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Dr. MICHAIL PAPANIKOLAOU
Cranfield University, Sustainable Manufacturing Systems Centre, Cranfield, MK43 0AL, UK

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Research Keywords & Expertise

0 Process Optimization
0 Software Development
0 Multi-Criteria Decision Making
0 Molecular dynamics modelling of manufacturing processes and micro/nano- flows
0 CFD modelling of casting processes

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Multi-Criteria Decision Making

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Chapter
Published: 30 April 2021 in Introduction to Mechanical Engineering
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This chapter presents some of the state-of-the art investigations on Molecular Dynamics simulations of Nanocutting processes. The basic theory of Molecular Dynamics simulations has been presented to facilitate the understanding of the fundamental principles of this numerical modelling method and the techniques employed to extract meaningful macroscopic properties out of atomistic simulations. The advances of Molecular Dynamics simulations with respect to modelling nanocutting processes are at core of this chapter. More specifically, fundamental and pioneering MD studies of nanocutting processes are thoroughly discussed with special emphasis laid on phenomena taking place during material removal, such as thermal softening, dislocation generation and stress evolution. The nature of the Molecular Dynamics simulation method allows for capturing and monitoring the aforementioned phenomena; this cannot be easily achieved via experimental and other modelling techniques such as Finite Element Analysis and Discrete Element Modelling. It is expected that, over the years to come, Molecular Dynamics simulations will be increasingly employed for investigating material removal processes due to the rapid development of computational power.

ACS Style

Francisco Rodriguez-Hernandez; Michail Papanikolaou; Konstantinos Salonitis. Atomistic Modelling of Nanocutting Processes. Introduction to Mechanical Engineering 2021, 195 -220.

AMA Style

Francisco Rodriguez-Hernandez, Michail Papanikolaou, Konstantinos Salonitis. Atomistic Modelling of Nanocutting Processes. Introduction to Mechanical Engineering. 2021; ():195-220.

Chicago/Turabian Style

Francisco Rodriguez-Hernandez; Michail Papanikolaou; Konstantinos Salonitis. 2021. "Atomistic Modelling of Nanocutting Processes." Introduction to Mechanical Engineering , no. : 195-220.

Conference paper
Published: 24 February 2021 in The Minerals, Metals & Materials Series
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It is well known that residual stresses are quite common in castings and they emerge due to uneven cooling conditions. Nowadays, the development of atomistic modelling techniques has allowed for the in-depth investigation of the solidification process mechanics as well as the distribution of residual stresses in the simulation domain. In this study we have performed three-dimensional molecular dynamics simulations to investigate the evolution of residual stresses during homogeneous nucleation in pure aluminium as well as their distribution over the simulation domain. A simulation box containing 1 million aluminium atoms placed on the sites of a face centred cubic (FCC) lattice has been melted and subsequently quenched under various cooling rates. The potential energy as well as the formation of grains has been monitored during quenching stages. Moreover, the present analysis is expanded to the distribution of the grain size and the number of grains as a function of the cooling rate. Finally, the obtained results suggest that the cooling rate significantly affects the distribution as well as the final magnitude of residual stresses in the solidified structure.

ACS Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Molecular Dynamics Simulations of the Evolution of Residual Stresses During Rapid Solidification of Aluminium. The Minerals, Metals & Materials Series 2021, 918 -927.

AMA Style

Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Molecular Dynamics Simulations of the Evolution of Residual Stresses During Rapid Solidification of Aluminium. The Minerals, Metals & Materials Series. 2021; ():918-927.

Chicago/Turabian Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2021. "Molecular Dynamics Simulations of the Evolution of Residual Stresses During Rapid Solidification of Aluminium." The Minerals, Metals & Materials Series , no. : 918-927.

Journal article
Published: 16 November 2020 in Applied Surface Science
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Grain size is one of the most critical factors affecting the mechanical and thermal properties of metallic materials. In this study the effect of the grain size of a workpiece made of pure Aluminium on the nanocutting process has been investigated via means of Molecular Dynamics simulations. The polycrystalline workpiece has been generated starting from a Face-Centred Cubic block of Aluminium atoms which was melted and subsequently quenched under various cooling rates in order to control the average grain size. The case of a monocrystalline workpiece has been considered as well. The generated workpieces were ground by a diamond abrasive. Simulations have been repeated in order to eliminate any statistical errors. The obtained results suggest that the average grain size of the workpiece significantly influences almost every aspect related to the nanocutting process. More specifically, it has been found that the cutting forces increase and the friction coefficient decreases with the grain size. Very small grain sizes lead to lower thermal conductivity and consequently high temperature at the cutting region. Finally, it has been shown that the high residual stresses at the grain boundaries can be relieved as the tool passes on top of the workpiece; this phenomenon resembles heat treatment. In summary, the nanocutting behaviour of polycrystalline materials depends on the average grain size and significantly differs from the case of monocrystalline materials. This should be taken into account in future numerical models of nanocutting processes.

ACS Style

Michail Papanikolaou; Konstantinos Salonitis. Grain size effects on nanocutting behaviour modelling based on molecular dynamics simulations. Applied Surface Science 2020, 540, 148291 .

AMA Style

Michail Papanikolaou, Konstantinos Salonitis. Grain size effects on nanocutting behaviour modelling based on molecular dynamics simulations. Applied Surface Science. 2020; 540 ():148291.

Chicago/Turabian Style

Michail Papanikolaou; Konstantinos Salonitis. 2020. "Grain size effects on nanocutting behaviour modelling based on molecular dynamics simulations." Applied Surface Science 540, no. : 148291.

Conference paper
Published: 11 September 2020 in Blockchain Technology and Innovations in Business Processes
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Capabilities of additive manufacturing (AM) for rapid tooling are well known in recent times. Rapid sand moulds are advantageous over traditional sand moulds in terms of cost, manufacturing time, flexibility, etc. This paper identifies metrics related to mould manufacturing and categorises them into four categories (cost, time, quality and environmental sustainability). A methodology based on the deterministic Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) multi-criteria decision-making algorithm is used to map at high resolution the influence of such categories on to the decision-making space when comparing AM with conventional sand mould making. Results show that AM is almost always clearly advantageous overall (excluding some very limited corner cases) for the examined case.

ACS Style

Emanuele Pagone; Prateek Saxena; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping. Blockchain Technology and Innovations in Business Processes 2020, 345 -355.

AMA Style

Emanuele Pagone, Prateek Saxena, Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping. Blockchain Technology and Innovations in Business Processes. 2020; ():345-355.

Chicago/Turabian Style

Emanuele Pagone; Prateek Saxena; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2020. "Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping." Blockchain Technology and Innovations in Business Processes , no. : 345-355.

Journal article
Published: 10 September 2020 in Metals
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In this investigation, three-dimensional molecular dynamics simulations have been performed in order to investigate the effects of the workpiece subsurface temperature on various nanocutting process parameters including cutting forces, friction coefficient, as well as the distribution of temperature and equivalent Von Mises stress at the subsurface. The simulation domain consists of a tool with a negative rake angle made of diamond and a workpiece made of copper. The grinding speed was considered equal to 100 m/s, while the depth of cut was set to 2 nm. The obtained results suggest that the subsurface temperature significantly affects all of the aforementioned nanocutting process parameters. More specifically, it has been numerically validated that, for high subsurface temperature values, thermal softening becomes dominant and this results in the reduction of the cutting forces. Finally, the dependency of local properties of the workpiece material, such as thermal conductivity and residual stresses on the subsurface temperature has been captured using numerical simulations for the first time to the authors’ best knowledge.

ACS Style

Michail Papanikolaou; Francisco Rodriguez Hernandez; Konstantinos Salonitis. Investigation of the Subsurface Temperature Effects on Nanocutting Processes via Molecular Dynamics Simulations. Metals 2020, 10, 1220 .

AMA Style

Michail Papanikolaou, Francisco Rodriguez Hernandez, Konstantinos Salonitis. Investigation of the Subsurface Temperature Effects on Nanocutting Processes via Molecular Dynamics Simulations. Metals. 2020; 10 (9):1220.

Chicago/Turabian Style

Michail Papanikolaou; Francisco Rodriguez Hernandez; Konstantinos Salonitis. 2020. "Investigation of the Subsurface Temperature Effects on Nanocutting Processes via Molecular Dynamics Simulations." Metals 10, no. 9: 1220.

Journal article
Published: 13 February 2020 in Metals
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Sand casting of lead sheet is a traditional manufacturing process used up to the present due to the special features of sand cast sheet such as their attractive sheen. Similarly to any casting process, sand casting of lead sheet suffers from the presence of surface defects. In this study, a surface defect type, hereby referred to as ‘grooves’, has been investigated. The focus has been laid on the identification of the main factors affecting defect formation in this process. Based on a set of screening experiments performed using Scanning Electron Microscopy (SEM) as well as the existing literature, a number of factors affecting the formation of such defects was identified and their corresponding significance was estimated using the Analysis of Variance (ANOVA) technique. The obtained results suggest that the most significant factor affecting defect formation in sand casting of lead sheet is the composition of the moulding mixture. Defect formation was also proven to be dependent on the sand grain fineness, the quality of the melt and some of the interactions between the aforementioned process parameters. Finally, an optimal set of process parameters leading to the minimisation of surface defects was identified.

ACS Style

Arun Prabhakar; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach. Metals 2020, 10, 252 .

AMA Style

Arun Prabhakar, Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach. Metals. 2020; 10 (2):252.

Chicago/Turabian Style

Arun Prabhakar; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2020. "Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach." Metals 10, no. 2: 252.

Conference paper
Published: 28 January 2020 in The Minerals, Metals & Materials Series
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Despite the continuous and remarkable development of experimental techniques for the investigation of microstructures and the growth of nuclei during the solidification of metals, there are still unknown territories around the topic of nucleation during solidification. Such nanoscale phenomena can be effectively observed by means of Molecular Dynamics (MD) simulations which can provide a deep insight into the formation of nuclei and the induced crystal structures. In this study, MD simulations have been performed to investigate the solidification of Aluminium melt and the effects of process parameters such as the cooling rate and hydrostatic pressure on the final properties of the solidified material. A large number of Aluminium atoms have been used in order to investigate the grain growth over time solidification. The population of the Face Centred Cubic (FCC) and amorphous (or non-crystalline) phases has been recorded during the evolution of the process to illustrate the nanoscale mechanisms during solidification. Finally, the exothermic nature of the solidification process has been effectively captured by measuring the temperature of the Al atoms during grain formation.

ACS Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Molecular Dynamics Simulations of the Solidification of Pure Aluminium. The Minerals, Metals & Materials Series 2020, 158 -167.

AMA Style

Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Molecular Dynamics Simulations of the Solidification of Pure Aluminium. The Minerals, Metals & Materials Series. 2020; ():158-167.

Chicago/Turabian Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2020. "Molecular Dynamics Simulations of the Solidification of Pure Aluminium." The Minerals, Metals & Materials Series , no. : 158-167.

Journal article
Published: 01 January 2020 in Metals
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The most common problems encountered in sand casting foundries are related to sand inclusions, air, and oxide films entrainment. These issues can be addressed to a good extent or eliminated by designing proper running systems. The design of a good running system should be based on John Campbell’s “10 casting rules”; it should hinder laminar and turbulent entrainment of the surface film on the liquid, as well as bubble entrainment. These rules have led to the establishment of a group of components such as high and low placed filters (HPF/LPF) and standard gate designs such as the trident gate (TG) and vortex gate (VG) which are incorporated in well-performing running system designs. In this study, the potential of the aforementioned running system designs to eliminate air entrainment and surface defects has been investigated via means of computational fluid dynamics (CFD) simulations. The obtained results suggest that the use of filters significantly enhances the quality of the final cast product; moreover, all of the gating system designs appear to perform better than the basic running system (BRS). Finally, the five in total running and gating system designs have been evaluated with respect to their ability to produce good quality cast products (reduced air entrainment and surface defects) and their sustainability component (runner scrap mass).

ACS Style

Michail Papanikolaou; Emanuele Pagone; Mark Jolly; Konstantinos Salonitis. Numerical Simulation and Evaluation of Campbell Running and Gating Systems. Metals 2020, 10, 68 .

AMA Style

Michail Papanikolaou, Emanuele Pagone, Mark Jolly, Konstantinos Salonitis. Numerical Simulation and Evaluation of Campbell Running and Gating Systems. Metals. 2020; 10 (1):68.

Chicago/Turabian Style

Michail Papanikolaou; Emanuele Pagone; Mark Jolly; Konstantinos Salonitis. 2020. "Numerical Simulation and Evaluation of Campbell Running and Gating Systems." Metals 10, no. 1: 68.

Original article
Published: 20 November 2019 in The International Journal of Advanced Manufacturing Technology
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Sandcast lead sheets are characterised by their superior aesthetic performance and mottled surface. Lead sheet casting is widely used in the construction industry for roofing and flashing applications, while the roots of this process can be tracked back to the Roman times. In this study, two-dimensional computational fluid dynamics (CFD) simulations have been performed to simulate the melt flow and solidification stages of the lead sandcasting process. The effects of process parameters such as pouring temperature, screed velocity and clearance between the screed and the sandbed on the final quality of the lead sheet are investigated. Lead sheet quality has been quantified by measuring the variance and the average value of the final sheet thickness over the sandbed length. The developed CFD model has been validated against experimental results by comparing the time evolution of the lead-sandbed interface temperature against data collected by thermocouples during the real-time process. The numerical results show that all of the aforementioned parameters affect the final quality of the cast product and suggest that superior quality lead sheets can be produced for a range of relatively low values of the pouring temperature and slow strickle motion.

ACS Style

Arun Prabhakar; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Sand casting of sheet lead: numerical simulation of metal flow and solidification. The International Journal of Advanced Manufacturing Technology 2019, 106, 177 -189.

AMA Style

Arun Prabhakar, Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Sand casting of sheet lead: numerical simulation of metal flow and solidification. The International Journal of Advanced Manufacturing Technology. 2019; 106 (1-2):177-189.

Chicago/Turabian Style

Arun Prabhakar; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2019. "Sand casting of sheet lead: numerical simulation of metal flow and solidification." The International Journal of Advanced Manufacturing Technology 106, no. 1-2: 177-189.

Journal article
Published: 12 November 2019 in Metals
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Despite the continuous and remarkable development of experimental techniques for the investigation of microstructures and the growth of nuclei during the solidification of metals, there are still unknown territories around this topic. The solidification in nanoscale can be effectively investigated by means of molecular dynamics (MD) simulations which can provide a deep insight into the mechanisms of the formation of nuclei and the induced crystal structures. In this study, MD simulations were performed to investigate the solidification of pure Aluminium and the effects of the cooling rate on the final properties of the solidified material. A large number of Aluminium atoms were used in order to investigate the grain growth over time and the formation of stacking faults during solidification. The number of face-centred cubic (FCC), hexagonal close-packed (HCP) and body-centred cubic (BCC) was recorded during the evolution of the process to illustrate the nanoscale mechanisms initiating solidification. The current investigation also focuses on the exothermic nature of the solidification process which has been effectively captured by means of MD simulations using 3 dimensional representations of the kinetic energy across the simulation domain.

ACS Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly; Michael Frank. Large-Scale Molecular Dynamics Simulations of Homogeneous Nucleation of Pure Aluminium. Metals 2019, 9, 1217 .

AMA Style

Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly, Michael Frank. Large-Scale Molecular Dynamics Simulations of Homogeneous Nucleation of Pure Aluminium. Metals. 2019; 9 (11):1217.

Chicago/Turabian Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly; Michael Frank. 2019. "Large-Scale Molecular Dynamics Simulations of Homogeneous Nucleation of Pure Aluminium." Metals 9, no. 11: 1217.

Journal article
Published: 02 October 2019 in The Journal of Chemical Physics
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The effects of surface irregularities and imperfections on the thermal resistance at a solid-liquid interface have been investigated using molecular dynamics. The molecular model comprises liquid argon confined between silver walls. The surface roughness was designed using fractal theory, introducing stochastic patterns of multiple scales that resemble realistic surface geometries. In agreement with most previous studies, we find that increasing the strength of the solid-liquid interactions monotonically reduces the thermal resistance across smooth interfaces. Yet, the behavior of the thermal resistance across rough surfaces is more complex. Following the initially anticipated decrease, the thermal resistance starts to increase once the strength of solid-liquid interaction increases past a threshold. We attribute the above behavior to two competing phenomena, namely, the area of the solid-liquid interface and the introduction of vibrational anharmonicities and localization of phonons resulting from the surface roughness. Finally, we demonstrate that, for the same fractal dimension and depth of surface roughness, different surfaces practically have the same thermal resistance, solid-liquid radial distribution function, and liquid density profiles. We conclude that the above fractal parameters are useful in deriving reduced models for properties related to the surface geometry.The effects of surface irregularities and imperfections on the thermal resistance at a solid-liquid interface have been investigated using molecular dynamics. The molecular model comprises liquid argon confined between silver walls. The surface roughness was designed using fractal theory, introducing stochastic patterns of multiple scales that resemble realistic surface geometries. In agreement with most previous studies, we find that increasing the strength of the solid-liquid interactions monotonically reduces the thermal resistance across smooth interfaces. Yet, the behavior of the thermal resistance across rough surfaces is more complex. Following the initially anticipated decrease, the thermal resistance starts to increase once the strength of solid-liquid interaction increases past a threshold. We attribute the above behavior to two competing phenomena, namely, the area of the solid-liquid interface and the introduction of vibrational anharmonicities and localization of phonons resulting from the su...

ACS Style

Michael Frank; Michail Papanikolaou; Dimitris Drikakis; Konstantinos Salonitis. Heat transfer across a fractal surface. The Journal of Chemical Physics 2019, 151, 134705 .

AMA Style

Michael Frank, Michail Papanikolaou, Dimitris Drikakis, Konstantinos Salonitis. Heat transfer across a fractal surface. The Journal of Chemical Physics. 2019; 151 (13):134705.

Chicago/Turabian Style

Michael Frank; Michail Papanikolaou; Dimitris Drikakis; Konstantinos Salonitis. 2019. "Heat transfer across a fractal surface." The Journal of Chemical Physics 151, no. 13: 134705.

Journal article
Published: 04 July 2019 in Applied Surface Science
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One of the most important grinding parameters is the real depth of cut which is always lower than its programmed value. This is because in reality abrasive grains of the grinding wheel are not fixed but attached to a bonding material which is deformed during the process. In this study we investigate the effect of the contact stiffness between a single abrasive grain and the workpiece on the depth of cut and the grinding process characteristics via three-dimensional Molecular Dynamics (MD) simulations. Contact stiffness has been modelled by attaching a single trapezoid abrasive grain to a spring in the normal grinding direction. MD experiments have been repeated due to the stochastic nature of the grinding process in favour of statistical accuracy. Various grinding speeds have been considered while the case of a rough abrasive-workpiece interface has been investigated as well using fractal models. Our results indicate that the trajectory followed by the abrasive grain is not a straight line, as in the case of a rigid abrasive, but a curved one, asymptotically converging towards the equilibrium point which corresponds to the selected value of the spring stiffness. This behaviour alongside the grinding velocity and rough abrasive-workpiece interface have been found to affect the grinding forces, friction coefficient, morphology of the ground surface and subsurface temperature. The present MD model has also been proven to be capable of capturing the thermal softening phenomenon at the abrasive-workpiece interface.

ACS Style

Michail Papanikolaou; Konstantinos Salonitis. Contact stiffness effects on nanoscale high-speed grinding: A molecular dynamics approach. Applied Surface Science 2019, 493, 212 -224.

AMA Style

Michail Papanikolaou, Konstantinos Salonitis. Contact stiffness effects on nanoscale high-speed grinding: A molecular dynamics approach. Applied Surface Science. 2019; 493 ():212-224.

Chicago/Turabian Style

Michail Papanikolaou; Konstantinos Salonitis. 2019. "Contact stiffness effects on nanoscale high-speed grinding: A molecular dynamics approach." Applied Surface Science 493, no. : 212-224.

Journal article
Published: 03 July 2019 in Energies
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Considering the manufacturing of automotive components, there exists a dilemma around the substitution of traditional cast iron (CI) with lighter metals. Currently, aluminum alloys, being lighter compared to traditional materials, are considered as a more environmentally friendly solution. However, the energy required for the extraction of the primary materials and manufacturing of components is usually not taken into account in this debate. In this study, an extensive literature review was performed to estimate the overall energy required for the manufacturing of an engine cylinder block using (a) cast iron and (b) aluminum alloys. Moreover, data from over 100 automotive companies, ranging from mining companies to consultancy firms, were collected in order to support the soundness of this investigation. The environmental impact of the manufacturing of engine blocks made of these materials is presented with respect to the energy burden; the “cradle-to-grave approach” was implemented to take into account the energy input of each stage of the component life cycle starting from the resource extraction and reaching to the end-of-life processing stage. Our results indicate that, although aluminum components contribute toward reduced fuel consumption during their use phase, the vehicle distance needed to be covered in order to compensate for the up-front energy consumption related to the primary material production and manufacturing phases is very high. Thus, the substitution of traditional materials with lightweight ones in the automotive industry should be very thoughtfully evaluated.

ACS Style

Konstantinos Salonitis; Mark Jolly; Emanuele Pagone; Michail Papanikolaou. Life-Cycle and Energy Assessment of Automotive Component Manufacturing: The Dilemma Between Aluminum and Cast Iron. Energies 2019, 12, 2557 .

AMA Style

Konstantinos Salonitis, Mark Jolly, Emanuele Pagone, Michail Papanikolaou. Life-Cycle and Energy Assessment of Automotive Component Manufacturing: The Dilemma Between Aluminum and Cast Iron. Energies. 2019; 12 (13):2557.

Chicago/Turabian Style

Konstantinos Salonitis; Mark Jolly; Emanuele Pagone; Michail Papanikolaou. 2019. "Life-Cycle and Energy Assessment of Automotive Component Manufacturing: The Dilemma Between Aluminum and Cast Iron." Energies 12, no. 13: 2557.

Preprint
Published: 11 June 2019
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Considering the manufacturing of automotive components, there exists a dilemma around the substitution of traditional Cast Iron (CI) with lighter metals. Nowadays, aluminium alloys, being lighter compared to traditional materials, are considered as a more environmentally friendly solution. However, the energy required for the extraction of the primary materials and manufacturing of components is usually not taken into account in this debate. In this study, an extensive literature review has been performed to estimate the overall energy required for the manufacturing of an engine cylinder block using (a) cast iron and (b) aluminium alloys. Moreover, data from over 100 automotive companies, ranging from mining companies to consultancy firms, have been collected in order to support the soundness of this investigation. The environmental impact of the manufacturing of engine blocks made of these materials is presented with respect to the energy burden; the “cradle-to-grave approach” has been implemented to take into account the energy input of each stage of the component lifecycle starting from the resource extraction and reaching to the end-of-life processing stage. Our results indicate that although aluminium components contribute towards reduced fuel consumption during their use phase, the vehicle distance needed to be covered in order to compensate for the up-front energy consumption related to the primary material production and manufacturing phases is very high. Thus, the substitution of traditional materials with lightweight ones in the automotive industry should be very thoughtfully evaluated.

ACS Style

Konstantinos Salonitis; Mark Jolly; Emanuele Pagone; Michail Papanikolaou. Life Cycle and Energy Assessment of Automotive Components Manufacturing: The Dilemma Between Aluminium and Cast Iron. 2019, 1 .

AMA Style

Konstantinos Salonitis, Mark Jolly, Emanuele Pagone, Michail Papanikolaou. Life Cycle and Energy Assessment of Automotive Components Manufacturing: The Dilemma Between Aluminium and Cast Iron. . 2019; ():1.

Chicago/Turabian Style

Konstantinos Salonitis; Mark Jolly; Emanuele Pagone; Michail Papanikolaou. 2019. "Life Cycle and Energy Assessment of Automotive Components Manufacturing: The Dilemma Between Aluminium and Cast Iron." , no. : 1.

Conference paper
Published: 01 December 2018 in Blockchain Technology and Innovations in Business Processes
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Casting is one of the most widely used, challenging and energy intensive manufacturing processes. Due to the complex engineering problems associated with casting, foundry engineers are mainly concerned with the quality of the final casting component. Consequently, energy efficiency is often disregarded and huge amounts of energy are wasted in favor of high quality casting parts. In this paper, a novel computational framework for the constrained minimization of the pouring temperature is presented and applied on the Constrained Rapid Induction Melting Single Shot Up-Casting (CRIMSON) process. Minimizing the value of the pouring temperature can lead to significant energy savings during the melting and holding processes as well as to higher yield rate due to the resulting reduction of the solidification time. Moreover, a multi-objective optimization component has been integrated into our scheme to assist decision makers with estimating the trade-off between process parameters.

ACS Style

Michail Papanikolaou; Emanuele Pagone; Konstantinos Salonitis; Mark Jolly; Charalampos Makatsoris. A Computational Framework Towards Energy Efficient Casting Processes. Blockchain Technology and Innovations in Business Processes 2018, 263 -276.

AMA Style

Michail Papanikolaou, Emanuele Pagone, Konstantinos Salonitis, Mark Jolly, Charalampos Makatsoris. A Computational Framework Towards Energy Efficient Casting Processes. Blockchain Technology and Innovations in Business Processes. 2018; ():263-276.

Chicago/Turabian Style

Michail Papanikolaou; Emanuele Pagone; Konstantinos Salonitis; Mark Jolly; Charalampos Makatsoris. 2018. "A Computational Framework Towards Energy Efficient Casting Processes." Blockchain Technology and Innovations in Business Processes , no. : 263-276.

Conference paper
Published: 01 December 2018 in Blockchain Technology and Innovations in Business Processes
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The automotive sector is one of the main end-use markets for metal casting worldwide. The strong competitive pressure typical of this industry have been influenced in the recent years by sustainability as a new factor promoted by legislation, increased societal awareness of relevant instances and resource scarcity. Energy efficiency, although only a part of sustainability, is important for the metal casting practice because of its nature of large consumer of energy per unit product. Therefore, the effective use of appropriate energy efficient metrics in foundries is of great interest. In this work, a set of indicators developed by the authors (and derived by traditional metrics) to analyse the energy performance of foundries will be used to compare high pressure die casting processes producing car transfer cases with different suitable materials. On the basis of this analysis, it will be shown that the most energy efficient material can be identified whereas the traditional metrics cannot detect such opportunity.

ACS Style

Emanuele Pagone; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Metal Casting Energy Efficient Metrics for Material Selection of Automotive Parts. Blockchain Technology and Innovations in Business Processes 2018, 290 -303.

AMA Style

Emanuele Pagone, Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Metal Casting Energy Efficient Metrics for Material Selection of Automotive Parts. Blockchain Technology and Innovations in Business Processes. 2018; ():290-303.

Chicago/Turabian Style

Emanuele Pagone; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2018. "Metal Casting Energy Efficient Metrics for Material Selection of Automotive Parts." Blockchain Technology and Innovations in Business Processes , no. : 290-303.

Journal article
Published: 11 October 2018 in Metals
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The appropriate design of feeders in a rigging system is critical for ensuring efficient compensation for solidification shrinkage, thus eliminating (shrinkage-related) porosity and contributing to the production of superior quality castings. In this study, a multi-objective optimisation framework combined with Computational Fluid Dynamics (CFD) simulations has been introduced to investigate the effect of the feeders’ geometry on shrinkage porosity aiming to optimise casting quality and yield for a novel counter-gravity casting process (CRIMSON). The weighted sum technique was employed to convert this multi-objective optimisation problem to a single objective one. Moreover, an evolutionary multi-objective optimisation algorithm (NSGA-II) has been applied to estimate the trade-off between the objective functions and support decision makers on selecting the optimum solution based on the desired properties of the final casting product and the process characteristics. This study is one of the first attempts to combine CFD simulations with multi-objective optimisation techniques in counter-gravity casting. The obtained results indicate the benefits of applying multi-objective optimisation techniques to casting processes.

ACS Style

Michail Papanikolaou; Emanuele Pagone; Konstantinos Georgarakis; Keith Rogers; Mark Jolly; Konstantinos Salonitis. Design Optimisation of the Feeding System of a Novel Counter-Gravity Casting Process. Metals 2018, 8, 817 .

AMA Style

Michail Papanikolaou, Emanuele Pagone, Konstantinos Georgarakis, Keith Rogers, Mark Jolly, Konstantinos Salonitis. Design Optimisation of the Feeding System of a Novel Counter-Gravity Casting Process. Metals. 2018; 8 (10):817.

Chicago/Turabian Style

Michail Papanikolaou; Emanuele Pagone; Konstantinos Georgarakis; Keith Rogers; Mark Jolly; Konstantinos Salonitis. 2018. "Design Optimisation of the Feeding System of a Novel Counter-Gravity Casting Process." Metals 8, no. 10: 817.

Article
Published: 13 March 2017 in Physical Review E
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This paper investigates the effect of surface roughness on fluid viscosity using molecular dynamics simulations. The three-dimensional model consists of liquid argon flowing between two solid walls whose surface roughness was modeled using fractal theory. In tandem with previously published experimental work, our results show that, while the viscosity in smooth channels remains constant across the channel width, in the presence of surface roughness it increases close to the walls. The increase of the boundary viscosity is further accentuated by an increase in the depth of surface roughness. We attribute this behavior to the increased momentum transfer at the boundary, a result of the irregular distribution of fluid particles near rough surfaces. Furthermore, although the viscosity in smooth channels has previously been shown to be independent of the strength of the solid-liquid interaction, here we show that in the presence of surface roughness, the boundary viscosity increases with the solid's wettability. The paper concludes with an analytical description of the viscosity as a function of the distance from the channel walls, the walls’ surface roughness, and the solid's wetting properties. The relation can potentially be used to adjust the fluid dynamics equations for a more accurate description of microfluidic systems.

ACS Style

Michail Papanikolaou; Michael Frank; Dimitris Drikakis. Effects of surface roughness on shear viscosity. Physical Review E 2017, 95, 033108 .

AMA Style

Michail Papanikolaou, Michael Frank, Dimitris Drikakis. Effects of surface roughness on shear viscosity. Physical Review E. 2017; 95 (3):033108.

Chicago/Turabian Style

Michail Papanikolaou; Michael Frank; Dimitris Drikakis. 2017. "Effects of surface roughness on shear viscosity." Physical Review E 95, no. 3: 033108.

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Published: 01 August 2016 in Physics of Fluids
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This paper investigates the effects of surface roughness on nanoflows using molecular dynamics simulations. A fractal model is employed to model wall roughness, and simulations are performed for liquid argon confined by two solid walls. It is shown that the surface roughness reduces the velocity in the proximity of the walls with the reduction being accentuated when increasing the roughness depth and wettability of the solid wall. It also makes the flow three-dimensional and anisotropic. In flows over idealized smooth surfaces, the liquid forms parallel, well-spaced layers, with a significant gap between the first layer and the solid wall. Rough walls distort the orderly distribution of fluid layers resulting in an incoherent formation of irregularly shaped fluid structures around and within the wall cavities.

ACS Style

Michail Papanikolaou; Michael Frank; Dimitris Drikakis. Nanoflow over a fractal surface. Physics of Fluids 2016, 28, 082001 .

AMA Style

Michail Papanikolaou, Michael Frank, Dimitris Drikakis. Nanoflow over a fractal surface. Physics of Fluids. 2016; 28 (8):082001.

Chicago/Turabian Style

Michail Papanikolaou; Michael Frank; Dimitris Drikakis. 2016. "Nanoflow over a fractal surface." Physics of Fluids 28, no. 8: 082001.