The 9th Global Congress on Manufacturing and Management (GCMM2008) was held from 12-14 November in Surfers Paradise and organised by Queensland University of Technology.  As sponsors of the conference, QMI Solutions was on hand to hear about some of the latest research activities occurring in the Asia-Pacific region, and contributed to a discussion panel themed around "Sustainable Manufacturing".

The main conference had a number of themes including developments in manufacturing processes, both old and new:

• AUT University in Auckland presented information on direct metal casting through 3D printing with a specific focus on the production of mould tools.  The process utilises a Z Corp printer filled with fine sand to build sand cast moulds with a quality level similar to traditional processes, although only non-ferrous materials can currently be cast.   
• An application of optical plasma spectroscopy as a tool for monitoring laser welding processes was described by a team from the University of Bari in Italy.  The retro-fittable unit detects perturbance in the signal which can be correlated to potential defects in the weld and acts as a type of process 'fingerprint'.  
• One presentation described new micro machining centres which combine both conventional machining processes with other small-scale processes such as grinding, EDM, turning and milling.  The systems are commercially available and have been purchased by a number of academic and industrial organisations in Japan, India and the US, including NASA and Panasonic.  Features as small as 2µm are possible while the smallest hole size is 6.5µm. 
• In electrochemical machining, Tokyo University are working on producing curved holes; a hinged electrode tip is connected to a flexible tube and 2 control wires are used to control the electrode posture.  The tube can also be rotated to produce spiral holes.  Using this process a hole 90mm deep can be produced in around 5 hours.

There were two presentations that centred on advanced materials, illustrating the application of 'shape memory' materials which change their geometry under an external influence such as a magnetic field or temperature change.  Actuators and switches can be designed for applications such as drug delivery, emergency bonnet release linkages and springs.

The modelling of manufacturing processes using tools such as finite element analysis was a recurring theme:

• King Mongkuts University in Bangkok presented an analytical study to minimise the distortion resulting from non-uniform extrusion die-exit speeds.The process utilises finite element analysis to optimise the shape and offset of pockets prior to the final extrusion die.
• FEA techniques are commonly used for predicting and analysing deformation type processes and events, but have limitations for large deformations and slow strain rates.  QUT are working on meshfree techniques which offer promise in applications such as metal forming, crack propagation across multi-part assemblies, dam emptying and breakage

A number of papers considered the impact of manufacturing processes on the environment:

• A research group from Korea including Kia Motors are investigating the use of hollow cap tips for resistance spot welding.  The hollow design localises the melt pool and changes the thermal profile of the join to ensure that minimal spatter is generated.  Less spatter means less grinding, resulting in a more environmentally sympathetic process
• Professor Serge Tichkiewich from the Grenoble Institute of Technology described some of the activities underway at GIT to support recycling and reuse in mechatronics and automotive applications in particular decision support systems that evolve as the product design changes

The conference provided some early insights into forthcoming technology developments in a number of Asia-Pacific regions, and technologies of potential benefits to Queensland will be further investigated. 

If you would like any more information about the technologies and processes described here, Dr Sara Eastwood at QMI Solutions. For more information about the GCMM conference, visit http://www.bee.qut.edu.au/