High-Performance and Sustainable Manufacturing: Bridging Precision Grinding, LCA, and Hybrid Additive Processes

The future of manufacturing demands a paradigm shift towards processes that are not only high-precision but also fundamentally sustainable and intelligently controlled. This talk will present a synthesis of research developed over the past decade, focusing on advanced manufacturing strategies that integrate efficiency, performance, and environmental responsibility, with a particular emphasis on abrasive processes and emerging hybrid technologies. The presentation is structured around three core pillars of modern manufacturing research:Precision and Performance in Abrasive Processes: We will delve into research on optimizing grinding for high-value components. This includes the development and application of patterned/textured grinding wheels to enhance performance and surface integrity, and the exploration of advanced cooling lubrication techniques, such as Cryogenic Assisted Grinding. Experimental and simulation-based studies (e.g., Finite Element Analysis on heat transfer) will be presented to quantify the gains in material removal rate, tool life, and energy efficiency, particularly when machining difficult-to-cut materials like superalloys. Sustainability Integration via Life Cycle Assessment (LCA): A critical aspect of industrial and systems engineering is the resource optimization and environmental footprint. This section will detail the application of Life Cycle Assessment (LCA) and combined hybrid modeling approaches to monitor and control manufacturing processes. Case studies will demonstrate how sustainability indicators can be effectively integrated into real-time process monitoring of machining operations to guide decision-making toward cleaner production and energy efficiency. The Nexus of Hybrid and Advanced Manufacturing: Addressing the challenges of modern industrial needs, the discussion will pivot to the use of emerging technologies. We will showcase recent work on Hybrid Manufacturing (HM), specifically combining Directed Energy Deposition (DED) additive manufacturing with High-Speed Machining (HSM). The focus will be on the critical subsequent operations, such as Laser Polishing and advanced finishing techniques, essential for achieving the stringent surface quality requirements for aerospace and high-performance applications. This presentation aims to provide the audience—engineers and researchers in Industrial and Systems Engineering—with a holistic perspective on transforming conventional manufacturing practices into high-performance, intelligent, and sustainable systems, highlighting both the technological breakthroughs and the systemic challenges remaining in the field.