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Assessment and Comparison of Various MCDM Approaches in the Selection of Manufacturing Process
The selection of manufacturing processes for a given application is a complex problem of multicriteria decision-making although there have been several different approaches that can be utilized to select a suitable alternative. However, identifying appropriate multicriteria decision-making approach from the list of available methods for a given application is a difficult task. This work suggests a methodology to assess different selection approaches, which are the technique for order of preference by similarity to ideal solution (TOPSIS), analytic hierarchy process (AHP), and VIKOR: stepwise procedure. This valuation was done depending on the following factors: number of alternative processes and criteria, agility through the process of decision-making, computational complexity, adequacy in supporting a group decision, and addition or removal of a criterion. A case study in this study was presented to analyse the evaluation methodology. The criteria used to evaluate and identify the best manufacturing process were categorized into productivity, accuracy, complexity, flexibility, material utilization, quality, and operation cost. Five manufacturing processes were considered, including gravity die casting, investment casting, pressure die casting, sand casting, and additive manufacturing. The results showed that each approach was suitable for the problems of manufacturing process selection, in particular toward the support of group decision-making and uncertainty modelling. Manufacturing processes were ranked based on their respective weights for AHP, TOPSIS, and VIKOR, and sand casting is the best. In terms of computational complexity, the VIKOR method performed better than TOPSIS and AHP. Moreover, the VIKOR and TOPSIS methods were better convenient to the selection of manufacturing processes for agility during the process of decision-making, the number of alternative processes and criteria, adequacy in supporting a group decision, and addition or removal of a criterion.
Journal Article
A comprehensive review of ultrasonic systems for casting aluminum alloys
Casting aluminum alloys with ultrasonic vibration assistance, known as ultrasonic-assisted casting (UAC), has emerged as a prominent topic in recent publications. The advantages of ultrasonic treatment when integrated with conventional casting (CC) techniques, such as direct-chill casting (DC casting), permanent mold casting, or sand casting, have been shown to effectively improve the mechanical properties and microstructural characteristics of cast ingots. The aim of this review is to analyze the literature on ultrasonic processing of aluminum alloys in the past 5 years, from 2019 to 2024. This paper reviews the existing literature and provides a detailed analysis of the experimental setup, the ultrasonic sonotrodes, highlighting their benefits, including reducing grain size, refining the phase structure, minimizing residual stresses, enhancing the tensile strength, elongation, and microhardness of casting samples. In this study, various UAC research with different ultrasonication techniques is discussed and specifically compared. The article also discusses cases in which reinforcing particles are used to improve the mechanical properties of castings during ultrasonic treatment. Additionally, the research discusses future trends in the development and application of UAC studies.
Journal Article
Dorodango : the Japanese art of making mud balls
\"The exquisite Japanese hikaru dorodango, or shiny mud ball, is created by rolling earth by hand into a perfect sphere and polishing it until it gleams. Not only are the results truly impressive, but this calm and meditative practice, once a playground game, has been rediscovered as a peaceful pastime. Known for inducing flow, the ultimate state of happiness, this simple art is being adopted by people of all ages. Alongside beautiful photographs of the process, master dorodango maker Bruce Gardner covers every aspect of making and finishing your dorodango, accompanied by inspiring words on the mindful qualities of this earthy activity.\" --supplied by publisher.
Book
Application of Stereolithography Based 3D Printing Technology in Investment Casting
Advanced methods for manufacturing high quality parts should be used to ensure the production of competitive products for the world market. Investment casting (IC) is a process where a wax pattern is used as a sacrificial pattern to manufacture high precision casting of solid metal parts. Rapid casting is in turn, a technique that eases the IC process by combining additive manufacturing (AM) technologies with IC. The use of AM technologies to create patterns for new industrial products is a unique opportunity to develop cost-effective methods for producing investment casting parts in a timely manner. Particularly, stereolithography (SLA) based AM is of interest due to its high dimensional accuracy and the smooth surface quality of the printed parts. From the first appearance of commercially available SLA printers in the market, it took a few decades until desktop SLA printers became available to consumers at a reasonable price. Therefore, the aim of this review paper is to analyze the state-of-the-art and applicability of SLA based 3D printing technology in IC manufacturing, as SLA based AM technologies have been gaining enormous popularity in recent times. Other AM techniques in IC are also reviewed for comparison. Moreover, the SLA process parameters, material properties, and current issues are discussed.
Journal Article
Auditioning for film and television : secrets from a casting director
\"'If you're working with Nancy Bishop you know you're in good, accomplished hands, whether you're a director or an actor.' - Neil Burger, Director of The Illusionist Auditioning for Film and Television is a must-have book and video guide for actors, written from the perspective of a Casting Director and offering practical advice on audition technique, scene analysis, online casting and social media. Auditioning for Film and Television is a practical workbook written from a casting director's point of view that teaches actors the craft of film auditioning in front of the camera. It shows actors how to use today's internet technologies to advance their careers and features success strategies and actual exercises to achieve results in the casting studio. A new edition of the popular Secrets from the Casting Couch, and now including video, Auditioning for Film and Television includes commentary, analysis and questions in workbook form for scenes from many celebrated films; exercises for actors to practise in front of a camera; and advice on career advancement and marketing in the age of social media\"-- Provided by publisher.
Book
Towards High-Quality Investment Casting of Ti-6Al-4V with Novel Calcium Zirconate Crucibles and Optimized Process Control
The investment casting of titanium and its alloys relies on a high resistance of the crucibles and shell molds in terms of temperature and reactivity. The availability of ceramic crucibles that offer sufficient resistance to the titanium melt enables vacuum induction melting (VIM). CaZrO3 prepared from a mixture of CaO and ZrO2 as a raw material for refractory ceramics shows a high corrosion resistance against metallic melts even under very high temperatures up to 1800 °C. Crucibles and shell molds of CaZrO3 were successfully produced and used in subsequent casting trials. This study is focused on the refractory crucibles suitable for casting Ti-6Al-4V (Ti-64) using a tilt casting machine. In order to evaluate the crucible reaction and, therefore, the quality of the castings, chemical analyses, investigations of the microstructures and hardness measurements were carried out. Careful control of the melting duration is mandatory to avoid crucible reactions that otherwise result in contamination of the cast with oxygen and zirconium. This was achieved by modified coil geometries. Under optimized casting conditions, the oxygen and zirconium impurity limits of ASTM B367-09 for titanium castings were met. Based on the correlations found, optimized casting parameters with regard to material quantity, coil geometry and heating power could be determined in order to provide guidance for a high-quality casting process with VIM.
Journal Article
A Novel Approach to Visualize Liquid Aluminum Flow to Advance Casting Science
Turbulent filling of molten metal in sand-casting leads to bi-films, porosity and oxide inclusions which results in poor mechanical properties and high scrap rate of sand castings. Hence, it is critical to understand the metal flow in sand-molds, i.e., casting hydrodynamics to eliminate casting defects. While multiple numerical methods have been applied to simulate this phenomenon for decades, harsh foundry environments and expensive x-ray equipment have limited experimental approaches to accurately visualize metal flow in sand molds. In this paper, a novel approach to solve this challenge is proposed using Succinonitrile (SCN) as a more accurate metal analog in place of water. SCN has a long history in solidification research due to its BCC (Body-Centered-Cubic) crystal structure and dendrite-like solidification (melting temperature ~60 °C) like molten aluminum. However, this is the first reported study on applying SCN through novel casting hydrodynamics to accurately visualize melt flow for casting studies. This paper used numerical simulations and experiments using both water and SCN to identify the critical dimensionless numbers to perform accurate metal flow analog testing. Froude’s number and wall roughness were identified as critical variables. Experimental results show that SCN flow testing was more accurate in recreating the flow profile of molten aluminum, thus validating its utility as a metal analog for metal flow research. Findings from this study can be used in future metal flow analysis such as: runner, in-gate and integrated filling-feeding-solidification studies.
Journal Article