapphire
by Chun-Hao Yang, Shao-Hua Yu and Hai-Ping Tsui
Processes 2024, 12(6), 1149; https://doi.org/10.3390/pr12061149 - 2 Jun 2024
Viewed by 692
Abstract
The main purpose of this study was to develop observation techniques and processing technology for the electrochemical discharge machining (ECDM) of sapphire wafers. To measure the effect of gas-film thickness, discharge-spark conditions, and droplet sliding frequency on machining quality and efficiency in ECDM, [...] Read more.
The main purpose of this study was to develop observation techniques and processing technology for the electrochemical discharge machining (ECDM) of sapphire wafers. To measure the effect of gas-film thickness, discharge-spark conditions, and droplet sliding frequency on machining quality and efficiency in ECDM, this research utilized high-speed cameras to observe the gas film thickness and formation of the gas film during ECDM. Additionally, this study observed the machining-gap phenomena during ECDM. The formation mechanism and machining characteristics of the gas film were understood through experiments. The machining parameters included the liquid level, working voltage, rotation speed, and duty factor. This study analyzed and discussed the effect of each machining parameter on the gas-film thickness, current, electrode consumption, and droplet sliding frequency. Moreover, this study aimed to obtain optimized machining parameters to overcome the difficulty of machining sapphire. The experimental results indicated that utilizing a high-speed camera to capture the phenomena between electrodes during electrochemical discharge could effectively observe the gas-film thickness and the coverage of the gas film. A higher bubble coalescence rate enhanced the machining capability and reduced the lateral discharge. Therefore, this study could obtain better machining-hole depths through observation and analysis to improve gas-film stability and machining capability. This study demonstrated that a liquid level of 700 µm, a working voltage of 48 V, a duty factor of 50%, and a tool electrode rotational speed of 200 rpm could achieve a hole depth of 86.7 µm and a hole diameter of 129.5 µm. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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22 pages, 4178 KiB  
Article
Modeling Challenges in Low-Carbon Manufacturing Adoption Using the ISM-MICMAC Approach: A Case of Green Tech Projects of the Chinese Automotive Industry
by Hanqin Yu, Yi Zhang and Naveed Ahmad
Processes 2024, 12(4), 749; https://doi.org/10.3390/pr12040749 - 8 Apr 2024
Cited by 1 | Viewed by 1461
Abstract
In addressing the issue of climate change, the Chinese government has established a definitive objective to attain its peak carbon emissions by 2030 and strive for carbon neutrality by 2060. This effort aims to progressively achieve a state of net-zero carbon dioxide (CO [...] Read more.
In addressing the issue of climate change, the Chinese government has established a definitive objective to attain its peak carbon emissions by 2030 and strive for carbon neutrality by 2060. This effort aims to progressively achieve a state of net-zero carbon dioxide (CO2) emissions. In the given scenario, this research examines challenges in promoting low-carbon manufacturing (LCM) within the Chinese automotive sector, specifically in the context of Green Tech projects. In view of greater emphasis on environmental sustainability and technological innovation, this study aims to uncover challenges restraining the adoption of LCM in one of the world’s largest automotive markets, China. A three-step methodology was adopted by incorporating a literature review, the Delphi method, Interpretive Structural Modeling (ISM), and MICMAC analysis. In the first stage, relevant articles were selected scientifically to identify the main challenges in previous studies by following the relevant keyword criteria. Further, challenges identified from the comprehensive literature review were screened through the Delphi method, and finally, challenges were modeled and clustered through ISM and MICMAC analysis. Data collected from the experts highlight that “difficulties in the transition towards energy efficient technologies”, “insufficient operational efficiency”, and “information imbalances and asymmetry” were the most critical challenges that hinder LCM initiatives in the automotive industry. This research serves as a valuable resource for academia, industry professionals, and policymakers in the quest to adopt LCM in the dynamic context of the Chinese automotive sector. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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18 pages, 5889 KiB  
Article
An Integrated Design Method for Used Product Remanufacturing Process Based on Multi-Objective Optimization Model
by Chao Ke, Yanxiang Chen, Muyang Gan, Yang Liu and Qunjing Ji
Processes 2024, 12(3), 518; https://doi.org/10.3390/pr12030518 - 4 Mar 2024
Viewed by 1187
Abstract
The design for the remanufacturing process (DFRP) is a key part of remanufacturing, which directly affects the cost, performance, and carbon emission of used product remanufacturing. However, used parts have various failure forms and defects, which make it hard to rapidly generate the [...] Read more.
The design for the remanufacturing process (DFRP) is a key part of remanufacturing, which directly affects the cost, performance, and carbon emission of used product remanufacturing. However, used parts have various failure forms and defects, which make it hard to rapidly generate the remanufacturing process scheme for simultaneously satisfying remanufacturing requirements regarding cost, performance, and carbon emissions. This causes remanufactured products to lose their energy-saving and emission-reduction benefits. To this end, this paper proposes an integrated design method for the used product remanufacturing process based on the multi-objective optimization model. Firstly, an integrated DFRP framework is constructed, including design information acquisition, the virtual model construction of DFRP solutions, and the multi-objective optimization of the remanufacturing process scheme. Then, the design matrix, sensitivity analysis, and least squares are applied to construct the mapping models between performance, carbon emissions, cost, and remanufacturing process parameters. Meanwhile, a DFRP multi-objective optimization model with performance, carbon emission, and cost as the design objectives is established, and a teaching–learning based adaptive optimization algorithm is employed to solve the optimization model to acquire a DFRP solution satisfying the target information. Finally, the feasibility of the method is verified by the DFRP of the turbine blade as an example. The results show that the optimized remanufacturing process parameters reduce carbon emissions by 11.7% and remanufacturing cost by USD 0.052 compared with the original process parameters, and also improve the tensile strength of the turbine blades, which also indicates that the DFPR method can effectively achieve energy saving and emission reduction and ensure the performance of the remanufactured products. This can greatly reduce the carbon emission credits of the large-scale remanufacturing industry and promote the global industry’s sustainable development; meanwhile, this study is useful for remanufacturing companies and provides remanufacturing process design methodology support. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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17 pages, 4705 KiB  
Article
An Intelligent Design Method for Remanufacturing Considering Remanufacturability and Carbon Emissions
by Peng Peng, Chao Ke and Jun Han
Processes 2023, 11(12), 3359; https://doi.org/10.3390/pr11123359 - 3 Dec 2023
Cited by 1 | Viewed by 1138
Abstract
Design for remanufacturing (DfRem) is to consider the remanufacturability of the product at the design stage, which can improve the remanufacturability of the product. Moreover, the DfRem solution has a significant impact on the carbon emissions of manufacturing processes. Unreasonable design solutions can [...] Read more.
Design for remanufacturing (DfRem) is to consider the remanufacturability of the product at the design stage, which can improve the remanufacturability of the product. Moreover, the DfRem solution has a significant impact on the carbon emissions of manufacturing processes. Unreasonable design solutions can significantly increase carbon emissions from manufacturing processes. However, there is no direct link between DfRem solutions and remanufacturability as well as manufacturing carbon emissions, which makes it difficult to quickly generate a rational DfRem solution that can enhance product remanufacturability and reduce carbon emissions simultaneously. To this end, this paper proposes an intelligent design method for remanufacturing that considers remanufacturability and manufacturing carbon emissions. First, an intelligent DfRem framework is constructed, which includes information acquisition, virtual model construction of the DfRem solution, and multi-objective optimization of the design solution. Then, the design matrix and sensitivity analysis are used to construct the mapping models between remanufacturability, carbon emissions, and DfRem parameters. Meanwhile, a multi-objective optimization model of DfRem with remanufacturability requirements and carbon emissions as design objectives is constructed, and an adaptive teaching and learning optimization algorithm is applied to solve the optimization model to obtain a DfRem solution that satisfies the objective information. Finally, the feasibility of the method is verified by DfRem of the injection mold as an example. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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26 pages, 81468 KiB  
Article
Ultrasonic Vibration-assisted Electrochemical Discharge Machining of Quartz Wafer Micro-Hole Arrays
by Chun-Hao Yang, Tai-Ching Wang, Jung-Chou Hung and Hai-Ping Tsui
Processes 2023, 11(12), 3300; https://doi.org/10.3390/pr11123300 - 26 Nov 2023
Cited by 1 | Viewed by 1516
Abstract
The micro-hole machining of quartz wafers depends on photolithography techniques akin to those used in semiconductor fabrication. These methods present challenges due to high equipment setup costs, large space requirements, and environmental pollution risks. This research applies ultrasonic vibration assistance in electrochemical discharge [...] Read more.
The micro-hole machining of quartz wafers depends on photolithography techniques akin to those used in semiconductor fabrication. These methods present challenges due to high equipment setup costs, large space requirements, and environmental pollution risks. This research applies ultrasonic vibration assistance in electrochemical discharge machining to create an array of micro-holes on quartz wafers. In the experiments, a self-prepared tungsten carbide micro-electrode array served as the tool electrode. This electrode was a 2 × 2 square array, with needles measuring 30 × 30 μm. A series of experiments was conducted to investigate the effects of various machining parameters, including working voltage, feed rate, duration time, duty factor, and ultrasonic power level, on the characteristics of the micro-hole array. The characteristics included average hole diameter and through-hole surface morphology. The experimental objective was to achieve a through-hole diameter of 80 μm with an accuracy of ±8 μm. During the electrochemical discharge machining, suitable ultrasonic vibrations can thin the insulating gas film coating on the electrode surface, resulting in a more uniform gas film. As the insulating gas film’s thickness decreased, so did the critical voltage needed for the electrochemical discharge machining, reducing the hole’s diameter expansion. The ultrasonic vibration assistance can enable the satisfaction of the dimensional accuracy requirement. The experimental results indicate that ultrasonic vibration assistance can effectively improve the processing capacity and reduce sample fragmentation. A working voltage of 44 V, feed rate of 1 μm/6 s, duration time of 30 μs, duty factor of 30%, and ultrasonic power level of 1 resulted in better inlet and outlet surface morphology without outlet fragmentation. Moreover, the average diameters of the inlet and outlet were roughly 80 μm while meeting the through-hole diameter of 80 μm with accuracy of ±8 μm. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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23 pages, 2313 KiB  
Article
Decision Making in a Closed-Loop Supply Chain with a Waste Management Program: Manufacturers’ Take-Back Activity and Governmental Subsidies for Remanufacturing
by Doo-Ho Lee and Eun-Hee Park
Processes 2023, 11(11), 3132; https://doi.org/10.3390/pr11113132 - 1 Nov 2023
Cited by 2 | Viewed by 1820
Abstract
As awareness of climate change increases, diverse initiatives such as subsidies for remanufactured products and take-back programs for end-of-life products have been taken to conserve energies and materials. This paper explores how the subsidy program affects manufacturer’s take-back activity in a closed-loop supply [...] Read more.
As awareness of climate change increases, diverse initiatives such as subsidies for remanufactured products and take-back programs for end-of-life products have been taken to conserve energies and materials. This paper explores how the subsidy program affects manufacturer’s take-back activity in a closed-loop supply chain and also analyzes how a coalition between a retailer and a remanufacturer affects the equilibrium decisions. Major findings of this paper reveal that (i) when a take-back program is implemented, the government imposes a high penalty on products that are not collected, thereby encouraging manufacturers to collect more used products, (ii) implementing a take-back program in conjunction with a subsidy program results in a greater reduction in environmentally negative impacts and an enhanced social welfare compared to implementing them separately, and (iii) a coalition between a retailer and a remanufacturer results in lowering the penalty imposed to a manufacturer, which leads to lowering the quantity of the collected and remanufactured products. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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16 pages, 13249 KiB  
Article
Development and Research Application of Optical Waveguide Microstructure Component Manufacturing Process for Triangle Roller Imprinting
by Yung-Jin Weng, Min-Ko Tsai and Jian-Zhi Chen
Processes 2023, 11(10), 2888; https://doi.org/10.3390/pr11102888 - 30 Sep 2023
Viewed by 919
Abstract
This research integrates the stable pressuring of the flat surface of roll-to-plate (R2P) imprinting, the fast production features of roll-to-roll (R2R) imprinting, and compound layer ring-type microstructure mold cavity manufacturing technology. Using the compound multilayer method with air molecule assistance, the stability of [...] Read more.
This research integrates the stable pressuring of the flat surface of roll-to-plate (R2P) imprinting, the fast production features of roll-to-roll (R2R) imprinting, and compound layer ring-type microstructure mold cavity manufacturing technology. Using the compound multilayer method with air molecule assistance, the stability of the roller imprinting process is enhanced. In addition, with precision modulation of the triangle roll-to-plate (TR2P) system, a stable microstructure roller imprinting manufacturing process is achieved. The experimental results indicate that the developed triangle roll-to-plate system can stabilize the imprinting process of the continuous microstructure array components. Also, by modulating the angles of the roller axis and the ring, the exterior features of the microstructure can also be adjusted. Gas-molecule-assisted continuous pressuring effectively elevated the roll imprinting angle and continuous pressuring time and reached a high replication rate of 99.14%. The optical waveguide microstructure component produced by this process and the average waveguide propagation losses of approximately 1.2~1.4 dB/cm show that it has optical stability and transparency after optical testing. The research proves that the manufacturing process can effectively provide an innovative process for the equipment and application of the microstructure component. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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19 pages, 3333 KiB  
Article
Exergy Loss Assessment Method for CNC Milling System Considering the Energy Consumption of the Operator
by Zhaohui Feng, Hua Zhang, Wei Li, Yajian Yu, Youjia Guan and Xinru Ding
Processes 2023, 11(9), 2702; https://doi.org/10.3390/pr11092702 - 9 Sep 2023
Cited by 1 | Viewed by 1365
Abstract
Modeling and assessing the sustainability of machining systems has been considered to be a crucial approach to improving the environmental performance of machining processes. As the most common machining system, the computer numerical control (CNC) milling system is a typical man–machine cooperative system [...] Read more.
Modeling and assessing the sustainability of machining systems has been considered to be a crucial approach to improving the environmental performance of machining processes. As the most common machining system, the computer numerical control (CNC) milling system is a typical man–machine cooperative system where the activities of the machine tool and operator generate material and energy consumption. However, the energy consumption of the operator in the CNC milling system has often been ignored in most existing research. Therefore, existing methods fail to provide a comprehensive understanding of the sustainability of the CNC milling system. To fill this gap, an exergy loss assessment method is proposed to investigate the sustainability of the CNC milling system, where the energy consumption of the operator, the energy consumption of the machine tool, and material consumption are taken into consideration. The key performance indexes of the energy consumption of the operator, the energy consumption of the machine tool, the exergy loss, and the specific exergy loss (SEL) are analyzed and modeled. To demonstrate the feasibility of the proposed method, a case study was carried out on a three-axis machining center (XH714D), in which the energy consumption of the operator, the energy consumption of the machine tool, the exergy loss of energy consumption, the exergy loss of chips, the exergy loss of compressed air, the exergy loss of cutting tool wear, the exergy loss of cooling liquid dissipation, and the SEL were found to be 169,750 J, 758,211 J, 603,131 J, 2,031,404 J, 22,023 J, 301,868 J, 2673 J, and 88.04 J/mm3, respectively. The proposed method is effective to assess the sustainability of the CNC milling system, and the established exergy loss models build a good basis for exergy efficiency optimization. Full article
(This article belongs to the Special Issue Low-Carbon Design and Manufacturing Processes)
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