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Toward New-Generation Intelligent Manufacturing
Zhou Ji, Li Peigen, Zhou Yanhong, Wang Baicun, Zang Jiyuan, Meng Liu
Engineering    2018, 4 (1): 11-20.   https://doi.org/10.1016/j.eng.2018.01.002
Abstract   PDF (1814KB)

Intelligent manufacturing is a general concept that is under continuous development. It can be categorized into three basic paradigms: digital manufacturing, digital-networked manufacturing, and newgeneration intelligent manufacturing. New-generation intelligent manufacturing represents an indepth integration of new-generation artificial intelligence (AI) technology and advanced manufacturing technology. It runs through every link in the full life-cycle of design, production, product, and service. The concept also relates to the optimization and integration of corresponding systems; the continuous improvement of enterprises’ product quality, performance, and service levels; and reduction in resources consumption. New-generation intelligent manufacturing acts as the core driving force of the new industrial revolution and will continue to be the main pathway for the transformation and upgrading of the manufacturing industry in the decades to come. Human-cyber-physical systems (HCPSs) reveal the technological mechanisms of new-generation intelligent manufacturing and can effectively guide related theoretical research and engineering practice. Given the sequential development, cross interaction, and iterative upgrading characteristics of the three basic paradigms of intelligent manufacturing, a technology roadmap for ‘‘parallel promotion and integrated development” should be developed in order to drive forward the intelligent transformation of the manufacturing industry in China.

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Intelligent Manufacturing in the Context of Industry 4.0: A Review
Ray Y. Zhong, Xun Xu, Eberhard Klotz, Stephen T. Newman
Engineering    2017, 3 (5): 616-630.   https://doi.org/10.1016/J.ENG.2017.05.015
Abstract   HTML   PDF (1607KB)

Our next generation of industry—Industry 4.0—holds the promise of increased flexibility in manufacturing, along with mass customization, better quality, and improved productivity. It thus enables companies to cope with the challenges of producing increasingly individualized products with a short lead-time to market and higher quality. Intelligent manufacturing plays an important role in Industry 4.0. Typical resources are converted into intelligent objects so that they are able to sense, act, and behave within a smart environment. In order to fully understand intelligent manufacturing in the context of Industry 4.0, this paper provides a comprehensive review of associated topics such as intelligent manufacturing, Internet of Things (IoT)-enabled manufacturing, and cloud manufacturing. Similarities and differences in these topics are highlighted based on our analysis. We also review key technologies such as the IoT, cyber-physical systems (CPSs), cloud computing, big data analytics (BDA), and information and communications technology (ICT) that are used to enable intelligent manufacturing. Next, we describe worldwide movements in intelligent manufacturing, including governmental strategic plans from different countries and strategic plans from major international companies in the European Union, United States, Japan, and China. Finally, we present current challenges and future research directions. The concepts discussed in this paper will spark new ideas in the effort to realize the much-anticipated Fourth Industrial Revolution.

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Integrated and Intelligent Manufacturing: Perspectives and Enablers
Yubao Chen
Engineering    2017, 3 (5): 588-595.   https://doi.org/10.1016/J.ENG.2017.04.009
Abstract   HTML   PDF (1484KB)

With ever-increasing market competition and advances in technology, more and more countries are prioritizing advanced manufacturing technology as their top priority for economic growth. Germany announced the Industry 4.0 strategy in 2013. The US government launched the Advanced Manufacturing Partnership (AMP) in 2011 and the National Network for Manufacturing Innovation (NNMI) in 2014. Most recently, the Manufacturing USA initiative was officially rolled out to further “leverage existing resources… to nurture manufacturing innovation and accelerate commercialization” by fostering close collaboration between industry, academia, and government partners. In 2015, the Chinese government officially published a 10-year plan and roadmap toward manufacturing: Made in China 2025. In all these national initiatives, the core technology development and implementation is in the area of advanced manufacturing systems. A new manufacturing paradigm is emerging, which can be characterized by two unique features: integrated manufacturing and intelligent manufacturing. This trend is in line with the progress of industrial revolutions, in which higher efficiency in production systems is being continuously pursued. To this end, 10 major technologies can be identified for the new manufacturing paradigm. This paper describes the rationales and needs for integrated and intelligent manufacturing (i2M) systems. Related technologies from different fields are also described. In particular, key technological enablers, such as the Internet of Things and Services (IoTS), cyber-physical systems (CPSs), and cloud computing are discussed. Challenges are addressed with applications that are based on commercially available platforms such as General Electric (GE)’s Predix and PTC’s ThingWorx.

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Two-Way 4D Printing: A Review on the Reversibility of 3D-Printed Shape Memory Materials
Amelia Yilin Lee, Jia An, Chee Kai Chua
Engineering    2017, 3 (5): 663-674.   https://doi.org/10.1016/J.ENG.2017.05.014
Abstract   HTML   PDF (2018KB)

The rapid development of additive manufacturing and advances in shape memory materials have fueled the progress of four-dimensional (4D) printing. With the right external stimulus, the need for human interaction, sensors, and batteries will be eliminated, and by using additive manufacturing, more complex devices and parts can be produced. With the current understanding of shape memory mechanisms and with improved design for additive manufacturing, reversibility in 4D printing has recently been proven to be feasible. Conventional one-way 4D printing requires human interaction in the programming (or shape-setting) phase, but reversible 4D printing, or two-way 4D printing, will fully eliminate the need for human interference, as the programming stage is replaced with another stimulus. This allows reversible 4D printed parts to be fully dependent on external stimuli; parts can also be potentially reused after every recovery, or even used in continuous cycles—an aspect that carries industrial appeal. This paper presents a review on the mechanisms of shape memory materials that have led to 4D printing, current findings regarding 4D printing in alloys and polymers, and their respective limitations. The reversibility of shape memory materials and their feasibility to be fabricated using three-dimensional (3D) printing are summarized and critically analyzed. For reversible 4D printing, the methods of 3D printing, mechanisms used for actuation, and strategies to achieve reversibility are also highlighted. Finally, prospective future research directions in reversible 4D printing are suggested.

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Simulating Resin Infusion through Textile Reinforcement Materials for the Manufacture of Complex Composite Structures
Robert S. Pierce, Brian G. Falzon
Engineering    2017, 3 (5): 596-607.   https://doi.org/10.1016/J.ENG.2017.04.006
Abstract   HTML   PDF (2946KB)

Increasing demand for weight reduction and greater fuel efficiency continues to spur the use of composite materials in commercial aircraft structures. Subsequently, as composite aerostructures become larger and more complex, traditional autoclave manufacturing methods are becoming prohibitively expensive. This has prompted renewed interest in out-of-autoclave processing techniques in which resins are introduced into a reinforcing preform. However, the success of these resin infusion methods is highly dependent upon operator skill and experience, particularly in the development of new manufacturing strategies for complex parts. Process modeling, as a predictive computational tool, aims to address the issues of reliability and waste that result from traditional trial-and-error approaches. Basic modeling attempts, many of which are still used in industry, generally focus on simulating fluid flow through an isotropic porous reinforcement material. However, recent efforts are beginning to account for the multiscale and multidisciplinary complexity of woven materials, in simulations that can provide greater fidelity. In particular, new multi-physics process models are able to better predict the infusion behavior through textiles by considering the effect of fabric deformation on permeability and porosity properties within the reinforcing material. In addition to reviewing previous research related to process modeling and the current state of the art, this paper highlights the recent validation of a multi-physics process model against the experimental infusion of a complex double dome component. By accounting for deformation-dependent flow behavior, the multi-physics process model was able to predict realistic flow behavior, demonstrating considerable improvement over basic isotropic permeability models.

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The Biofunctions of Phytochemicals and Their Applications in Farm Animals: The Nrf2/Keap1 System as a Target
Si Qin, De-Xing Hou
Engineering    2017, 3 (5): 738-752.   https://doi.org/10.1016/J.ENG.2017.03.011
Abstract   HTML   PDF (1118KB)

Reactive oxygen species (ROS) can be caused by mechanical, thermal, infectious, and chemical stimuli, and their negative effects on the health of humans and other animals are of considerable concern. The nuclear factor (erythroid-derived 2)-like 2/Kelch-like ECH-associated protein 1 (Nrf2/Keap1) system plays a major role in maintaining the balance between the production and elimination of ROS via the regulation of a series of detoxifying and antioxidant enzyme gene expressions by means of the antioxidant response element (ARE). Dietary phytochemicals, which are generally found in vegetables, fruits, grains, and herbs, have been reported to have health benefits and to improve the growth performance and meat quality of farm animals through the regulation of Nrf2-mediated phase II enzymes in a variety of ways. However, the enormous quantity of somewhat chaotic data that is available on the effects of phytochemicals needs to be properly classified according to the functions or mechanisms of phytochemicals. In this review, we first introduce the antioxidant properties of phytochemicals and their relation to the Nrf2/Keap1 system. We then summarize the effects of phytochemicals on the growth performance, meat quality, and intestinal microbiota of farm animals via targeting the Nrf2/Keap1 system. These exhaustive data contribute to better illuminate the underlying biofunctional properties of phytochemicals in farm animals.

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Control for Intelligent Manufacturing: A Multiscale Challenge
Han-Xiong Li, Haitao Si
Engineering    2017, 3 (5): 608-615.   https://doi.org/10.1016/J.ENG.2017.05.016
Abstract   HTML   PDF (1761KB)

The Made in China 2025 initiative will require full automation in all sectors, from customers to production. This will result in great challenges to manufacturing systems in all sectors. In the future of manufacturing, all devices and systems should have sensing and basic intelligence capabilities for control and adaptation. In this study, after discussing multiscale dynamics of the modern manufacturing system, a five-layer functional structure is proposed for uncertainties processing. Multiscale dynamics include: multi-time scale, space-time scale, and multi-level dynamics. Control action will differ at different scales, with more design being required at both fast and slow time scales. More quantitative action is required in low-level operations, while more qualitative action is needed regarding high-level supervision. Intelligent manufacturing systems should have the capabilities of flexibility, adaptability, and intelligence. These capabilities will require the control action to be distributed and integrated with different approaches, including smart sensing, optimal design, and intelligent learning. Finally, a typical jet dispensing system is taken as a real-world example for multiscale modeling and control.

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Particle Size and Crystal Phase Effects in Fischer-Tropsch Catalysts
Jin-Xun Liu, Peng Wang, Wayne Xu, Emiel J. M. Hensen
Engineering    2017, 3 (4): 467-476.   https://doi.org/10.1016/J.ENG.2017.04.012
Abstract   HTML   PDF (2496KB)

Fischer-Tropsch synthesis (FTS) is an increasingly important approach for producing liquid fuels and chemicals via syngas—that is, synthesis gas, a mixture of carbon monoxide and hydrogen—generated from coal, natural gas, or biomass. In FTS, dispersed transition metal nanoparticles are used to catalyze the reactions underlying the formation of carbon-carbon bonds. Catalytic activity and selectivity are strongly correlated with the electronic and geometric structure of the nanoparticles, which depend on the particle size, morphology, and crystallographic phase of the nanoparticles. In this article, we review recent works dealing with the aspects of bulk and surface sensitivity of the FTS reaction. Understanding the different catalytic behavior in more detail as a function of these parameters may guide the design of more active, selective, and stable FTS catalysts.

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The Recent Technological Development of Intelligent Mining in China
Jinhua Wang,Zenghua Huang
Engineering    2017, 3 (4): 439-444.   https://doi.org/10.1016/J.ENG.2017.04.003
Abstract   HTML   PDF (1658KB)

In the last five years, China has seen the technological development of intelligent mining and the application of the longwall automation technology developed by the Longwall Automation Steering Committee. This paper summarizes this great achievement, which occurred during the 12th Five-Year Plan (2011–2015), and which included the development of a set of intelligent equipment for hydraulic-powered supports, information transfers, dynamic decision-making, performance coordination, and the achievement of a high level of reliability despite difficult conditions. Within China, the intelligent system of a set of hydraulic-powered supports was completed, with our own intellectual property rights. An intelligent mining model was developed that permitted unmanned operation and single-person inspection on the work face. With these technologies, the number of miners on the work face can now be significantly reduced. Miners are only required to monitor mining machines on the roadway or at the surface control center, since intelligent mining can be applied to extract middle-thick or thick coal seams. As a result, miners’ safety has been improved. Finally, this paper discusses the prospects and challenges of intelligent mining over the next ten years.

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Modeling and Experimental Validation of the Electron Beam Selective Melting Process
Wentao Yan, Ya Qian, Weixin Ma, Bin Zhou, Yongxing Shen, Feng Lin
Engineering    2017, 3 (5): 701-707.   https://doi.org/10.1016/J.ENG.2017.05.021
Abstract   HTML   PDF (3552KB)

Electron beam selective melting (EBSM) is a promising additive manufacturing (AM) technology. The EBSM process consists of three major procedures: ① spreading a powder layer, ② preheating to slightly sinter the powder, and ③ selectively melting the powder bed. The highly transient multi-physics phenomena involved in these procedures pose a significant challenge for in situ experimental observation and measurement. To advance the understanding of the physical mechanisms in each procedure, we leverage high-fidelity modeling and post-process experiments. The models resemble the actual fabrication procedures, including ① a powder-spreading model using the discrete element method (DEM), ② a phase field (PF) model of powder sintering (solid-state sintering), and ③ a powder-melting (liquid-state sintering) model using the finite volume method (FVM). Comprehensive insights into all the major procedures are provided, which have rarely been reported. Preliminary simulation results (including powder particle packing within the powder bed, sintering neck formation between particles, and single-track defects) agree qualitatively with experiments, demonstrating the ability to understand the mechanisms and to guide the design and optimization of the experimental setup and manufacturing process.

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An Internet of Energy Things Based on Wireless LPWAN
Yonghua Song,Jin Lin,Ming Tang,Shufeng Dong
Engineering    2017, 3 (4): 460-466.   https://doi.org/10.1016/J.ENG.2017.04.011
Abstract   HTML   PDF (1225KB)

Under intense environmental pressure, the global energy sector is promoting the integration of renewable energy into interconnected energy systems. The demand-side management (DSM) of energy systems has drawn considerable industrial and academic attention in attempts to form new flexibilities to respond to variations in renewable energy inputs to the system. However, many DSM concepts are still in the experimental demonstration phase. One of the obstacles to DSM usage is that the current information infrastructure was mainly designed for centralized systems, and does not meet DSM requirements. To overcome this barrier, this paper proposes a novel information infrastructure named the Internet of Energy Things (IoET) in order to make DSM practicable by basing it on the latest wireless communication technology: the low-power wide-area network (LPWAN). The primary advantage of LPWAN over general packet radio service (GPRS) and area Internet of Things (IoT) is its wide-area coverage, which comes with minimum power consumption and maintenance costs. Against this background, this paper briefly reviews the representative LPWAN technologies of narrow-band Internet of Things (NB-IoT) and Long Range (LoRa) technology, and compares them with GPRS and area IoT technology. Next, a wireless-to-cloud architecture is proposed for the IoET, based on the main technical features of LPWAN. Finally, this paper looks forward to the potential of IoET in various DSM application scenarios.

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Advances in Cost-Efficient Thin-Film Photovoltaics Based on Cu(In,Ga)Se2
Michael Powalla, Stefan Paetel, Dimitrios Hariskos, Roland Wuerz, Friedrich Kessler, Peter Lechner, Wiltraud Wischmann, Theresa Magorian Friedlmeier
Engineering    2017, 3 (4): 445-451.   https://doi.org/10.1016/J.ENG.2017.04.015
Abstract   HTML   PDF (3655KB)

In this article, we discuss the leading thin-film photovoltaic (PV) technology based on the Cu(In,Ga)Se2 (CIGS) compound semiconductor. This contribution includes a general comparison with the conventional Si-wafer-based PV technology and discusses the basics of the CIGS technology as well as advances in world-record-level conversion efficiency, production, applications, stability, and future developments with respect to a flexible product. Once in large-scale mass production, the CIGS technology has the highest potential of all PV technologies for cost-efficient clean energy generation.

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A Research Review on the Key Technologies of Intelligent Design for Customized Products
Shuyou Zhang, Jinghua Xu, Huawei Gou, Jianrong Tan
Engineering    2017, 3 (5): 631-640.   https://doi.org/10.1016/J.ENG.2017.04.005
Abstract   HTML   PDF (4339KB)

The development of technologies such as big data and cyber-physical systems (CPSs) has increased the demand for product design. Product digital design involves completing the product design process using advanced digital technologies such as geometry modeling, kinematic and dynamic simulation, multi-disciplinary coupling, virtual assembly, virtual reality (VR), multi-objective optimization (MOO), and human-computer interaction. The key technologies of intelligent design for customized products include: a description and analysis of customer requirements (CRs), product family design (PFD) for the customer base, configuration and modular design for customized products, variant design for customized products, and a knowledge push for product intelligent design. The development trends in intelligent design for customized products include big-data-driven intelligent design technology for customized products and customized design tools and applications. The proposed method is verified by the design of precision computer numerical control (CNC) machine tools.

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An Intelligent Non-Collocated Control Strategy for Ball-Screw Feed Drives with Dynamic Variations
Hui Liu, Jun Zhang, Wanhua Zhao
Engineering    2017, 3 (5): 641-647.   https://doi.org/10.1016/J.ENG.2017.04.007
Abstract   HTML   PDF (1626KB)

The ball-screw feed drive has varying high-order dynamic characteristics due to flexibilities of the slender screw spindle and joints between components, and an obvious feature of non-collocated control when a direct position measurement using a linear scale is employed. The dynamic characteristics and non-collocated situation have long been the source of difficulties in motion and vibration control, and deteriorate the achieved accuracy of the axis motion. In this study, a dynamic model using a frequency-based substructure approach is established, considering the flexibilities and their variation. The position-dependent variation of the dynamic characteristics is then fully investigated. A corresponding control strategy, which is composed of a modal characteristic modifier (MCM) and an intelligent adaptive tuning algorithm (ATA), is then developed. The MCM utilizes a combination of peak filters and notch filters, thereby shaping the plant dynamics into a virtual collocated system and avoiding control spillover. An ATA using an artificial neural network (ANN) as a smooth parameter interpolator updates the parameters of the filters in real time in order to cope with the feed drive’s dynamic variation. Numerical verification of the effectiveness and robustness of the proposed strategy is shown for a real feed drive.

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Developments and Prospects of Long-Span High-Speed Railway Bridge Technologies in China
Shunquan Qin, Zongyu Gao
Engineering    2017, 3 (6): 787-794.   https://doi.org/10.1016/j.eng.2017.11.001
Abstract   PDF (3022KB)

With the rapid developments of the high-speed railway in China, a great number of long-span bridges have been constructed in order to cross rivers and gorges. At present, the longest main span of a constructed high-speed railway bridge is only 630 m. The main span of Hutong Yangtze River Bridge and of Wufengshan Yangtze River Bridge, which are under construction, will be much longer, at 1092 m each. In order to overcome the technical issues that originate from the extremely large dead loading and the relatively small structural stiffness of long-span high-speed railway bridges, many new technologies in bridge construction, design, materials, and so forth have been developed. This paper carefully reviews progress in the construction technologies of multi-function combined bridges in China, including combined highway and railway bridges and multi-track railway bridges. Innovations and practices regarding new types of bridge and composite bridge structures, such as bridges with three cable planes and three main trusses, inclined main trusses, slab-truss composite sections, and steel-concrete composite sections, are introduced. In addition, investigations into high-performance materials and integral fabrication and erection techniques for long-span railway bridges are summarized. At the end of the paper, prospects for the future development of long-span high-speed railway bridges are provided.

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Additive Design and Manufacturing of Jet Engine Parts
Pinlian Han
Engineering    2017, 3 (5): 648-652.   https://doi.org/10.1016/J.ENG.2017.05.017
Abstract   HTML   PDF (2280KB)

The additive design (AD) and additive manufacturing (AM) of jet engine parts will revolutionize the traditional aerospace industry. The unique characteristics of AM, such as gradient materials and micro-structures, have opened up a new direction in jet engine design and manufacturing. Engineers have been liberated from many constraints associated with traditional methodologies and technologies. One of the most significant features of the AM process is that it can ensure the consistency of parts because it starts from point(s), continues to line(s) and layer(s), and ends with the competed part. Collaboration between design and manufacturing is the key to success in fields including aerodynamics, thermodynamics, structural integration, heat transfer, material development, and machining. Engineers must change the way they design a part, as they shift from the traditional method of “subtracting material” to the new method of “adding material” in order to manufacture a part. AD is not the same as designing for AM. A new method and new tools are required to assist with this new way of designing and manufacturing. This paper discusses in detail what is required in AD and AM, and how current problems can be solved.

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A Comprehensive Comparison of the Analytical and Numerical Prediction of the Thermal History and Solidification Microstructure of Inconel 718 Products Made by Laser Powder-Bed Fusion
Patcharapit Promoppatum, Shi-Chune Yao, P. Chris Pistorius, Anthony D. Rollett
Engineering    2017, 3 (5): 685-694.   https://doi.org/10.1016/J.ENG.2017.05.023
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The finite-element (FE) model and the Rosenthal equation are used to study the thermal and microstructural phenomena in the laser powder-bed fusion of Inconel 718. A primary aim is to comprehend the advantages and disadvantages of the Rosenthal equation (which provides an analytical alternative to FE analysis), and to investigate the influence of underlying assumptions on estimated results. Various physical characteristics are compared among the FE model, Rosenthal equation, and experiments. The predicted melt pool shapes compared with reported experimental results from the literature show that both the FE model and the analytical (Rosenthal) equation provide a reasonably accurate estimation. At high heat input, under conditions leading to keyholing, the reported melt width is narrower than predicted by the analytical equation. Moreover, a sensitivity analysis based on choices of the absorptivity is performed, which shows that the Rosenthal approach is more sensitive to absorptivity, compared with the FE approach. The primary reason could be the effect of radiative and convective losses, which are assumed to be negligible in the Rosenthal equation. In addition, both methods predict a columnar solidification microstructure, which agrees well with experimental reports, and the primary dendrite arm spacing (PDAS) predicted with the two approaches is comparable with measurements.

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A Multiscale Understanding of the Thermodynamic and Kinetic Mechanisms of Laser Additive Manufacturing
Dongdong Gu, Chenglong Ma, Mujian Xia, Donghua Dai, Qimin Shi
Engineering    2017, 3 (5): 675-684.   https://doi.org/10.1016/J.ENG.2017.05.011
Abstract   HTML   PDF (5303KB)

Selective laser melting (SLM) additive manufacturing (AM) technology has become an important option for the precise manufacturing of complex-shaped metallic parts with high performance. The SLM AM process involves complicated physicochemical phenomena, thermodynamic behavior, and phase transformation as a high-energy laser beam melts loose powder particles. This paper provides multiscale modeling and coordinated control for the SLM of metallic materials including an aluminum (Al)-based alloy (AlSi10Mg), a nickel (Ni)-based super-alloy (Inconel 718), and ceramic particle-reinforced Al-based and Ni-based composites. The migration and distribution mechanisms of aluminium nitride (AlN) particles in SLM-processed Al-based nanocomposites and the in situ formation of a gradient interface between the reinforcement and the matrix in SLM-processed tungsten carbide (WC)/Inconel 718 composites were studied in the microscale. The laser absorption and melting/densification behaviors of AlSi10Mg and Inconel 718 alloy powder were disclosed in the mesoscale. Finally, the stress development during line-by-line localized laser scanning and the parameter-dependent control methods for the deformation of SLM-processed composites were proposed in the macroscale. Multiscale numerical simulation and experimental verification methods are beneficial in monitoring the complicated powder-laser interaction, heat and mass transfer behavior, and microstructural and mechanical properties development during the SLM AM process.

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Some Challenges of Deep Mining
Charles Fairhurst
Engineering    2017, 3 (4): 527-537.   https://doi.org/10.1016/J.ENG.2017.04.017
Abstract   HTML   PDF (4649KB)

An increased global supply of minerals is essential to meet the needs and expectations of a rapidly rising world population. This implies extraction from greater depths. Autonomous mining systems, developed through sustained R&D by equipment suppliers, reduce miner exposure to hostile work environments and increase safety. This places increased focus on “ground control” and on rock mechanics to define the depth to which minerals may be extracted economically. Although significant efforts have been made since the end of World War II to apply mechanics to mine design, there have been both technological and organizational obstacles. Rock in situ is a more complex engineering material than is typically encountered in most other engineering disciplines. Mining engineering has relied heavily on empirical procedures in design for thousands of years. These are no longer adequate to address the challenges of the 21st century, as mines venture to increasingly greater depths. The development of the synthetic rock mass (SRM) in 2008 provides researchers with the ability to analyze the deformational behavior of rock masses that are anisotropic and discontinuous—attributes that were described as the defining characteristics of in situ rock by Leopold Müller, the president and founder of the International Society for Rock Mechanics (ISRM), in 1966. Recent developments in the numerical modeling of large-scale mining operations (e.g., caving) using the SRM reveal unanticipated deformational behavior of the rock. The application of massive parallelization and cloud computational techniques offers major opportunities: for example, to assess uncertainties in numerical predictions; to establish the mechanics basis for the empirical rules now used in rock engineering and their validity for the prediction of rock mass behavior beyond current experience; and to use the discrete element method (DEM) in the optimization of deep mine design. For the first time, mining—and rock engineering—will have its own mechanics-based “laboratory.” This promises to be a major tool in future planning for effective mining at depth. The paper concludes with a discussion of an opportunity to demonstrate the application of DEM and SRM procedures as a laboratory, by back-analysis of mining methods used over the 80-year history of the Mount Lyell Copper Mine in Tasmania.

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Characteristics of Inconel Powders for Powder-Bed Additive Manufacturing
Quy Bau Nguyen, Mui Ling Sharon Nai, Zhiguang Zhu, Chen-Nan Sun, Jun Wei, Wei Zhou
Engineering    2017, 3 (5): 695-700.   https://doi.org/10.1016/J.ENG.2017.05.012
Abstract   HTML   PDF (2176KB)

In this study, the flow characteristics and behaviors of virgin and recycled Inconel powder for powder-bed additive manufacturing (AM) were studied using different powder characterization techniques. The results revealed that the particle size distribution (PSD) for the selective laser melting (SLM) process is typically in the range from 15 μm to 63 μm. The flow rate of virgin Inconel powder is around 28 s·(50 g)-1. In addition, the packing density was found to be 60%. The rheological test results indicate that the virgin powder has reasonably good flowability compared with the recycled powder. The inter-relation between the powder characteristics is discussed herein. A propeller was successfully printed using the powder. The results suggest that Inconel powder is suitable for AM and can be a good reference for researchers who attempt to produce AM powders.

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Review on Alkali Element Doping in Cu(In,Ga)Se2 Thin Films and Solar Cells
Yun Sun,Shuping Lin,Wei Li,Shiqing Cheng,Yunxiang Zhang,Yiming Liu,Wei Liu
Engineering    2017, 3 (4): 452-459.   https://doi.org/10.1016/J.ENG.2017.04.020
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This paper reviews the development history of alkali element doping on Cu(In,Ga)Se2 (CIGS) solar cells and summarizes important achievements that have been made in this field. The influences of incorporation strategies on CIGS absorbers and device performances are also reviewed. By analyzing CIGS surface structure and electronic property variation induced by alkali fluoride (NaF and KF) post-deposition treatment (PDT), we discuss and interpret the following issues: ① The delamination of CIGS thin films induced by Na incorporation facilitates CuInSe2 formation and inhibits Ga during low-temperature co-evaporation processes. ② The mechanisms of carrier density increase due to defect passivation by Na at grain boundaries and the surface. ③ A thinner buffer layer improves the short-circuit current without open-circuit voltage loss. This is attributed not only to better buffer layer coverage in the early stage of the chemical bath deposition process, but also to higher donor defect (CdCu+) density, which is transferred from the acceptor defect (VCu) and strengthens the buried homojunction. ④ The KF-PDT-induced lower valence band maximum at the absorber surface reduces the recombination at the absorber/buffer interface, which improves the open-circuit voltage and the fill factor of solar cells.

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Research Progress in the Application of Chinese Herbal Medicines in Aquaculture: A Review
Hongyu Pu, Xiaoyu Li, Qingbo Du, Hao Cui, Yongping Xu
Engineering    2017, 3 (5): 731-737.   https://doi.org/10.1016/J.ENG.2017.03.017
Abstract   HTML   PDF (1501KB)

Due to increasing safety concerns regarding human consumption of fish products, an increasing number of medicinal chemicals are prohibited from use in aquaculture. As a result, Chinese herbal medicines are being increasingly used, coining the use of the term “green medicine.” Research shows that Chinese herbal medicines have many beneficial effects on fish, including growth promotion, enhancement of disease resistance, and improvement in meat quality. Many effective ingredients have been discovered in Chinese herbal medicines, which function to promote feed intake, improve meat flavor, and increase digestive enzyme activity. They also regulate and participate in processes that improve the specific and non-specific immunity of fish; however, the composition of Chinese herbal medicines is very complex and it is often difficult to identify the effective ingredients. This article reviews the latest research and application progress in Chinese herbal medicines regarding growth and feed utilization, immunity and disease resistance, and the meat quality of cultured fish. It also discusses research on the chemical constituents of classical Chinese medicinal herbs and problems with the application of Chinese herbal medicines in fish culture. This article concludes by proposing that future studies on Chinese herbal medicines should focus on how to cheaply refine and extract the effective ingredients in classical Chinese medicinal herbs, as well as how to use them efficiently in aquaculture.

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A Review on the 3D Printing of Functional Structures for Medical Phantoms and Regenerated Tissue and Organ Applications
Kan Wang, Chia-Che Ho, Chuck Zhang, Ben Wang
Engineering    2017, 3 (5): 653-662.   https://doi.org/10.1016/J.ENG.2017.05.013
Abstract   HTML   PDF (2991KB)

Medical models, or “phantoms,” have been widely used for medical training and for doctor-patient interactions. They are increasingly used for surgical planning, medical computational models, algorithm verification and validation, and medical devices development. Such new applications demand high-fidelity, patient-specific, tissue-mimicking medical phantoms that can not only closely emulate the geometric structures of human organs, but also possess the properties and functions of the organ structure. With the rapid advancement of three-dimensional (3D) printing and 3D bioprinting technologies, many researchers have explored the use of these additive manufacturing techniques to fabricate functional medical phantoms for various applications. This paper reviews the applications of these 3D printing and 3D bioprinting technologies for the fabrication of functional medical phantoms and bio-structures. This review specifically discusses the state of the art along with new developments and trends in 3D printed functional medical phantoms (i.e., tissue-mimicking medical phantoms, radiologically relevant medical phantoms, and physiological medical phantoms) and 3D bio-printed structures (i.e., hybrid scaffolding materials, convertible scaffolds, and integrated sensors) for regenerated tissues and organs.

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Monitoring, Warning, and Control of Rockburst in Deep Metal Mines
Xia-Ting Feng,Jianpo Liu,Bingrui Chen,Yaxun Xiao,Guangliang Feng,Fengpeng Zhang
Engineering    2017, 3 (4): 538-545.   https://doi.org/10.1016/J.ENG.2017.04.013
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This paper reviews the recent achievements made by our team in the mitigation of rockburst risk. It includes the development of neural network modeling on rockburst risk assessment for deep gold mines in South Africa, an intelligent microseismicity monitoring system and sensors, an understanding of the rockburst evolution process using laboratory and in situ tests and monitoring, the establishment of a quantitative warning method for the location and intensities of different types of rockburst, and the development of measures for the dynamic control of rockburst. The mitigation of rockburst at the Hongtoushan copper mine is presented as an illustrative example.

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Nutritional and Metabolic Consequences of Feeding High-Fiber Diets to Swine: A Review
Atta K. Agyekum, C. Martin Nyachoti
Engineering    2017, 3 (5): 716-725.   https://doi.org/10.1016/J.ENG.2017.03.010
Abstract   HTML   PDF (534KB)

At present, substantial amounts of low-cost, fibrous co-products are incorporated into pig diets to reduce the cost of raising swine. However, diets that are rich in fiber are of low nutritive value because pigs cannot degrade dietary fiber. In addition, high-fiber diets have been associated with reduced nutrient utilization and pig performance. However, recent reports are often contradictory and the negative effects of high-fiber diets are influenced by the fiber source, type, and inclusion level. In addition, the effects of dietary fiber on pig growth and physiological responses are often confounded by the many analytical methods that are used to measure dietary fiber and its components. Several strategies have been employed to ameliorate the negative effects associated with the ingestion of high-fiber diets in pigs and to improve the nutritive value of such diets. Exogenous fiber-degrading enzymes are widely used to improve nutrient utilization and pig performance. However, the results of research reports have not been consistent and there is a need to elucidate the mode of action of exogenous enzymes on the metabolic and physiological responses in pigs that are fed high-fiber diets. On the other hand, dietary fiber is increasingly used as a means of promoting pig gut health and gestating sow welfare. In this review, dietary fiber and its effects on pig nutrition, gut physiology, and sow welfare are discussed. In addition, areas that need further research are suggested to gain more insight into dietary fiber and into the use of exogenous enzymes to improve the utilization of high-fiber diets by pigs.

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A Large Range Flexure-Based Servo System Supporting Precision Additive Manufacturing
Zhen Zhang, Peng Yan, Guangbo Hao
Engineering    2017, 3 (5): 708-715.   https://doi.org/10.1016/J.ENG.2017.05.020
Abstract   HTML   PDF (3529KB)

This paper presents the design, development, and control of a large range beam flexure-based nano servo system for the micro-stereolithography (MSL) process. As a key enabler of high accuracy in this process, a compact desktop-size beam flexure-based nanopositioner was designed with millimeter range and nanometric motion quality. This beam flexure-based motion system is highly suitable for harsh operation conditions, as no assembly or maintenance is required during the operation. From a mechanism design viewpoint, a mirror-symmetric arrangement and appropriate redundant constraints are crucial to reduce undesired parasitic motion. Detailed finite element analysis (FEA) was conducted and showed satisfactory mechanical features. With the identified dynamic models of the nanopositioner, real-time control strategies were designed and implemented into the monolithically fabricated prototype system, demonstrating the enhanced tracking capability of the MSL process. The servo system has both a millimeter operating range and a root mean square (RMS) tracking error of about 80?nm for a circular trajectory.

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Computational Tools for the Integrated Design of Advanced Nuclear Reactors
Nicholas W. Touran,John Gilleland,Graham T. Malmgren,Charles Whitmer,William H. Gates III
Engineering    2017, 3 (4): 518-526.   https://doi.org/10.1016/J.ENG.2017.04.016
Abstract   HTML   PDF (1656KB)

Advanced nuclear reactors offer safe, clean, and reliable energy at the global scale. The development of such devices relies heavily upon computational models, from the pre-conceptual stages through detailed design, licensing, and operation. An integrated reactor modeling framework that enables seamless communication, coupling, automation, and continuous development brings significant new capabilities and efficiencies to the practice of reactor design. In such a system, key performance metrics (e.g., optimal fuel management, peak cladding temperature in design-basis accidents, levelized cost of electricity) can be explicitly linked to design inputs (e.g., assembly duct thickness, tolerances), enabling an exceptional level of design consistency. Coupled with high-performance computing, thousands of integrated cases can be executed simultaneously to analyze the full system, perform complete sensitivity studies, and efficiently and robustly evaluate various design tradeoffs. TerraPower has developed such a tool—the Advanced Reactor Modeling Interface (ARMI) code system—and has deployed it to support the TerraPower Traveling Wave Reactor design and other innovative energy products currently under development. The ARMI code system employs pre-existing tools with strong pedigrees alongside many new physics and data management modules necessary for innovative design. Verification and validation against previous and new physical measurements, which remain an essential element of any sound design, are being carried out. This paper summarizes the integrated core engineering tools and practices in production at TerraPower.

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Universal Method for the Prediction of Abrasive Waterjet Performance in Mining
Eugene Averin
Engineering    2017, 3 (6): 888-891.   https://doi.org/10.1016/j.eng.2017.12.004
Abstract   PDF (281KB)

Abrasive waterjets (AWJs) can be used in extreme mining conditions for hard rock destruction, due to their ability to effectively cut difficult-to-machine materials with an absence of dust formation. They can also be used for explosion, intrinsic, and fire safety. Every destructible material can be considered as either ductile or brittle in terms of its fracture mechanics. Thus, there is a need for a method to predict the efficiency of cutting with AWJs that is highly accurate irrespective of material. This problem can be solved using the energy conservation approach, which states the proportionality between the material removal volume and the kinetic energy of AWJs. This paper describes a method based on this approach, along with recommendations on reaching the most effective level of destruction. Recommendations are provided regarding rational ranges of values for the relation of abrasive flow rate to water flow rate, standoff distance, and size of abrasive particles. I also provide a parameter to establish the threshold conditions for a material’s destruction initiation based on the temporary-structural approach of fracture mechanics.

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Key Technologies and Applications of the Design and Manufacturing of Non-Circular TBMs
Jianbin Li
Engineering    2017, 3 (6): 905-914.   https://doi.org/10.1016/j.eng.2017.12.002
Abstract   PDF (4190KB)

With the rapid development of the exploitation of underground space, more and more large- or superlarge-diameter tunnel-boring machines (TBMs) are being employed to construct underground space projects. At present, because conventional circular TBMs cannot completely meet the requirements of underground space exploitation regarding the cross-section and space-utilization ratio, non-circular TBMs, which are the tunneling equipment for an ideal cross-section, have become the new market growth point. This paper first presents the technical features and development status of non-circular TBMs. Next, in reference to typical projects and technological innovation, this paper investigates key techniques including shield design optimization, multi-cutterhead excavation, special-shaped segment erection, and soil conditioning in loess strata for a rectangular pipe-jacking machine and a horseshoe-shaped TBM, in order to provide a set of feasible solutions for the design, manufacture, and construction of non-circular TBMs. Relevant engineering practice shows that non-circular TBMs with customized design and manufacture have great advantages in terms of construction schedule, settlement control, and space utilization.

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Insights into the Organotemplate-Free Synthesis of Zeolite Catalysts
Yeqing Wang,Qinming Wu,Xiangju Meng,Feng-Shou Xiao
Engineering    2017, 3 (4): 567-574.   https://doi.org/10.1016/J.ENG.2017.03.029
Abstract   HTML   PDF (3194KB)

As the most important nanoporous material, zeolites, which have intricate micropores, are essential heterogeneous catalysts in industrial processes. Zeolites are generally synthesized with organic templates under hydrothermal conditions; however, this method is environmentally unfriendly and costly due to the formation of harmful gases and polluted water. This article briefly summarizes the role of organic templates and describes designed routes for the organotemplate-free synthesis of zeolites, aided by zeolite seeds and zeolite seeds solution. Furthermore, this review explicates that the micropore volume decreases with an increase of the Si/Al ratios in the organotemplate-free synthesis of zeolite products, where Na+ exists as an alkali cation. This feature is very important in directing the synthesis of zeolite catalysts with controllable Si/Al ratios under organotemplate-free conditions, and is thus important for the efficient design of zeolites.

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