Table Of ContentSustainable Material Forming
and Joining
Sustainable Material Forming
and Joining
Edited by
R. Ganesh Narayanan and Jay S. Gunasekera
CRC Press
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Contents
Preface...............................................................................................................................................ix
Acknowledgments .............................................................................................................................xi
Editors ............................................................................................................................................xiii
Contributors .....................................................................................................................................xv
Chapter 1
Introduction to Sustainable Manufacturing Processes ......................................................................1
R. Ganesh Narayanan and Jay S. Gunasekera
Chapter 2
Sustainability in Material Forming .................................................................................................19
Zhengjie Jia, R. Ganesh Narayanan, N. K. B. M. P. Nanayakkara, and Jay S. Gunasekera
Chapter 3
Sustainability in Joining ..................................................................................................................39
R. Ganesh Narayanan
Chapter 4
Friction and Lubrication in Sustainable Metal Forming .................................................................59
N. K. B. M. P. Nanayakkara and R. Ganesh Narayanan
Chapter 5
Development in Materials for Sustainable Manufacturing ..............................................................77
Saptarshi Dutta and P. S. Robi
Chapter 6
Steel: A Sustainable Material of the Future .....................................................................................91
Sumitesh Das
Chapter 7
Strategies to Improve the Forming Quality of Sheets ...................................................................101
R. Ganesh Narayanan
Chapter 8
Computations and Sustainability in Material Forming .................................................................121
Zhengjie Jia and R. Ganesh Narayanan
v
vi Contents
Chapter 9
Hot Stamping of Ultra-High-Strength Steel Parts .........................................................................157
Ken-ichiro Mori
Chapter 10
Tubular Hydroforming and Hydropiercing ....................................................................................171
Nader Asnafi
Chapter 11
Some Recent Developments in Microforming ...............................................................................223
Ming Yang, Tetsuhide Shimizu, Tsuyoshi Furushima, and Tomomi Shiratori
Chapter 12
Mechanical Joining Processes .......................................................................................................245
V. Satheeshkumar and R. Ganesh Narayanan
Chapter 13
Hybrid Joining Processes ...............................................................................................................263
V. Satheeshkumar and R. Ganesh Narayanan
Chapter 14
Green Lubricants and Lubrication .................................................................................................281
Sayanti Ghosh, Lalit Kumar, Vivek Rathore, Shivanand M. Pai, and Bharat L. Newalkar
Chapter 15
LASER-Based Manufacturing as a Green Manufacturing Process ..............................................303
Ashish K. Nath, Sagar Sarkar, Gopinath Muvvala, Debapriya Patra Karmakar,
Shitanshu S. Chakraborty, Suvradip Mullick, and Yuvraj K. Madhukar
Chapter 16
Models and Approaches for Sustainable Performance Measurement ...........................................367
S. Vinodh and K. J. Manjunatheshwara
Chapter 17
Sustainable Manufacturing—Getting Future Ready .....................................................................391
Prasad Modak
Chapter 18
Dissemination of Sustainability and Education .............................................................................409
R. Ganesh Narayanan and Jay S. Gunasekera
Contents vii
Chapter 19
Sustainability, Health, and Environment: A Case Study of Waste Management Sector ...............427
Radha Goyal, Ashish Jain, and Shyamli Singh
Author Index ..................................................................................................................................435
Subject Index ..................................................................................................................................445
Preface
Material forming and joining have been important manufacturing processes for centuries. The
main advantages of these processes include material conservation, enhancement of mechanical and
metallurgical properties, and their suitability for mass production. However, in the past, little atten-
tion has been paid to green and sustainability issues such as energy saving, reduction of pollution,
and protecting the environment. Some of the approaches toward sustainable and green manufactur-
ing are as follows: enhanced use of renewable energy, establishment of green buildings, reduction of
specific consumption of energy and water and materials, reduction in specific emissions of wastes,
effluents, maximize recycling of wastes, water, etc. Considering the importance of the subject, the
editors organized a Global Initiative of Academic Networks (GIAN) course on “Green Material
Forming and Joining” few years ago. This laid the basic framework for the book. The book is
intended to emphasize the importance of sustainability with reference to manufacturing and in
particular to material forming and joining processes.
This book has a total of 19 chapters. Chapters 1–8 contribute to the basics of sustainable
manufacturing and joining. Chapter 1 provides an introduction to sustainable material forming and
joining. The basic material forming and joining processes are also briefly introduced in this chap-
ter, and sustainable manufacturing has been highlighted with the help of few research examples.
Chapter 2 covers sustainable material forming with some industry case studies. Chapter 3 covers
sustainable joining, which initially highlights the sustainable initiatives followed in conventional
joining methods, and later on, emphasizes the importance of novel joining methods like friction
stir welding, joining by forming, etc. Chapter 4 deals with improving sustainability in friction and
lubrication in metal forming practice. Types of lubricants and additives, selection of lubricants, and
lubrication methods are also briefly introduced in this chapter. This chapter also includes a short
note on bio-lubricants. Chapter 5 discusses the development of materials for sustainable manu-
facturing. Chapter 6 discusses steel as a projected sustainable material for future. Chapter 7 deals
with strategies to improve the forming quality of sheets. Such forming quality improvement helps
in sustainable manufacturing. Chapter 8 discusses the importance of computations and analyses in
sustainable manufacturing with some industrial and research case studies.
Chapters 9–15 describe some special topics in material forming and joining that are relevant from
a sustainable manufacturing point of view. Chapter 9 introduces hot stamping of sheets, specifically
the high-strength steel grades. Chapter 10 covers the hydroforming of tubes and hydropiercing. The
importance of computations and analytical modeling is also briefly emphasized in this chapter. Chapter
11 covers some of the recent developments in the field of microforming. Mechanical joining processes
and hybrid joining processes are considered crucial in sustainable manufacturing. Chapters 12 and
13 cover a comprehensive discussion on these two topics. Chapter 14 discusses green lubricants and
lubrication, including the importance of various biodegradable-based lubricant base stocks. Chapter
15 covers an elaborate discussion on how LASER-based manufacturing helps in green manufacturing.
Chapters 16–19 cover sustainability aspects. Chapter 16 discusses about models for sustain-
ability measurement. Chapter 17 presents the evolution and future of sustainability in a sustainable
manufacturing environment. Chapter 18 covers strategies to disseminate the significance of sustain-
ability through education. Finally, Chapter 19 connects sustainability, health, and environment with
a case study of the waste management sector.
The authors have given bird’s-eye views of these specific topics. Readers are encouraged to
refer to the extensive reference database provided in the chapters for in-depth details. The authors
and editors have taken extreme care and interest in presenting the concepts and acknowledging the
original sources. We believe the manufacturing researchers and academia will welcome the book.
Any constructive feedback from the readers is encouraged.
R. Ganesh Narayanan and Jay S. Gunasekera
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