Operation Conditions Empirical Optimization for Sustainability Manufacturing

Sustainable manufacturing is a valuable tool for measuring and enhancing the machining performance. The implementation of sustainability frameworks in concerned industries poses enormous challenges despite various frameworks available in the literature. Thus, the objective of this paper is to present an integrated sustainability assessment framework wherein two machining scenarios (dry and wet turning) have been analysed by conducting experiments based on the process for a manufactured component in an industry from economic and environmental perspectives. The study further evaluates the economic and environmental indicators such as cost per component and energy consumption for Taguchi array design using empirical relations to evaluate sustainability by grey relational analysis and further optimise the machining performance by particle swarm optimisation. The results, however, indicate the possibility of transitioning the machining process from wet to dry at specific operating conditions with improved performance. In addition to this, the study also presents an illustration of social sustainability assessment framework which has been proposed after consultation with various manufacturing industries in order to make it convenient for them to implement and enhance the sustainability aspects of the machining process.

The idea of sustainability is based on three main pillars which are the society, the environment, and the economy, and is aimed at meeting the requirements of the present generation, and ensuring the ability of fulfillment of needs for future generations. The sustainability requires implementation of energy and resource-efficient technologies, which are environmentally friendly, reduce production waste and incorporate their effective management, and maintain financially-effective as well. On account of the effort and costs associated with the titanium manufacturing, there is a consequential need for improved sustainable production of this material. Extensively utilization of titanium and its alloys for specialized applications in the fields of aerospace, medical and general industry, caused by their high specific strength and excellent corrosion resistance, drive the development of this class of materials. Nevertheless, despite their desirable properties, they are generally considered as products of high-cost. This work presents an overview of current titanium production methods, their critical evaluation, as well as trends in titanium production development processes in conjunction with the idea of sustainable manufacturing. This paper focuses on titanium production processes with particular emphasis on the operating conditions, the effect of energy consumption and environmental impact assessment of current and proposed technologies of titanium production. The main object of this work is to discuss the challenges, economic and environmental aspects of titanium and its alloys’ production methods.

This article discusses the critical importance of adhering to occupational safety and environmental standards in the chemical industry, particularly when working with hazardous substances. Chemical production involves the handling of toxic, flammable, explosive, and corrosive materials, which pose serious risks to human health and the environment if not managed properly. Therefore, ensuring workplace safety and minimizing environmental impact are essential components of sustainable chemical manufacturing. In chemical enterprises, the potential hazards include chemical spills, gas leaks, fires, explosions, and long-term exposure to harmful substances. These risks require robust safety protocols, strict regulatory compliance, and the continuous monitoring of operational conditions. The article emphasizes the need for comprehensive industrial safety management systems that cover hazard identification, risk assessment, incident prevention, and emergency response. Key aspects of occupational safety in the chemical sector include: Use of Personal Protective Equipment (PPE): Ensuring workers are equipped with and trained to use chemical-resistant gloves, goggles, respirators, protective suits, and other PPE appropriate to the substances handled. Workplace Monitoring: Regular control of air quality, temperature, pressure levels, and detection of gas leaks using automated sensors and real-time monitoring systems. Safety Training and Procedures: Periodic training on handling hazardous chemicals, proper storage and labeling, emergency evacuation, and first aid. Technical Safety Measures: Use of explosion-proof equipment, automatic shutdown systems, leak containment systems, and proper ventilation in processing areas. From an environmental perspective, the chemical industry faces challenges such as the generation of toxic waste, air and water pollution, and the consumption of large quantities of energy and raw materials.

Laser powder bed fusion of metals (PBF-LB/M) is increasingly recognised as a pivotal technology to drive the green transition in manufacturing. While its high material efficiency and minimised resource usage offer sustainability benefits, the energy-intensive nature of the process poses a major environmental challenge. This study explores potential avenues to asymptotically reduce the carbon footprint of the PBF-LB/M process through a multifaceted approach, to realise its full potential as a sustainable manufacturing process. A cradle-to-gate scope is used to identify the key drivers of environmental impact and propose a structured sequence of targeted optimisations of the operating conditions, each quantified using a life cycle approach. Key strategies to reduce environmental impact—including switching to renewable energy, using lower impact gases such as nitrogen, increasing recycled content, on-site nitrogen generation and optimising component design—are progressively implemented and their cumulative impact is quantitatively assessed within the GHG Protocol. The paper provides a clear roadmap through a sequence of scenarios for sustainable PBF-LB/M, to meet the requirements of responsible manufacturing.

Controlled growth of MPA-capped ZnS quantum dots through concentration-modulated single injection hydrothermal method