Processes for environmentally friendly and/or cost-effective manufacturing
Z.W. Zhong
Abstract
This article reviews environmentally friendly and/or cost-effective processes. Topics covered are minimum-quantity-lubrication (MQL), cryogenic-cooling and near-dry-machining; polishing slurries; recycled metals; processing wood materials; microfluidic paper devices; life-cycle-assessment; electrical-discharge-machining; friction-stir-processing; and green and/or cost-effective processes. Findings include that environmentally-friendly-slurries are hot research-topics for polishing wafers. For cost, health and environment considerations, MQL emerges as a popular and innovative-research topic. To augment material yield and decrease pollution, solid-state-recycling was conducted to recycle chips. Waterjet turning of wood composites solved the problems of the matrix sticking to machining tools. The performance of wood products is significantly influenced by their surface roughness, which depends on machining processes and anatomical wood structures. Novel approaches were proposed for fast-manufacturing of microfluidic paper devices, with advantages of low energy-consumption and costs. Lifecycle models resulted in indicators under resources, ecosystem quality and human health, and provided the information for further advances of environmentally-friendly processes. Electric discharge machining (EDM) employs hydrocarbons-based dielectrics, and this generates hazardous gas-emission and leads to safety, health and environmental issues. To overcome the problems, innovative green-machining was proposed by conducting sustainable near-dry EDM, which significantly decreased gas-emissions. Copper foam plates were sintered by employing friction stir welding, and the method was cost-effective.