Increasing the Sustainability of the Hybrid Mold Technique through Combined Insert Polymeric Material and Additive Manufacturing Method Design

To reduce plastic waste generation from failed product batches during industrial injection molding, the sustainable production of representative prototypes is essential. Interesting is the more recent hybrid injection molding (HM) technique, in which a polymeric mold core and cavity are produced via additive manufacturing (AM) and are both placed in an overall metal housing for the final polymeric part production. HM requires less material waste and energy compared to conventional subtractive injection molding, at least if its process parameters are properly tuned. In the present work, several options of AM insert production are compared with full metal/steel mold inserts, selecting isotactic polypropylene as the injected polymer. These options are defined by both the AM method and the material considered and are evaluated with respect to the insert mechanical and conductive properties, also considering Moldex3D simulations. These simulations are conducted with inputted measured temperature-dependent AM material properties to identify in silico indicators for wear and to perform cooling cycle time minimization. It is shown that PolyJetted Digital acrylonitrile-butadiene-styrene (ABS) polymer and Multi jet fusioned (MJF) polyamide 11 (PA11) are the most promising. The former option has the best durability for thinner injection molded parts, and the latter option the best cooling cycle times at any thickness, highlighting the need to further develop AM options.

Evaluation of different cooling management strategies for lactating Holstein × Gir dairy cows

Heat stress negatively impacts production, reproduction, and health of ruminants and strategies to alleviate these losses are warranted. Therefore, 4 experiments evaluated different cooling strategies on vaginal temperature (VT) of Holstein × Gir cows. Experiment 1 compared different amounts of water (2- or 4-L) over a 1-hour period from 1000 to 1100 h and 1600 to 1700 h. Experiment 2 evaluated the effects of sprinkling duration (in hours; 1- or 2-H), whereas Exp. 3 evaluated the effects of water amount (4- or 8-L) applied for 1- or 2-H. Lastly, the effects of a cooling strategy on specific hours of the day, starting at either 0700 (T-1) or 1100 h (T-2; Exp. 4), were evaluated. In all experiments, 12 Holstein × Gir cows were used in a 2 × 2 Latin Square Design containing 2 periods of 6 days each. Temperature and humidity index (THI) were recorded hourly and VT was recorded every 10-min throughout the experiments. As expected, an hour effect was observed for THI (P < 0.0001), which peaked early in the afternoon. In Exp. 1, a treatment × hour interaction was observed (P < 0.0001) for VT, as animals assigned to receive 4-L had a reduced VT at 1100, 1600, 1700, and 2300 h (P ≤ 0.03). During the cooling applications, cows receiving 4-L for 1 hour had a reduced VT from 60 to 150 minutes (P ≤ 0.04). In Exp. 2, a treatment × hour interaction was observed (P < 0.0001) for VT, as animals assigned to receive 4-L of water for 2-H had a reduced VT at 1200 h (P = 0.05). Moreover, during the cooling process, VT was reduced for 2-H cows from 140 to 170 min after the beginning of the cooling process (P ≤ 0.05). In Exp. 3, animals assigned to receive 4-L+2H had a reduced VT at 1200, 1700, 1800, and 1900 h (P < 0.001). A treatment × hour interaction was observed (P < 0.0001), as VT was reduced for 4-L+2-H cows from 130 to 180 min after the beginning of the cooling process (P ≤ 0.05). In Exp. 4, by the time when the first cooling cycle of T-1 was applied (0700 h), T-1 cows consistently had (P ≤ 0.05) a reduced VT up to the hottest hours and greatest THI of the day (1400 and 1500 h). This pattern was maintained until the end of the last cooling cycle, whereas T-2 cows had a reduced VT. In summary, 4 L of water over a 5-min cycle for a period of 2 hours twice a day maintained VT of Holstein × Gir cows at lower levels. Moreover, the hour at which the first cooling cycle starts also should be considered when evaluating the efficacy of a cooling strategy for an entire day.

Investigation of Dissimilar Resistance Spot Welding Process of AISI 304 and AISI 1060 Steels with TLBO-ANFIS and Sensitivity Analysis

In this work, the process of dissimilar resistance spot welding (RSW) for AISI 304 and AISI 1060 steel sheets is experimentally investigated. The effects of the main process parameters such as welding current, electrode force, welding cycle, and cooling cycle on the tensile-shear strength (TSS) of dissimilar RSW joints are studied. To this aim, using a central composite experimental design based on response surface methodology (RSM), the experimental tests were performed. Furthermore, from the test results, an adaptive neuro-fuzzy inference system (ANFIS) was developed to model and estimate the TSS. The optimal parameters of the ANFIS system were obtained using a teaching-learning-based optimization (TLBO) algorithm. In order to model the process behavior, the results of experiments were used for the training (70% of the data) and testing (30% of the data) of the adaptive inference system. The accuracy of the obtained model was investigated via different plots and statistical criteria including root mean square error, correlation coefficient, and mean absolute percentage error. The findings show that the ANFIS network successfully predicts the TSS. In addition, the network error in estimating the TSS in the training and test section is equal to 0.08% and 5.87%, respectively. After modeling with TLBO-ANFIS, the effect of each input parameter on TSS of the dissimilar joints is quantitatively measured using the Sobol sensitivity analysis method. The results show that increasing in welding current and welding cycle leads to an increase in the TSS of joints. It is concluded that TSS decreases with increases in the electrode force and cooling cycle.