El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The purpose of this paper is to provide a proposal of a production management model using lean manufacturing techniques to improve on-time deliveries of a metal-mechanic company that works in a make-to-order (MTO) manufacture of industrial fans environment. The proposal of the research refers to the implementation of a production management model in a metal mechanic company in Peru and analyze the effect in on-time delivery rate of the company. In one month of operation after the implementation of the pro-posed model, the on-time delivery rate of the company increased from 35% to 80%. Likewise, the problems present in the metalworking research company may be the same in many metalworking companies in the country, so the present investigation will serve as an example for the possible solution of the problems of other companies.

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Metalworking fluids (MWFs) are coolants and lubricants, which are widely employed in metal cutting works. They are designed to be a long lasting product. Manufacturers have designed MWFs with lack of awareness of end-of-life disposal by including biocides, which make biological treatment challenging. Here, Syntilo 9913 was used as a case study to develop a cradle-to-grave product that was biologically stable in use but amenable to sustainable hybrid biological treatment at end-of-life. The product was reverse engineered employing factorial design approach based on a priori knowledge of the product components. From the combinatorial work, it was observed that chemical interactions can results in synergistic and antagonistic effects in terms of the toxicity and biodegradability. One of the major components of most MWFs are amines such as Triethanolamine (TEA). TEA does not biodeteriorate in single compound screening, but in combination with many other components TEA was found to cause "softening" of MWF formulations. Octylamine was found to be best for "bio-hardening" but it was not economically sustainable. Hence, the modified biocide-free synthetic MWF, Syntilo 1601, was reformulated with TEA, isononanoic acid, neodecnoic acid, Cobratec TT50S, and pluronic 17R40, which were resistant to biological treatment. Although, no change in the overall oxidation state of the MWF, metabolic activity did occur as breakdown products were observed. This suggested that both raw materials and metabolic breakdown products were recalcitrant. Thus, immobilisation agents were applied to aid further biodegradation by removing toxic bottleneck compounds. It was found that hybrid nano-iron and kaffir lime leaf performed similarly in removing chemical oxygen demand and ammonium from the system. Work in this Thesis demonstrated that the combined use of biological treatment and immobilisation agents effectively overcome the limitations of biological treatment alone by removing bottleneck compounds, which allowed greater COD reduction. This laboratory scale is a proof of principle, which needs to be tested at full scale.

In metal machining processes, the regulation of heat generation and lubrication at the contact point are achieved by application of a fluid referred to as metalworking fluid (MWF). This has the combined features of the cooling properties of water and lubricity of oil. MWFs inevitably become operationally exhausted with age and intensive use, which leads to compromised properties, thereby necessitating their safe disposal. Disposal of this waste through a biological route is an increasingly attractive option, since it is effective with relatively low energy demands when compared to current physical and chemical options. However, biological treatment is challenging since MWF are chemically complex, including the addition of toxic biocides which are added specifically to retard microbial deterioration whilst the fluids are operational. This makes bacterial treatment exceptionally challenging and has stimulated the search and need to assess technologies which complement biological treatment. In this study the remediation, specifically of the recalcitrant component of a semi-synthetic MWF, employing a novel hybrid treatment approach consisting of both bacteriological and chemical treatment, was investigated. Three chemical pre-treatment methods (Fenton’s oxidation, nano-zerovalent iron (nZVI) oxidation and ozonation) of the recalcitrant components followed by bacterial degradation were examined. The synergistic interaction of Fenton’s-biological oxidation and nZVI-biodegradation led to an overall COD reduction of 92% and 95.5% respectively, whereas pre-treatment with ozone reduced the total pollution load by 70% after a post-biological step. An enhancement in biodegradability was observed after each of the chemical treatments, thus facilitating the overall treatment process. The findings from this study established that the use of non-pathogenic microorganisms to remediate organic materials present in MWF wastewater is a favourable alternative to energy demanding physical and chemical treatment options. However, optimal performance of this biological process may require chemical enhancement, particularly for those components that are resistant to biological transformation.

This work characterized burn-off emissions from automobiles. After an exhaustive literature review, engine temperatures were determined to reach a maximum temperature of approximately 110oC, while exhaust system components reached a maximum temperature around 600oC. Metal-drawing fluids were used to bend the exhaust system components during manufacturing. Because these components were not rinsed prior to incorporation into a vehicle, residues could be left on the surfaces. An experimental test chamber was constructed to conduct controlled testing of three metalworking fluids of various types to mimic real-world conditions. Real-time particle number measurements were made using a condensation particle counter and an optical particle counter. The temperature at which burn-off begins to occur was found to be around 120 to 150oC. This burn-off was found to be an evaporation-condensation phenomenon when metalworking fluid residues vaporize and condense forming fine (0.1µm to 2.5µm) and ultrafine (<0.1µm) aerosols. The temperature dependency of this phenomenon was observed to follow the Clausius-Clapeyron equation that states as temperature increases, vapor pressure increases. Most aerosol particles were observed to be in the range of less than 0.01µm to approximately 2.0µm.

Manufacturing of dies has been presenting greater requirements of geometrical accuracy, dimensional precision and surface quality as well as decrease in costs and manufacturing times. Although proper cutting parameter values are utilized to obtain high geometrical accuracy and surface quality, there may exist geometrical discrepancy between the designed and the manufactured surface profile of the die cavities. In milling process / cutting speed, step over and feed are the main cutting parameters and these parameters affect geometrical accuracy and surface quality of the forging die cavities. In this study, effects of the cutting parameters on geometrical error have been examined on a representative die cavity profile. To remove undesired volume in the die cavities, available cutting strategies are investigated. Feed rate optimization is performed to maintain the constant metal removal rate along the trajectory of the milling cutter during rough cutting process. In the finish cutting process of the die cavities, Design of Experiment Method has been employed to find out the effects of the cutting parameters on the geometrical accuracy of the manufactured cavity profile. Prediction formula is derived to estimate the geometrical error value in terms of the values of the cutting parameters. Validity of the prediction formula has been tested by conducting verification experiments for the representative die geometry and die cavity geometry of a forging part used in industry. Good agreement between the predicted error values and the measured error values has been observed.

Severe plastic deformation (SPD) results in ultra-fine grain sizes in metals and alloys. Equal channel angular pressing (ECAP) is one of the special SPD methods aiming to introduce high plastic strains into the bulk materials without changing their cross section. ECAP results in improvement in hardness and strength while still satisfying acceptable ductility level. The combined effects of ECAP and subsequent heat treatments, i.e. post-aging and post-annealing, on the microstructure and hardness of the 2024 aluminum alloy were investigated. An ECAP die with 120&amp / #730 / channel angle was constructed. Subgrain formation, increase in dislocation density and dislocation tangling were observed after ECAP, and subgrain growth was detected after post annealing. The specimens revealed higher hardness values after ECAP at room temperature, and further increase in hardness was observed following post-aging at 80&amp / #730 / C, 100&amp / #730 / C and 190&amp / #730 / C. Effect of the aging temperature on the deformed specimens was investigated, and the aging behaviors of the severely deformed and undeformed samples at 190&amp / #730 / C were compared.

The purpose of this study is to estimate the residual stress state in steel weldments by using Magnetic Barkhausen Noise (MBN) technique. For obtaining accurate, fast and continuous residual stress measurements a set up for single pass welded plates was designed and used. In order to convert the MBN values to residual stress values a calibration set up was also designed and a procedure for obtaining calibration curves was developed. After welding of low-C steel plates, residual stresses on heat affected zone (HAZ) and parent metal were measured by MBN technique. The results were verified by the hole drilling method. Microstructural investigation and hardness measurements were also conducted.

In this study, a cold worked tool steel and a low carbon steel ( St 37 ), which were joined by brazing, were subjected to impact and shear loading. The end product is used as paper cutting blades in the industry. Effects of different brazing filler metals on the delamination of the blades under impact loading and on the impact toughness of the blades were studied. The target is to achieve higher impact toughness values without delamination. Impact toughness of the steels, joined by Cu, CuNi and BNi brazing filler metals and separation of brazed surfaces under shear loading were studied. The microstructures that were formed as a result of each application were studied by scanning electron microscopy and x-ray diffraction. The results indicate that brittle intermetallic compounds are formed in BNi brazing filler metal application. It is observed that CuNi alloy with 24% wt Ni form stronger bonds with the base metals than pure Cu and 10% wt Ni CuNi alloy.