Desirie C.

Alinsub BSIE-3101

Thermodynamics is a branch of science which deals with energy and work of a system. It
was discovered by Nicolas Léonard Sadi Carnot in 1824. Nicolas Léonard Sadi Carnot is known
as the "Father of Thermodynamics" for his numerous scientific discoveries, which include the
Carnot heat engine, Carnot theorem, and Carnot efficiency. Thermodynamics are observed not
only in experiments done in laboratories but, it can be also seen in our day-to-day routines or
anything under the sun. Some examples include: Sweating in a crowded room, or even a simple
melting of ice cube. Aside from that, thermodynamics is also found in several disciplines such as
Engineering; chemical, physical, and mechanical engineering are only a few examples of science
and engineering disciplines where thermodynamics can be applied.

On the other hand, it is possible that the Industrial Engineering field can also be touched
by the different principles and applications thermodynamics. Industrial engineers create systems
that help people and society achieve higher levels of production, efficiency, effectiveness, and
quality. An industrial engineer serves a dual purpose: to improve human ability to operate,
manage, and control the whole production system, as well as to assure the safety and well-being
of those who work in it. Today, industrial engineering mostly focuses on improving a system.
With the goal of increasing efficiency, ensuring that the system is doing the work it was designed
to do, and preparing the system for future occupations, among other things.

Although there are various departments that can be spearheaded by industrial engineers,
they are usually assigned to manufacturing and management departments. The process of turning
raw materials into finished goods using different tools, machinery or manual labor or even
chemical processing. According to Bureau of Economic Analysis in 2014, In terms of total
output, manufacturing is by far the most important sector of the US economy. While here in the
Philippines, Manufacturing comprises more than half of the Philippines's industrial sector and
accounts for almost a quarter of the country's Gross Domestic Product (GDP). Manufacturing
methods and equipment, and all genuine processes and systems, are subject to change. As
industrial engineers are assigned to innovate or improve processes to maintain efficiency, they
should understand the basic principles of thermodynamics that is applied to machines used in
manufacturing.
Product in Formation—The Workpiece

Via the first law, the manufactured product’s energy content is given by

dUp = δQp + δWp (1)

where δQp is the net heat transfer between the surroundings and the component during
manufacturing and δWp is the net work that transforms the material. Here, surroundings include
machinery and the immediate vicinity of the composite system. Via the second law, the entropy
change during manufacturing is given as

dSp = (δQ / Tp) + δS’p (2)

where Tp is the component’s instantaneous absolute temperature (in K) and δS’p ≥ 0 is

the produced or generated entropy in the component. The principles of minimum entropy
generation and least energy dissipation also assert that δS’p ≥ 0. In Equation (2), the first right-
hand side term is entropy transfer out of the component via heat. Equations (1) and (2) combine
to give

dUp = TpdSp − TpδS’p + δWp (3)

which can be re-arranged and combined with the component’s Helmholtz free energy A =
U −TS to give the entropy production or generation

δS’p = (δWp − dAp − SpdTp) / Tp (4)

where

dAp = dUp − TpdSp − SpdTp (5)

is the change in the component’s Helmholtz free energy, the differential minimum work
required for product manufacture or the maximum work that can be extracted/obtained from the
product in service (after manufacture). TpdSp is the heat transfer in/out of the workpiece and
SpdTp is the internal energy dissipation (within the workpiece via compositional
change/diffusion or induced at the workpiece-process interface via friction or other external
heating). Some non-thermal processes that are not temperature-controlled may yield a workpiece
temperature rise driven by the workpiece entropy content Sp, the significance of which depends
on the material properties, e.g., the coefficient of thermal expansion, melting point, and the
nature of the manufacturing process. Manufacturing processes increase the workpiece’s
Helmholtz energy—its utility or useful energy to do work—to a maximum (finished state), dAp
≥ 0, while reducing its overall utility-based entropy, dSp ≤ 0. Hence, the effect Inventions 2019,
of the relatively low non-microstructure-changing temperature rise dTp is further minimized by
the manufacturing process-reduced entropy content Sp = S0 + dSp, where S0 is the initial
material entropy content. This indicates that during most non-thermal manufacture, the last term
of Equation (5) can be neglected to simplify Equation (4) as

δS’p = (δWp − dAp) / Tp ≥ 0. (6)

The actual work δWp includes dissipative phenomena at the machine-workpiece interface
that do not contribute to the product’s desired final form, e.g., using a non-ideal cutting tool for a
machining task will increase δWp for a given dAp, and in turn, the entropy generation δS’p is
increased. Therefore, it is easily inferred that a low δS’p is desirable. As mentioned previously,
the second law prohibits negative entropy generation in all real systems/processes, i.e., δS’p ≥ 0
or δWp ≥ dAp, establishing δS’p = 0 or δWp = dAp as the limit of possibility or ideal
(reversible) case. In other words, conforming with everyday experience, one cannot obtain from
the product more than what has gone into its formation (efficiency ≥ 100% is unattainable), a
corollary of the second law known as the Carnot limitation.

Equation (6) further indicates that the ideal case is only possible under perfectly
isothermal conditions

dTp = 0.

 Manufacturing Equipment and Process—The Machinery

In addition to characterizing and detecting unusual phenomena at the machine-workpiece

interface, of significant interest are the efficiency and degradation of the manufacturing
equipment and process. As done for the workpiece, the energy balance of the machinery is

dUm/c = δQm/c + δWm/c (7)

where the net machine work (work that changes/degrades the machine) is

δWm/c = δWin − δWp, (8)

the difference between the input work (e.g., power supplied to the lathe or the CNC machine
during operation) and the actual product formation work. Equation (8) indicates that some of the
input power is lost between the input point and the machine-workpiece interface. Hence, a low
δWm/c is always desired. δWm/c includes all the energy conversion losses, friction, Ohmic
dissipation, corrosion, plasticity, and shaft misalignment effects, and should be resolved into
appropriate constituents based on an order of magnitude analysis of the specific system or
manufacturing process. Combine energy and entropy balance on the machinery (substituting
entropy balance and Equation (8) into Equation (7) yields

dUm/c = Tm/c

(dS − δS’)m/c + δWin − δWp. (9)

Rearranging with the Helmholtz free energy change dAm/c = dUm/c − Tm/cdSm/c −
Sm/cdTm/c, the entropy generation in the machinery is

δS’m/c = (δWin − δWp − dAm/c − Sm/cdTm/c) / Tm/c ≥ 0. (10)

Here, dAm/c is the differential ideal energy change, which can be specified via nominal
machine/process specifications, or dropped if unknown, to give an instantaneous entropy
generation for low-amplitude temperature changes (adequate for most pseudo-steady non-
thermal processes)

δS’m/c = (δWin − δWp) / Tm/c ≥ 0, (11)

the quotient of the difference between the machinery input work and actual interface work
required to manufacture the component, and the representative machine temperature. Equation
(11) includes all the dissipative phenomena taking place in the machinery during manufacture.
Note that highly dissipative processes such as friction can generate significant heat, which if not
transferred out via cooling, results in a substantial value of Sm/cdTm/c, a measure of the
interfacial thermal fluctuations. Total entropy generation in both the workpiece and the
machinery, from Equations (6) and (11),

δS’total = δS’p + δS’m/c = [(δWp − dAp) / Tp] + [(δWin − δWp) / Tm/c]. (12)

If Tp ≈ Tm/c, Equation (12) becomes δS’total = (δWin − dAp) / Tp. (14) δS’total, Equation (13),
measures the efficiency of the entire system-process interaction and can be used as a first
(overall system) analysis parameter, given its relative ease of evaluation: δWin is usually
known/measurable and dAp is easily specified and typically standardized for a product and/or
manufacturing task (e.g., drilling a hole in a thick steel plate or adding a thickener to grease in

production)—a straight line joins the Helmholtz energy states before and after the task, an
artifact of the thermodynamic state principle. With a known/measured δWp, Equations (6) and
(11) give the individual contributions from the workpiece and the machinery respectively.
Further sub-system analyses can be performed as necessary to determine the significant sources
of irreversibility in the process.

The application of thermodynamics in the Industrial Engineering field tells us that it is

not only present in chemistry or other science-related departments. Thermodynamics also exists
in the manufacturing industry, where industrial engineers usually work. In-depth knowledge of
how essential it is for the machines and workpieces, helps us understand the possible ways to
improve the system or integrate the parts of the machine. Although industrial engineers do not
solely focus on thermodynamics, we need to know its basic principle since it has something to do
with our future occupation. Our curriculum which involves a wide variety of courses corresponds
to the characteristic of the industrial engineers of being flexible and jack of all trades. As we take
courses like thermodynamics which at the beginning, seem to be irrelevant to our career, made
sense as we have researched its importance to the manufacturing industry. Therefore, the
concepts, theories, and calculations involving thermodynamics will be applied and integrated
from here and for the years to come.
References

Osara, J. (2019). Thermodynamics of Manufacturing Processes--The Workpiece and the

Machinery. https://www.researchgate.net/publication/333124779

Georgios, M. (2009). Thermodynamics for Process and Product Design.

https://www.researchgate.net/publication/285374911

Crawford, M. (2012). Nicolas Léonard Sadi Carnot. https://www.asme.org/topics-

resources/content/nicolas-leonard-sadi-carnot