School of Aerospace, Transport and Manufacturing (SATM)
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Item Open Access Chapter 5: Comprehensive study on tool wear during machining of fiber-reinforced polymeric composites(Springer, 2020-12-23) Ismail, Sikiru Oluwarotimi; Sarfraz, Shoaib; Niamat, Misbah; Mia, Mozammel; Gupta, Munish Kumar; Pimenov, Danil Yu; Shehab, EssamThe use of fiber reinforced polymeric (FRP) composites has increased rapidly, especially in many manufacturing (aerospace, automobile and construction) industries. The machining of composite materials is an important manufacturing process. It has attracted several studies over the last decades. Tool wear is a key factor that contributes to the cost of the machining process annually. It occurs due to sudden geometrical damage, frictional force and temperature rise at the tool-work interaction region. Moreover, tool wear is an inevitable, gradual and complex phenomenon. It often causes machined-induced damage on the workpiece/FRP composite materials. Considering the geometry of drill, tool wear may occur at the flank face, rake face and/or cutting edge. There are several factors affecting the tool wear. These include, but are not limited to, drilling parameters and environments/conditions, drill/tool materials and geometries, FRP composite compositions and machining techniques. Hence this chapter focuses on drilling parameters, tool materials and geometries, drilling environments, types of tool wear, mechanisms of tool wear and methods of measurement of wear, effects of wear on machining of composite materials and preventive measures against rapid drill wear. Conclusively, some future perspectives or outlooks concerning the use of drill tools and their associated wears are elucidated, especially with the advancement in science and technologyItem Open Access Chapter 8: Boundaries: Their Influence on Managing Safety in Outsourcing(Springer, 2023-10-19) Pilbeam, ColinBoundaries are an essential feature of an organization and integral to the on-going process of organizing. Outsourcing not only disrupts the configuration of organizational boundaries but also compounds the safety management challenges faced by an organization. This chapter connects these two observations through an examination of the composite nature of the organizational boundary. Misalignment between organizations in one or more of the three clusters of processes (physical, mental or social) that comprise the boundary create differences which may contribute to the safety management challenges commonly experienced in outsourcing. Boundary spanning skills that manage these processes are vital for successful working relationships between organizations but are rarely taught in safety training.Item Open Access Dynamic mode II delamination in through thickness reinforced composites(Springer, 2016-09-21) Yasaee, Mehdi; Mohamed, Galal; Pellegrino, Antonio; Petrinic, Nik; Hallett, Stephen R.Through thickness reinforcement (TTR) technologies have been shown to provide effective delamination resistance for laminated composite materials. The addition of this reinforcement allows for the design of highly damage tolerant composite structures, specifically when subjected to impact events. The aim of this investigation was to understand the delamination resistance of Z-pinned composites when subjected to increasing strain rates. Z-pinned laminated composites were manufactured and tested using three point end notched flexure (3ENF) specimens subjected to increasing loading rates from quasi-static (~0m/s) to high velocity impact (5m/s), using a range of test equipment including drop weight impact tower and a split Hopkinson bar (SHPB). Using a high speed impact camera and frame by frame pixel tracking of the strain rates, delamination velocities as well as the apparent fracture toughness of the Z-pinned laminates were measured and analysed. Experimental results indicate that there is a transition in the failure morphology of the Z-pinned laminates from quasi-static to high strain rates. The fundamental physical mechanisms that generate this transition are discussed.Item Open Access Energy efficiency status-quo at UK foundries: the “small-is-beautiful” project(Springer, 2017-02-12) Jolly, Mark R.; Salonitis, Konstantinos; Charnley, Fiona; Ball, Peter D.; Ahmad Mehrabi, Hamid; Pagone, EmanueleItem Open Access Environmental assessment of recycling carbon fibre-reinforced composites: current challenges and future opportunities(Springer, 2022-11-19) Meiirbekov, Arshyn; Amantayeva, Akniyet; Tokbolat, Serik; Suleimen, Aidar; Sarfraz, Shoaib; Shehab, EssamThe increasing application of carbon fiber reinforced polymer composites (CFRP) across different industries raises environmental concerns. It requires focusing on the end-of-life phase of the product/material. The environmental benefits of CFRP recycling over conventional ways of treatment are apparent. However, estimating the environmental impacts is followed up with various challenges. In this study, the aspects of environmental assessment of CFRP recycling and their respective challenges are examined. CFRP recycling methods such as mechanical treatment, pyrolysis, fluidized bed process, and solvolysis have been previously studied in the context of energy and environmental assessment under the Life-Cycle-Assessment (LCA) framework. This study focused on the identification of challenges associated with variability of applied methods used, comparability, scaling results, data, uncertainty, and resource-demanding process of LCA. Recommendations on overcoming the identified challenges are provided and discussed.Item Open Access Gesture detection towards real-time ergonomic analysis for intelligent automation assistance(Springer, 2016-07-10) Mgbemena, Chika Edith; Oyekan, John; Tiwari, Ashutosh; Xu, Yuchun; Fletcher, Sarah R.; Hutabarat, Windo; Prabhu, Vinayak AshokManual handling involves transporting of load by hand through lifting or lowering and operators on the manufacturing shop floor are daily faced with constant lifting and lowering operations which leads to Work-Related Musculoskeletal Disorders. The trend in data collection on the Shop floor for ergonomic evaluation during manual handling activities has revealed a gap in gesture detection as gesture triggered data collection could facilitate more accurate ergonomic data capture and analysis. This paper presents an application developed to detect gestures towards triggering real-time human motion data capture on the shop floor for ergonomic evaluations and risk assessment using the Microsoft Kinect. The machine learning technology known as the discrete indicator—precisely the AdaBoost Trigger indicator was employed to train the gestures. Our results show that the Kinect can be trained to detect gestures towards real-time ergonomic analysis and possibly offering intelligent automation assistance during human posture detrimental tasks.Item Open Access Human capability evaluation approach for cybersecurity in critical industrial infrastructure(Springer, 2016-07-10) Ani, Uchenna P.; He, Hongmei; Tiwari, AshutoshEvery organization is as frail as its frailest human link in the cyber security of Industry Control System (ICS), which is without predisposition to conceivable technological solutions for enforcing security. Noticeably, human-involved systems are becoming more chaotic, and gravely under attacks due to irregular actions or inactions of human entities in the constituent chain. Many industrial cyber-attacks have successfully defeated technological security solutions through preying on human weaknesses in knowledge and skills, and manipulating insiders within organizations into unsuspectingly delivering entry and access to sensitive industrial assets. In order to help enterprises assess the level of employees’ cyber security awareness and responsiveness, and enhance ICS Cyber security knowledge and skills for ICS protection, a Workforce Cyber Security Capability evaluation model is presented, and theoretically validated. A capability evaluation will allow industries to have a better understanding of the potential state of consciousness, readiness and diagnostic abilities of the industries; thus improve the prevention, detection, and response to any cyber-specific incidents.Item Open Access Improving water efficiency in the beverage industry with the internet of things(IGI, 2021-08-31) Jagtap, Sandeep; Skouteris, George; Choudhari, Vilendra; Rahimifard, ShahinThe food and beverage industry is one of the most water-intensive industries, with water required for various processes (e.g., washing, cooking, cleaning) at almost every stage of the production, as well as being a key constituent in many food and drink products. Therefore, a real-time efficient water management strategy is imperative, and the novel internet of things (IoT)-based technologies can be of significant help in developing it. This chapter presents the architecture of an IoT-based water-monitoring system followed by the demonstration of a case study of a beverage factory wherein the monitoring system helped understand the detailed water usage as well as finding solutions and addressing overconsumption of water during the manufacturing processes. The successful deployment of IoT helped reduce the annual water consumption by 6.7%, monitor water usage in real-time, and improve it.Item Open Access Investigating pilots’ operational behaviours while interacting with different types of inceptors(Springer, 2022-06-16) Korek, Wojciech Tomasz; Li, Wen-Chin; Lu, Linghai; Lone, MudassirThere are different designs of inceptors applied in the modern flight deck. How do pilots define how to precisely control the aircraft as their intention? Ten pilots have been asked to take part in the flight simulation trials. They were given tasks to execute using sidestick, Xbox gamepad and touchscreen controller and provide feedback using the System Usability Scale. The aim was to investigate the feasibility of replacing conventional inceptors in aircraft. The results have shown that there is a potential in introducing alternate Human-Computer Interaction (HCI) methods in the flight deck, especially in terms of learnability, however there is still a lot of work before it happens. This paper summarises the ‘pilot study’ results and shows the potential for further research.Item Open Access Investigating the effects of signal light position on human workload and reaction time in human-robot collaboration tasks(Springer, 2016-07-10) Johnson, Teegan L.; Fletcher, Sarah R.; Webb, PhilipCritical to a seamless working relationship in human-robot collaborative environments is effective and frequent communication. This study looked to assess whether placing a light source on a robot was more effective for informing the human operator of the status of the robot than conventional human-machine interfaces for industrial system signaling such as light towers. Participants completed an assembly task while monitoring a robot and changes to the light sources: either from one of two light towers or LED strip lights attached to the robot. Workload was assessed by measuring reaction times to light changes and by counting number of completed assemblies. Although both the ANOVA and Friedman tests returned none significant results, total misses per condition showed that the participants did not miss any of the robot lights, whereas signals were missed for the light towers.Item Open Access A Kriging approach to model updating for damage detection(Springer, 2022-06-16) Dessena, Gabriele; Ignatyev, Dmitry I.; Whidborne, James F.; Zanotti Fragonara, LucaFor complex or large structures, the model updating process can be long and tedious and numerical methods can be computationally expensive. Hence, practitioners and researchers often resort to meta-modelling techniques when large problems are met. Even so, traditional methodologies, such as the Efficient Global Optimisation, can be slow and give sub-optimal results. This work proposes a new methodology for the model updating of numerical systems based on a novel Kriging approach for the scope of damage detection and quantification. The framework proposed is based on a global-local optimisation strategy recently developed by the authors, the refined Efficient Global Optimisation, herein used to tweak finite element models’ parameters to match the modal data extracted from a numerical system by using the residuals of the modified total modal assurance criterion. The main advantage to existing direct optimisation and meta-modelling frameworks is the more efficient use of computational e ort for higher dimensional problems, which is verified with the use of a numerical system.Item Open Access Life cycle sustainability assessment of repair through wire and arc additive manufacturing(Springer, 2022-01-01) Pagone, Emanuele; Antonissen, Joachim; Martina, FilomenoExtending the useful life of a product through repair can significantly reduce the environmental impact associated with its production, and it can be less resource intensive than other environmentally virtuous practices like recycling. Wire and arc additive manufacturing (WAAM) appears to be a promising approach in this context, being characterized by high-resource efficiency, flexibility to perform repairs, and having recently gained industrial maturity. In this work, a methodology to assess the life cycle environmental sustainability of repaired products through WAAM will be presented with a real-world, industrial case study.Item Open Access Light-weight Mg/Al dissimilar structures welded by CW laser for weight saving applications(Springer, 2017-08-25) Gao, Qiong; Meco, Sonia; Wang, KehongWith the increasing demand of light-weight alloys, such as magnesium (Mg) and aluminum (Al), the need for joining these two alloys is unavoidable. In this study, AZ31B Mg and 1060 Al alloys were joined by continuous wave laser micro-welding using a 0.05 mm thick Cu/Zn interlayer. The microstructure and phases constituent of the weld seam were examined by optical microscope, SEM and EDS. The formation and distribution of the intermetallic compounds (IMCs) and the relationship between these structures and the micro-hardness of the weld were discussed in detail. The effect of Cu/Zn interlayer on the performance of Mg/Al joint was also analyzed. The results showed that Mg/Al IMCs were formed in the weld, which indicates that the Cu/Zn foil could not prevent the reaction between Mg and Al. However, the addition of Cu and Zn into the weld pool refined the microstructure by improving the number of eutectic structures. The micro-hardness of Mg/Al IMCs in the middle of the weld was very high which can be detrimental to the toughness of the Mg/Al joints.Item Open Access Long Period Grating Based Fibre Optic Chemical Sensors(Springer, 2016-11-03) Korposh, Sergiy; Lee, Seung-Woo; James, Stephen W.The principle of operation of optical fibre long period grating (LPG) sensors is described. In particular, the chapter explores the use of LPGs as a chemical sensing platform, discussing the fabrication of LPGs and the various approaches that have been employed to modify the cladding of the LPG and thus sensitise the LPG. Examples of the practical application of LPG chemical sensors are provided.Item Open Access Molecular dynamics simulation (MDS) to study nanoscale machining processes(CRC Press, 2017-02-25) Goel, Saurav; Chavoshi, Saeed Zare; Murphy, AdrianMolecular Dynamics Simulations (MDS) are constantly being used to make important contributions to our fundamental understanding of material behaviour, at the atomic scale, for a variety of thermodynamic processes. This chapter shows that molecular dynamics simulation is a robust numerical analysis tool in addressing a range of complex nanofinishing (machining) problems that are otherwise difficult or impossible to understand using other methods. For example the mechanism of nanometric cutting of silicon carbide is influenced by a number of variables such as machine tool performance, machining conditions, material properties, and cutting tool performance (material microstructure and physical geometry of the contact) and all these variables cannot be monitored online through experimental examination. However, these could suitably be studied using an advanced simulation based approach such as MDS. This chapter details how MD simulation can be used as a research and commercial tool to understand key issues of ultra precision manufacturing research problems and a specific case was addressed by studying diamond machining of silicon carbide. While this is appreciable, there are a lot of challenges and opportunities in this fertile area. For example, the world of MD simulations is dependent on present day computers and the accuracy and reliability of potential energy functions [109]. This presents a limitation: Real-world scale simulation models are yet to be developed. The simulated length and timescales are far shorter than the experimental ones which couples further with the fact that contact loading simulations are typically done in the speed range of a few hundreds of m/sec against the experimental speed of typically about 1 m/sec [17]. Consequently, MD simulations suffer from the spurious effects of high cutting speeds and the accuracy of the simulation results has yet to be fully explored. The development of user-friendly software could help facilitate molecular dynamics as an integral part of computer-aided design and manufacturing to tackle a range of machining problems from all perspectives, including materials science (phase of the material formed due to the sub-surface deformation layer), electronics and optics (properties of the finished machined surface due to the metallurgical transformation in comparison to the bulk material), and mechanical engineering (extent of residual stresses in the machined component) [110]. Overall, this chapter provided key information concerning diamond machining of SiC which is classed as hard, brittle material. From the analysis presented in the earlier sections, MD simulation has helped in understanding the effects of crystal anisotropy in nanometric cutting of 3C-SiC by revealing the atomic-level deformation mechanisms for different crystal orientations and cutting directions. In addition to this, the MD simulation revealed that the material removal mechanism on the (111) surface of 3C-SiC (akin to diamond) is dominated by cleavage. These understandings led to the development of a new approach named the “surface defect machining” method which has the potential to be more effective to implement than ductile mode micro laser assisted machining or conventional nanometric cutting.Item Open Access Molecular dynamics simulations of the solidification of pure aluminium(Springer, 2020-01-28) Papanikolaou, Michail; Salonitis, Konstantinos; Jolly, Mark R.Despite the continuous and remarkable development of experimental techniques for the investigation of microstructures and the growth of nuclei during the solidification of metals, there are still unknown territories around the topic of nucleation during solidification. Such nanoscale phenomena can be effectively observed by means of Molecular Dynamics (MD) simulations which can provide a deep insight into the formation of nuclei and the induced crystal structures. In this study, MD simulations have been performed to investigate the solidification of Aluminium melt and the effects of process parameters such as the cooling rate and hydrostatic pressure on the final properties of the solidified material. A large number of Aluminium atoms have been used in order to investigate the grain growth over time solidification. The population of the Face Centred Cubic (FCC) and amorphous (or non-crystalline) phases has been recorded during the evolution of the process to illustrate the nanoscale mechanisms during solidification. Finally, the exothermic nature of the solidification process has been effectively captured by measuring the temperature of the Al atoms during grain formation.Item Open Access A multi-objective and multidisciplinary optimisation algorithm for microelectromechanical systems(2017-09-14) Farnsworth, Michael; Tiwari, Ashutosh; Zhu, Meiling; Benkhelifa, ElhadjMicroelectromechanical systems (MEMS) are a highly multidisciplinary field and this has large implications on their applications and design. Designers are often faced with the task of balancing the modelling, simulation and optimisation that each discipline brings in order to bring about a complete whole system. In order to aid designers, strategies for navigating this multidisciplinary environment are essential, particularly when it comes to automating design synthesis and optimisation. This paper outlines a new multi-objective and multidisciplinary strategy for the application of engineering design problems. It employs a population-based evolutionary approach that looks to overcome the limitations of past work by using a non-hierarchical architecture that allows for interaction across all disciplines during optimisation. Two case studies are presented, the first focusing on a common speed reducer design problem found throughout the literature used to validate the methodology and a more complex example of design optimisation, that of a MEMS bandpass filter. Results show good agreement in terms of performance with past multi-objective multidisciplinary design optimisation methods with respect to the first speed reducer case study, and improved performance for the design of the MEMS bandpass filter case study.Item Open Access Nanomaterials based biosensing: methods and principle of detection(Springer, 2022-12-01) Kumar, Nirmal; Goel, Gaurav; Goel, SauravThe food and medical sectors have to abide by the strict regulations of quality control and this requires strict monitoring of various types of chemicals and pathogens. These requirements have brought laurels to the field of biosensing to develop the most capable sensors to detect a target property instantly as well as precisely. Biosensors integrated with the nanotechnological approach makes them simple and tiny in size, which also provides a point-of-care platform. The last two decades have been devoted to developing different biosensors using nanoscale materials due to their sensitive and unique properties. Search is on, for the combination of materials for biosensors, which can make them multipurpose, inexpensive and eco-friendly. The molecules or analytes can be detected through different working principles of biosensors. Biosensing is a wide area and a number of biosensors exist with each having their own working principles and/or combination of two-three principles making them a hybrid sensor. This book chapter is aimed to revisit different working principles of biosensors in light of the growing use of various nanomaterials (nanoparticles, nanowire, and nanosheet) and various other materials that are in use in the development of biosensor.Item Open Access Numerical process modelling and simulation of campbell running systems designs(Springer, 2019-02-09) Lyu, Chengcheng; Papanikolaou, Michail; Jolly, Mark R.In the 1980s, John Campbell developed a new casting process from his research in the industry over a number of years. The Cosworth process was for delivering very high-quality aluminium components for the automotive industry. The process was very capital-intensive and not very flexible for smaller companies delivering lower volumes of product. However, the principles behind the process have been taken and used to develop a range of different so-called running systems to help improve the quality of castings. Some of these designs have been published in ‘Castings Handbook’ [1] authored by Campbell. This paper presents the results of an MSc project during which a number of the proposed designs from Campbell’s Mini Casting Handbook [2] for certain features in running systems have been modelled using a validated CFD software.Item Open Access Probability of potential collision for aircraft encounters in high density airspaces(INTECH, 2012-08-01) Arnaldo, R; Sáez Nieto, Francisco Javier; Garcia, E; Portillo, YFailure Management consists of a set of functions that enable the detection, isolation, and correction of anomalous behavior in a monitored system trying to prevent system failures. An effective failure management should monitor the system looking for errors and faults that could end up in a failure and overcome such issues when they arise.