A study of metallurgical simulations and mechanical analyses for casting valve products through OPEX approach

Year 2025, Volume: 5 Issue: 2, 675 - 695, 31.07.2025

Erhan Özkan

https://doi.org/10.61112/jiens.1591935

Abstract

In this study, information about the improvement of metallurgical simulations for the processes, and mechanical analyses for the designs of valves, which are generally preferred made of bronze in marine industry and thought to not be able to be improved much anymore, was shared with the operational excellence (OPEX) approach. The two-dimensional (2D) designs of the products to be analysed were made in AutoCAD, and the three-dimensional (3D) designs were made by using design and solid modelling program (Solidworks). Mechanical analyses for determining the mechanical strength of the specimens were performed with the help of finite element analysis (FEA) method by using the ANSYS software. The definition of the fluid resistance and flow coefficients were carried out by using computational fluid dynamics (CFD) with the help of ANSYS fluid option. The casting stages’ simulations were carried out to define filling time, change in temperature, internal stresses, which causing micro and macro shrinkages, and solidification mechanism by using Anycasting. Simufact Forming simulation program was used for defining the parameters of disc material production by hot forging method. Minitab data analysis program was selected to provide a correlation in the torque value between the disc and the body. The total consumed energy and carbon footprint was determined by using Solidworks sustainability report. Cast body weight and production time was improved 19.46% and 26.67% respectively, and hot forged valve core disc were produced with zero defect by OPEX approach. 31.87% energy savings with a total energy consumption, and 26.05% carbon footprint improvement was achieved in existing products. Finally, 81.50% improvement in the flow coefficient and 204.89% improvement in fluid resistance coefficient has been obtained as an excellence part of this study.

Keywords

Metallurgy , Mechanical Analysis , Simulation , Casting , OPEX

OPEX yaklaşımı yoluyla döküm vana ürünleri İçin metalurjik simülasyonlar ve mekanik analizler üzerine bir çalışma

Abstract

Bu çalışmada, denizcilik sektöründe yaygın olarak bronzdan yapılan ve artık fazla geliştirilemeyeceği düşünülen vanaların tasarımlarına yönelik mekanik analizler ve proseslere yönelik metalurjik simülasyonların iyileştirilmesi hakkında bilgiler operasyonel mükemmellik (OPEX) yaklaşımı ele alınarak paylaşılmıştır. Analizi yapılacak ürünlerin iki boyutlu (2D) tasarımları AutoCAD programında, üç boyutlu (3D) tasarımları ise tasarım ve katı modelleme programı (Solidworks) kullanılarak yapılmıştır. Numunelerin mekanik dayanımlarının belirlenmesine yönelik mekanik analizler, ANSYS yazılımı kullanılarak sonlu elemanlar analizi (FEA) yöntemi yardımıyla gerçekleştirilmiştir. Akışkan direnci ve akış katsayılarının tanımı, ANSYS akışkan seçeneği yardımıyla hesaplamalı akışkanlar dinamiği (CFD) kullanılarak yapılmıştır. Anycasting kullanılarak dolum süresi, sıcaklık değişimi, mikro ve makro büzülmeye neden olan iç gerilmeler ve katılaşma mekanizmasının tanımlanması amacıyla döküm aşamalarının simülasyonları gerçekleştirilmiştir. Sıcak dövme yöntemiyle disk malzeme üretim parametrelerinin tanımlanması için Simufact Forming simülasyon programı kullanılmıştır. Minitab veri analiz programı, disk ile gövde arasındaki tork değerinde korelasyon sağlamak üzere seçilmiştir. Toplam tüketilen enerji ve karbon ayak izi Solidworks sürdürülebilirlik raporu kullanılarak belirlenmiştir. Çalışma neticesinde döküm gövde ağırlığı ve üretim süresi sırasıyla %19,46 ve %26,67 iyileştirildi ve OPEX yaklaşımıyla sıcak dövme valf göbeği diski sıfır hatayla üretildi. Toplam enerji tüketiminde %31,87 enerji tasarrufu, mevcut ürünlerde ise %26,05 karbon ayak izi iyileştirmesi sağlandı. Son olarak bu çalışmanın mükemmellik yaklaşımı neticesinde geliştirilen bir parçasında akış katsayısında %81,50, akışkan direnci katsayısında ise %204,89 iyileşme elde edilmiştir.

Keywords

Metalurji , Mekanik analiz , Simülasyon , Döküm , OPEX

References

• Elmqvist T, Andersson E, Frantzeskaki N, McPhearson T, Olsson P, Gaffney O, Folke C (2019) Sustainability and resilience for transformation in the urban century. Nature sustainability 2(4):267-273. https://doi.org/10.1038/s41893-019-0250-1
• Caniglia G, Lüderitz C, von Wirth T, Fazey I, Martín-López B, Hondrila K, Lang DJ (2021) A pluralistic and integrated approach to action-oriented knowledge for sustainability. Nature Sustainability 4(2):93-100. https://doi.org/10.1038/s41893-020-00616-z
• Joshi S, Sharma M, Bartwal S, Joshi T, Prasad M (2024) Critical challenges of integrating OPEX strategies withI 4.0 technologies in manufacturing SMEs: A few pieces of evidence from developing economies. The TQM Journal 36(1):108-138. https://doi.org/10.1108/TQM-08-2022-0245
• Fraenkel L, Wei Z, Ramsey C, Wiedmeyer C, Michaud K, Neogi T, Broniatowski DA (2021) OPEX: development of a novel overall patient experience measure to facilitate interpretation of comparison effectiveness studies. PLoS One 16(1):e0245598. https://doi.org/10.1371/journal.pone.0245598
• Brunekreeft G and Rammerstorfer M (2021) OPEX-risk as a source of CAPEX-bias in monopoly regulation. Competition and Regulation in Network Industries 22(1):20-34. https://doi.org/10.1177/1783591720983184
• Latif MA, Bedewi M, Abdullayev A, Al Saadi N, Saleem BM, Al Bairaq AM, Al Ameri AF (2019) Holistic approach to prolong giant onshore abu dhabi gas field production plateau and optimize CAPEX/OPEX using an ıntegrated asset model as a digital twin. In Abu Dhabi International Petroleum Exhibition and Conference (p. D031S066R002) SPE. https://doi.org/10.2118/197659-MS
• Cahyo W N (2019) A proposed framework to apply operational excellence (opex) as a business strategy. JEMIS (Journal of Engineering & Management in Industrial System) 7(1):15-24. https://doi.org/10.21776/ub.jemis.2019.007.01.3
• Morell-Santandreu O, Santandreu-Mascarell C, García-Sabater J (2020) Sustainability and kaizen: business model trends in healthcare. Sustainability 12(24):10622. https://doi.org/10.3390/su122410622
• Singh H, Li C, Cheng P, Wang X, Hao G, Liu Q (2023) Real-time optimization and decarbonization of oil and gas production value chain enabled by industry 4.0 technologies: a critical review. SPE Production & Operations 38(03):433-451. https://doi.org/10.2118/214301-PA
• Goyal A, Agrawal R, Chokhani RK, Saha C (2019) Waste reduction through kaizen approach: a case study of a company in India. Waste Management & Research 37(1):102-107. https://doi.org/10.1177/0734242X18796205
• Senapathi M and Drury‐Grogan ML (2021) Systems thinking approach to implementing kanban: a case study. Journal of Software: Evolution and Process 33(4):e2322. https://doi.org/10.1002/smr.2322
• Alaidaros H, Omar M, Romli R (2021) The state of the art of agile kanban method: challenges and opportunities. Independent Journal of Management & Production 12(8):2535-2550. https://doi.org/10.14807/ijmp.v12i8.1482
• Kumar H, Bhinde T, Dias E, Billiter T (2020) Leveraging ıntegrated production modeling and digital platforms to maximize liquid yield and reduce opex from liquid-rich marcellus reservoirs–a field study. In SPE Annual Technical Conference and Exhibition (p. D041S052R004) SPE. https://doi.org/10.2118/201746-MS
• Spagnolo S, Corti L, Guglielmo C, Luppina S, Maliardi A, Nambiar V, Mollaev A (2019) Cable deployed esp-solution to decrease opex reducing workover needs and retrofitting existing completion. In Abu Dhabi International Petroleum Exhibition and Conference (p. D031S083R003) SPE. https://doi.org/10.2118/197596-MS
• Dalri-Cecato L, Battistelli AA, Lapolli FR (2020) Capex and opex evaluation of a membrane bioreactor aiming at water reuse. Water, Energy and Food Nexus in the Context of Strategies for Climate Change Mitigation 137-152. https://doi.org/10.1007/978-3-030-57235-8_12
• Al-Jumah A, Saadi F, Harthy K, Lawati S, Khaburi S, Battashi F, Harthi M (2019) Taking a nap: passive eor ımplementation for resilient management of cost and opex for a polymer flood project with horizontal wells in south sultanate of oman. In SPE Gas & Oil Technology Showcase and Conference (p. D021S013R002) SPE. https://doi.org/10.2118/198671-MS
• Beskorovainyi V, Petryshyn L, Shevchenko O (2020) Specific subset effective option in technology design decisions. Applied Aspects of Information Technology 3(1):443-455. https://doi.org/10.15276/aait.01.2020.6
• Desing H, Widmer R, Beloin-Saint-Pierre D, Hischier R, Wäger P (2019) Powering a sustainable and circular economy-an engineering approach to estimating renewable energy potentials within earth system boundaries. Energies 12(24):4723. https://doi.org/10.3390/en12244723
• Sebastián-Heredero E (2020) Universal desing learning guidelines. Revista Brasileira de Educacao Especial, 26(4):733-768. https://doi. org/10.1590/1980-54702020v26e0155
• Mariotti N, Bonomo M, Fagiolari L, Barbero N, Gerbaldi C, Bella F, Barolo C (2020) Recent advances in eco-friendly and cost-effective materials towards sustainable dye-sensitized solar cells. Green chemistry 22(21):7168-7218. 10.1039/D0GC01148G
• Brouwer W, van Baal P, van Exel J, Versteegh M (2019) When is it too expensive? cost-effectiveness thresholds and health care decision-making. The European Journal of Health Economics 20:175-180. https://doi.org/10.1007/s10198-018-1000-4
• Ezeilo UR, Lee CT, Huyop F, Zakaria II, Wahab RA (2019) Raw oil palm frond leaves as cost-effective substrate for cellulase and xylanase productions by trichoderma asperellum uc1 under solid-state fermentation. Journal of Environmental Management 243:206-217. https://doi.org/10.1016/j.jenvman.2019.04.113
• Brancalion PH, Meli P, Tymus JR, Lenti FE, Benini RM, Silva APM, Holl KD (2019) What makes ecosystem restoration expensive? a systematic cost assessment of projects in Brazil. Biological Conservation 240:108274. https://doi.org/10.1016/j.biocon.2019.108274
• Yang D, Yan Q, Zhu E, Lv J, He WM (2022) Carbon–sulfur bond formation via photochemical strategies: an efficient method for the synthesis of sulfur-containing compounds. Chinese Chemical Letters 33(4):1798-1816. https://doi.org/10.1016/j.cclet.2021.09.068
• Minh B Q, Schmidt HA, Chernomor O, Schrempf D, Woodhams MD, Von Haeseler A, Lanfear R (2020) Iq-tree 2: new models and efficient methods for phylogenetic inference in the genomic era. Molecular biology and evolution 37(5):1530-1534. https://doi.org/10.1093/molbev/msaa015
• Xie E, Wang W, Yu Z, Anandkumar A, Alvarez JM, Luo P (2021) Segformer: simple and efficient design for semantic segmentation with transformers. Advances in neural information processing systems 34:12077-12090.
• Dong Y, Su H, Wu B, Li Z, Liu W, Zhang T, Zhu J (2019) Efficient decision-based black-box adversarial attacks on face recognition. In proceedings of the IEEE/CVF conference on computer vision and pattern recognition pp 7714-7722.
• Aghahosseini A, Khosravifard A, Bui TQ (2019) Efficient analysis of dynamic fracture mechanics in various media by a novel meshfree approach. Theoretical and Applied Fracture Mechanics 99:161-176. https://doi.org/10.1016/j.tafmec.2018.12.002
• Ren J, Cao JP, Zhao XY, Yang FL, Wei XY (2019) Recent advances in syngas production from biomass catalytic gasification: a critical review on reactors, catalysts, catalytic mechanisms and mathematical models. Renewable and Sustainable Energy Reviews 116:109426. https://doi.org/10.1016/j.rser.2019.109426
• Godam EG, Omego C, Ochonogor C (2019) Dissecting excellence theory in public relations practices of electricity distribution companies in Nigeria. International Journal of English Language and Communication Studies 5(2):14-25.
• Aithal PS (2021) Business excellence through the theory of accountability. International Journal of Case Studies in Business, IT, and Education (IJCSBE) 5(1):88-115. https://mpra.ub.uni-muenchen.de/107894/
• Bashir M (2019) Toward excellence in public relations: identifying practices and barriers in Kuwaiti corporate, governmental and non-profit organizations. Journal of Public Relations Research 31(3-4):118-132. https://doi.org/10.1080/1062726X.2019.1679633
• Mohamadi L, Hejazi Dinan P, Shamsipour P (2020) The effectiveness of enabling environment for ıq, excellence, and social skills: a function of dynamic systems theory. Motor Behavior 12(39):69-88. https://doi.org/10.22089/mbj.2018.5141.1598
• Clavé N and Estécahandy M (2023) Optimizing the balance between production availability, capex and opex of projects while managing environmental aspects with a simulation tool. Abu Dhabi International Petroleum Exhibition and Conference SPE. https://doi.org/10.2118/216865-MS
• Ioannou A, Andrew A, Brennan F (2018) Parametric capex, opex, and lcoe expressions for offshore wind farms based on global deployment parameters. Energy Sources, Part B: Economics, Planning, and Policy 13(5):281-290. https://doi.org/10.1080/15567249.2018.1461150
• Bovera F, Schiavo LL, Vailati R (2024) Combining forward-looking expenditure targets and fixed opex-capex shares for a future-proof ınfrastructure regulation: the ross approach in Italy. Current Sustainable/Renewable Energy Reports 1-11. https://doi.org/10.1007/s40518-024-00239-4
• Antony J, Sony M, Lameijer B, Bhat S, Jayaraman R, Gutierrez L (2024) Towards a design science research (dsr) methodology for operational excellence (OPEX) initiatives. The TQM Journal 36(8):2383-2397. https://doi.org/10.1108/TQM-01-2023-0017
• Pató Z, Baker P, Rosenow J (2019) Performance-based regulation: Aligning incentives with clean energy outcomes. Brussels: Regulatory Assistance Project (RAP). https://www.raponline.org/wp-content/uploads/2023/09/rap-zp-pb-jr-performance-based-regulation-2019-june2.pdf
• Murugan M (2024) Operational excellence (opex) through entrepreneur’s strategic business decision making and emotional contagion in the service industry. Salud, Ciencia y Tecnología-Serie de Conferencias (3) 902.
• Trakulsunti Y, Antony J, Garza-Reyes JA, Tortorella GL, Chuayjan W, Foster M (2024) An exploration of operational excellence methodologies implementation in the logistics sectors: a global study. The TQM Journal. https://doi.org/10.1108/TQM-10-2023-0313
• Tissir S, Cherrafi A, Chiarini A, Elfezazi S, Shokri A, Antony J (2024) Lean six sigma and ındustry 4.0 implementation framework for operational excellence: a case study. Total Quality Management & Business Excellence 35(9-10):1015-1053. https://doi.org/10.1080/14783363.2024.2351979