Dongfang Zhao, Jacob Meves, Anirban Mondal, M. Saha, Yingtao Liu
In this paper, a multi-walled nanotube-based nanocomposite is developed for the 3D printing of embedded strain sensors in structural composites. The formulation of nanocomposites is investigated, and the optimal nanotube concentration is identified, considering multiple aspects including cost, processing capability, and printing capability. The developed nanocomposites are directly printed onto glass fiber fabrics using the material extrusion-based additive manufacturing method. Then, the 3D printed nanocomposites in the format of strain gauges are employed for the fabrication of continuous fiber-reinforced composites with embedded sensors. To demonstrate the load and strain sensing capability, composite laminate beam samples are fabricated for testing. The microstructures, potentially embedded voids, and nanoparticle distributions are characterized using a scanning electron microscope. Moreover, the load sensing functionality of the manufactured glass fiber composites using embedded nanocomposite strain gauge is characterized under 3-point bending load conditions. The sensitivity, repeatability, and reliability of the 3D printed nanocomposites are experimentally characterized using a standard mechanical testing system. Particularly, the effects of maximum load and load rates on sensitivities of the developed composites are tested. The 3D printed strain gauges can be used for the monitoring of composite integrity, indicating their safety and reliability under complex and fatigue loading conditions.
{"title":"Additive Manufacturing of Embedded Strain Sensors in Structural Composites","authors":"Dongfang Zhao, Jacob Meves, Anirban Mondal, M. Saha, Yingtao Liu","doi":"10.1115/imece2022-94366","DOIUrl":"https://doi.org/10.1115/imece2022-94366","url":null,"abstract":"\u0000 In this paper, a multi-walled nanotube-based nanocomposite is developed for the 3D printing of embedded strain sensors in structural composites. The formulation of nanocomposites is investigated, and the optimal nanotube concentration is identified, considering multiple aspects including cost, processing capability, and printing capability. The developed nanocomposites are directly printed onto glass fiber fabrics using the material extrusion-based additive manufacturing method. Then, the 3D printed nanocomposites in the format of strain gauges are employed for the fabrication of continuous fiber-reinforced composites with embedded sensors. To demonstrate the load and strain sensing capability, composite laminate beam samples are fabricated for testing. The microstructures, potentially embedded voids, and nanoparticle distributions are characterized using a scanning electron microscope. Moreover, the load sensing functionality of the manufactured glass fiber composites using embedded nanocomposite strain gauge is characterized under 3-point bending load conditions. The sensitivity, repeatability, and reliability of the 3D printed nanocomposites are experimentally characterized using a standard mechanical testing system. Particularly, the effects of maximum load and load rates on sensitivities of the developed composites are tested. The 3D printed strain gauges can be used for the monitoring of composite integrity, indicating their safety and reliability under complex and fatigue loading conditions.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"44 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131444457","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ethan Wescoat, Joshua D. Bradford, Matthew Krugh, L. Mears
Remaining Useful Life (RUL) is critical to optimizing part life and reducing maintenance costs in a predictive maintenance strategy. Current methods of remaining useful life predictions are significantly dependent on operating conditions and time as input features. However, these features do not fully encompass the variability of real-world operating conditions and notably as the bearing nears failure. This work provides an improved failure representation by exploring the underlying data distribution parameters of a bearing failure dataset generated using the Purposeful Failure Methodology under varying operating conditions and then provides a comparison to the widely used NASA/IMS bearing run-to-failure dataset. Laboratory experiments utilized a bearing test stand to capture failure states for fatigue and contamination failure mode. The fatigue and contamination failure procession is compared to the failed bearings from the NASA Bearing dataset to examine similarities in the underlying data distribution between either dataset. A Weibull distribution is then fitted to both datasets. The resulting distributions exhibit similar trends, dependent on the damage stage. Based on the fitted parameters, a decreasing trend for the Weibull parameters was influenced by the changing speed in the engraving test case with similar trends to the NASA bearing dataset. The resulting understanding of the data distribution parameters will be used to improve the end of RUL calculation by describing the distribution fit that best determines the bearing life modification numbers.
{"title":"Exploration in Using the Weibull Distribution for Characterizing Trends in Bearing Failure Operational Changes","authors":"Ethan Wescoat, Joshua D. Bradford, Matthew Krugh, L. Mears","doi":"10.1115/imece2022-95441","DOIUrl":"https://doi.org/10.1115/imece2022-95441","url":null,"abstract":"\u0000 Remaining Useful Life (RUL) is critical to optimizing part life and reducing maintenance costs in a predictive maintenance strategy. Current methods of remaining useful life predictions are significantly dependent on operating conditions and time as input features. However, these features do not fully encompass the variability of real-world operating conditions and notably as the bearing nears failure. This work provides an improved failure representation by exploring the underlying data distribution parameters of a bearing failure dataset generated using the Purposeful Failure Methodology under varying operating conditions and then provides a comparison to the widely used NASA/IMS bearing run-to-failure dataset. Laboratory experiments utilized a bearing test stand to capture failure states for fatigue and contamination failure mode. The fatigue and contamination failure procession is compared to the failed bearings from the NASA Bearing dataset to examine similarities in the underlying data distribution between either dataset. A Weibull distribution is then fitted to both datasets. The resulting distributions exhibit similar trends, dependent on the damage stage. Based on the fitted parameters, a decreasing trend for the Weibull parameters was influenced by the changing speed in the engraving test case with similar trends to the NASA bearing dataset. The resulting understanding of the data distribution parameters will be used to improve the end of RUL calculation by describing the distribution fit that best determines the bearing life modification numbers.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125424555","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Technological advancements have led to the transition of manufacturing industries to Smart Manufacturing and Industry 4.0. Promising concepts such as Digital Twin and Digital Thread could help speed up the transition. One benefit of using digital twins is to enable continuity of lifecycle information. However, currently, most digital-twin implementations focus on modeling a particular lifecycle stage of a physical element in “silos”. This makes companies missing out on up to 65% of possible value of digital twin investments. This also results in it challenging to incorporate diverse data streams from different lifecycle stages. Digital thread has been used to represent information flow along the product lifecycle. Using information across product lifecycle stages will facilitate interoperability and reusability of digital twins. Because data from each lifecycle stage could be accessed and managed systematically, this will ensure the value and the credibility of the digital twin. A lot of confusion still remains in industry about what are digital twin and digital thread as well as their relationships. Using lifecycle data from a digital thread for digital twin implementation is complex because of the heterogeneity of standards and technologies involved. In this paper, we provide definitions of both digital twin and digital thread; we highlight the benefit of using them for interoperability and reusability of a digital twin for product lifecycle management and analysis; we propose a methodology for implementing digital twins using lifecycle data supported by a digital thread. Finally, we showcase the proposed methodology by providing an example of integrating digital twins with a digital thread.
{"title":"A Methodology for Digital Twins of Product Lifecycle Supported by Digital Thread","authors":"Laetitia V. Monnier, Guodong Shao, S. Foufou","doi":"10.1115/imece2022-95182","DOIUrl":"https://doi.org/10.1115/imece2022-95182","url":null,"abstract":"\u0000 Technological advancements have led to the transition of manufacturing industries to Smart Manufacturing and Industry 4.0. Promising concepts such as Digital Twin and Digital Thread could help speed up the transition. One benefit of using digital twins is to enable continuity of lifecycle information. However, currently, most digital-twin implementations focus on modeling a particular lifecycle stage of a physical element in “silos”. This makes companies missing out on up to 65% of possible value of digital twin investments. This also results in it challenging to incorporate diverse data streams from different lifecycle stages. Digital thread has been used to represent information flow along the product lifecycle. Using information across product lifecycle stages will facilitate interoperability and reusability of digital twins. Because data from each lifecycle stage could be accessed and managed systematically, this will ensure the value and the credibility of the digital twin. A lot of confusion still remains in industry about what are digital twin and digital thread as well as their relationships. Using lifecycle data from a digital thread for digital twin implementation is complex because of the heterogeneity of standards and technologies involved. In this paper, we provide definitions of both digital twin and digital thread; we highlight the benefit of using them for interoperability and reusability of a digital twin for product lifecycle management and analysis; we propose a methodology for implementing digital twins using lifecycle data supported by a digital thread. Finally, we showcase the proposed methodology by providing an example of integrating digital twins with a digital thread.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"43 8","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"113941984","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Simon A. Schiele, C. Rehekampff, Andreas Schroeffer, Laurin Schweigert, T. C. Lueth
High prices and complex control are still an inhibitor to the wider use of robotic systems. Additive Manufacturing in combination with automated design, on the one hand, enables the low-cost production of robots and mechanism and, on the other hand, creates new possibilities for fabricating innovative systems, such as continuum robots and compliant mechanisms. The problem thereby is not the manufacturing itself but the design of the necessary individual models specified for certain additive manufacturing processes, which is complex and needs expert knowledge. This work deals with the design of snake-like compliant mechanisms and proposes an automated framework to design mechanisms for specified end-effector poses. Using rolling-contact flexure joints designed for fused deposition modeling (FDM) 3D printing, flexible segments are developed, which can be assembled to form a task-specific mechanism. Only with the specification of the end-effector configurations and few geometric boundary conditions all surface models for printing this mechanism with FDM are generated automatically. Furthermore, an approach to improve the accuracy of these mechanisms, regardless of the used 3D printer, is presented.
{"title":"Automated Design of FDM-Printable Snake-Like Compliant Mechanisms With Predefined End-Effector Poses","authors":"Simon A. Schiele, C. Rehekampff, Andreas Schroeffer, Laurin Schweigert, T. C. Lueth","doi":"10.1115/imece2022-96568","DOIUrl":"https://doi.org/10.1115/imece2022-96568","url":null,"abstract":"\u0000 High prices and complex control are still an inhibitor to the wider use of robotic systems. Additive Manufacturing in combination with automated design, on the one hand, enables the low-cost production of robots and mechanism and, on the other hand, creates new possibilities for fabricating innovative systems, such as continuum robots and compliant mechanisms. The problem thereby is not the manufacturing itself but the design of the necessary individual models specified for certain additive manufacturing processes, which is complex and needs expert knowledge. This work deals with the design of snake-like compliant mechanisms and proposes an automated framework to design mechanisms for specified end-effector poses. Using rolling-contact flexure joints designed for fused deposition modeling (FDM) 3D printing, flexible segments are developed, which can be assembled to form a task-specific mechanism. Only with the specification of the end-effector configurations and few geometric boundary conditions all surface models for printing this mechanism with FDM are generated automatically. Furthermore, an approach to improve the accuracy of these mechanisms, regardless of the used 3D printer, is presented.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116758853","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Mahmudul Hassan, Sk Md Alimuzzaman, Jianfeng Ma, M. Jahan
One of the shortcomings of 3D printed or laminated carbon fiber reinforced polymer (CFRP) composites is that their dimensional precision and surface finish fall short of the normal tolerance requirements for most industrial applications. Machining is often necessary as a post-processing step to get the CFRP parts in appropriate form. This research uses numerical modeling and simulation with ABAQUS/Explicit, a commercially available sophisticated finite element analysis (FEA) software program, to compare the machining behavior and post-processing capabilities of laminated and 3D printed CFRP composites. The effects of machining parameters, such as, feed, cutting speed and depth of cut (DOC), and 3D printing parameters like percentage of overlap between neighboring passes and layer heights, have been investigated. Cutting forces, strain, chip and burr development, and the consequent surface topology have all been used to assess the post-processing capability or machining behavior of CFRPs. A 3D model was built using appropriate damage initiation and propagations factors such as ductile and shear damage, as well as the Johnson-Cook criteria for plasticity. C3D8R elements, which are 8-node brick elements, were used to mesh each layer of the laminated workpiece model. For 3D printed models, linear tetrahedral elements, also known as C3D4T, were employed to capture changes in elemental level. The cutting and thrust forces generated increased as the DOC, cutting speed and feed rate increased. Chip formation was primarily controlled by stiffness and flute shape of the cutting tool, and 3D print direction. It was seen that the surface quality is better for laminated CFRPs. The highest cutting force obtained are found to have an essentially proportional correlation with feed, layer height, and spindle speed. Finally, the findings are persuasive, and they may be utilized to direct actual machining operations and achieve the required results.
{"title":"A Comparative Numerical Investigation on Machining of Laminated and 3D Printed CFRP Composites","authors":"Mahmudul Hassan, Sk Md Alimuzzaman, Jianfeng Ma, M. Jahan","doi":"10.1115/imece2022-95257","DOIUrl":"https://doi.org/10.1115/imece2022-95257","url":null,"abstract":"\u0000 One of the shortcomings of 3D printed or laminated carbon fiber reinforced polymer (CFRP) composites is that their dimensional precision and surface finish fall short of the normal tolerance requirements for most industrial applications. Machining is often necessary as a post-processing step to get the CFRP parts in appropriate form. This research uses numerical modeling and simulation with ABAQUS/Explicit, a commercially available sophisticated finite element analysis (FEA) software program, to compare the machining behavior and post-processing capabilities of laminated and 3D printed CFRP composites. The effects of machining parameters, such as, feed, cutting speed and depth of cut (DOC), and 3D printing parameters like percentage of overlap between neighboring passes and layer heights, have been investigated. Cutting forces, strain, chip and burr development, and the consequent surface topology have all been used to assess the post-processing capability or machining behavior of CFRPs. A 3D model was built using appropriate damage initiation and propagations factors such as ductile and shear damage, as well as the Johnson-Cook criteria for plasticity. C3D8R elements, which are 8-node brick elements, were used to mesh each layer of the laminated workpiece model. For 3D printed models, linear tetrahedral elements, also known as C3D4T, were employed to capture changes in elemental level. The cutting and thrust forces generated increased as the DOC, cutting speed and feed rate increased. Chip formation was primarily controlled by stiffness and flute shape of the cutting tool, and 3D print direction. It was seen that the surface quality is better for laminated CFRPs. The highest cutting force obtained are found to have an essentially proportional correlation with feed, layer height, and spindle speed. Finally, the findings are persuasive, and they may be utilized to direct actual machining operations and achieve the required results.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"23 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115248189","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
X-ray computed tomography scans are being increasingly employed as a non-destructive testing method for the detection of internal defects and material identification. However, mean Hounsfield Unit (HU) measurements for many metals and alloys are unreported in the literature due to the high HU values of metals and their alloys and also due to the wide range of possible combinations of X-ray scanning parameters. For this reason, developing a method that can accurately predict the mean Hounsfield unit value of a material given its elemental composition and mean Hounsfield measurements of its constituent elements is valuable and can help fill the gap for under-reported materials. In this study, first, the mean Hounsfield values for AA2011 are predicted using two methods based on the mixture model. Second, the effect of the X-ray scanning parameters on the predictive accuracy of the mean Hounsfield Unit value for AA2011 is studied. To this end, X-ray CT scans are performed at three X-ray tube current levels (50, 100, and 200 mAs) and two tube voltage levels (120 and 140kVp). Also considered is the effect of scan window size (field of scan view) as represented by voxel size where three sizes (0.00287, 0.0176, and 0.0452 mm3) are utilized. The effect of sample thickness is assessed via three thickness levels (1.5, 3, and 6 mm). The findings show that both methods show good predictive ability with the second method showing greater accuracy.
{"title":"Predicting the Hounsfield Unit (HU) of Aluminum Alloy AA2011 From the Weight Fractions of its Alloying Elements: An X-Ray Computed Tomography Study","authors":"A. Baydoun, R. Hamade","doi":"10.1115/imece2022-95313","DOIUrl":"https://doi.org/10.1115/imece2022-95313","url":null,"abstract":"\u0000 X-ray computed tomography scans are being increasingly employed as a non-destructive testing method for the detection of internal defects and material identification. However, mean Hounsfield Unit (HU) measurements for many metals and alloys are unreported in the literature due to the high HU values of metals and their alloys and also due to the wide range of possible combinations of X-ray scanning parameters. For this reason, developing a method that can accurately predict the mean Hounsfield unit value of a material given its elemental composition and mean Hounsfield measurements of its constituent elements is valuable and can help fill the gap for under-reported materials.\u0000 In this study, first, the mean Hounsfield values for AA2011 are predicted using two methods based on the mixture model. Second, the effect of the X-ray scanning parameters on the predictive accuracy of the mean Hounsfield Unit value for AA2011 is studied. To this end, X-ray CT scans are performed at three X-ray tube current levels (50, 100, and 200 mAs) and two tube voltage levels (120 and 140kVp). Also considered is the effect of scan window size (field of scan view) as represented by voxel size where three sizes (0.00287, 0.0176, and 0.0452 mm3) are utilized. The effect of sample thickness is assessed via three thickness levels (1.5, 3, and 6 mm). The findings show that both methods show good predictive ability with the second method showing greater accuracy.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"14 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125015605","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Vilma Fernström, Johan Lööf, A. Frampton, Lena Brunnacker, Kristina Wärmefjord, R. Söderberg
In this paper the focus is on variation analysis for composite CFRP (carbon fibre reinforced polymers) parts. A detailed study of possible sources of variation in manufacturing of CFRP parts is presented. Based on the variables identified a simulation chain on how to manage and simulate this variation is described. This paper also presents a logical approach to how a digital twin for a fully automated production line of compression molded CFRP parts can be built, and to investigate and quantify how much each individual variable contributes to the final variation in the component.
{"title":"Variation Analysis of Carbon Fibre Reinforced Polymers Light Weight Aero Engine Parts","authors":"Vilma Fernström, Johan Lööf, A. Frampton, Lena Brunnacker, Kristina Wärmefjord, R. Söderberg","doi":"10.1115/imece2022-95539","DOIUrl":"https://doi.org/10.1115/imece2022-95539","url":null,"abstract":"\u0000 In this paper the focus is on variation analysis for composite CFRP (carbon fibre reinforced polymers) parts. A detailed study of possible sources of variation in manufacturing of CFRP parts is presented. Based on the variables identified a simulation chain on how to manage and simulate this variation is described. This paper also presents a logical approach to how a digital twin for a fully automated production line of compression molded CFRP parts can be built, and to investigate and quantify how much each individual variable contributes to the final variation in the component.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128991470","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The current massive use of machine learning and the 5G networks have supported the high demand for the digital twin and made it more popular and common in the industrial sector and scientific research related to smart manufacturing. As part of this research study, the currently available opportunities for smart manufacturing using digital twins have been reviewed and discussed in the industry 4.0 field. While digital twins have garnered much attention in the industrial internet of things, their use in smart manufacturing has been much less common. This discussion here focuses on the open challenges in smart manufacturing and industry 4.0 and suggests that in some cases. Digital twins should be treated differently to enhance industrial processes and smart manufacturing applications. On the other hand, this research examines the impact of digital twins on smart manufacturing and sustainable production rates, aiming to promote the industry’s digital transformation to meet the required production rate. The research discussed the digital twin concept and its origins and perspectives from academia and industrial sectors. It reveals its potential for the digitalization of manufacturing. Also, the review discussed how the digital twins could support the integrated, flexible, and collaborative manufacturing environments associated with the fourth industrial revolution. Different industrial operational technologies and communication technologies have profoundly changed smart manufacturing. Intelligent and automated information exchange, automated machine control, and interoperable production systems have all been enabled by Industry 4.0. System-level CPS and digital twins can collaborate through Smart Service Platforms for Digital Twins. In addition to optimizing production configurations, the digital twin is used to determine the impact of decisions made during modifications or upgrades. By analyzing the predictive maintenance of manufacturing lines, the time between production delays will be reduced. A specific alarm or notification will be sent to the user to enable them to take quick action. A digital twin application analyzes and simulates data by controlling, monitoring, and optimizing variables based on various factors in both online and offline modes. This study seeks to evaluate the evolution of digital twin concepts and their relevance to smart manufacturing. It summarized and explained the current state of digital twins in manufacturing literature, highlighting future directions for studies and the highest potential for future applications.
{"title":"A Review of the Design and Implementation of Digital Twins for Smart Manufacturing","authors":"Shafahat Ali, S. Abdallah, S. Pervaiz","doi":"10.1115/imece2022-97113","DOIUrl":"https://doi.org/10.1115/imece2022-97113","url":null,"abstract":"\u0000 The current massive use of machine learning and the 5G networks have supported the high demand for the digital twin and made it more popular and common in the industrial sector and scientific research related to smart manufacturing. As part of this research study, the currently available opportunities for smart manufacturing using digital twins have been reviewed and discussed in the industry 4.0 field. While digital twins have garnered much attention in the industrial internet of things, their use in smart manufacturing has been much less common. This discussion here focuses on the open challenges in smart manufacturing and industry 4.0 and suggests that in some cases. Digital twins should be treated differently to enhance industrial processes and smart manufacturing applications. On the other hand, this research examines the impact of digital twins on smart manufacturing and sustainable production rates, aiming to promote the industry’s digital transformation to meet the required production rate. The research discussed the digital twin concept and its origins and perspectives from academia and industrial sectors. It reveals its potential for the digitalization of manufacturing. Also, the review discussed how the digital twins could support the integrated, flexible, and collaborative manufacturing environments associated with the fourth industrial revolution.\u0000 Different industrial operational technologies and communication technologies have profoundly changed smart manufacturing. Intelligent and automated information exchange, automated machine control, and interoperable production systems have all been enabled by Industry 4.0. System-level CPS and digital twins can collaborate through Smart Service Platforms for Digital Twins. In addition to optimizing production configurations, the digital twin is used to determine the impact of decisions made during modifications or upgrades. By analyzing the predictive maintenance of manufacturing lines, the time between production delays will be reduced. A specific alarm or notification will be sent to the user to enable them to take quick action. A digital twin application analyzes and simulates data by controlling, monitoring, and optimizing variables based on various factors in both online and offline modes. This study seeks to evaluate the evolution of digital twin concepts and their relevance to smart manufacturing. It summarized and explained the current state of digital twins in manufacturing literature, highlighting future directions for studies and the highest potential for future applications.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"63 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122286020","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Cyber-Manufacturing Systems (CMS) are vulnerable to cyber-manufacturing attacks ironically because of its very beneficial advance: seamless integration with informational and operational entities. Beyond traditional cyber-attack practices, attackers against CMS have an enlarged attack vectors to penetrate CMS through and have a broader spectrum of eventual consequences. Although the significance of this new problem started being widely recognized, actual occurrences of cyber-manufacturing attacks — that can provide useful empirical data — have been relatively of a low number. Furthermore, recent research has been focused on developing solutions to prevent or detect cyber-manufacturing attacks. However, such solutions can be more effectively devised if a thorough understanding of the nature of various attacks is achieved first. To develop effective solutions against cyber-manufacturing attacks, it is of utmost important to understand motivations of the attacker, behaviors of the attacks, patterns of the attack, and impacts of these attacks. The comprehensive analysis of cyber-manufacturing attacks can be achieved by conducting an in-depth investigation of the attacks, identifying vulnerabilities caused by the attacks, and experimenting the attacks in a controlled CMS environment. This research presents how a cyber-manufacturing testbed can be utilized to achieve the above goal. It contributes toward the goal by accomplishing four tasks. First, it established a cyber-manufacturing system testbed. Second, the research identified attack surfaces in the designed testbed and performed an in-depth investigation for cyber-attacks that can infiltrate the established testbed. Based on the second task, it developed a ranking system. Finally, based on the ranking system, high-impact attack scenarios have been identified, demonstrated and analyzed on the cyber-manufacturing testbed.
{"title":"Comprehensive Analysis of Cyber-Manufacturing Attacks Using a Cyber-Manufacturing Testbed","authors":"Romesh Prasad, Y. Moon","doi":"10.1115/imece2022-94075","DOIUrl":"https://doi.org/10.1115/imece2022-94075","url":null,"abstract":"\u0000 Cyber-Manufacturing Systems (CMS) are vulnerable to cyber-manufacturing attacks ironically because of its very beneficial advance: seamless integration with informational and operational entities. Beyond traditional cyber-attack practices, attackers against CMS have an enlarged attack vectors to penetrate CMS through and have a broader spectrum of eventual consequences. Although the significance of this new problem started being widely recognized, actual occurrences of cyber-manufacturing attacks — that can provide useful empirical data — have been relatively of a low number. Furthermore, recent research has been focused on developing solutions to prevent or detect cyber-manufacturing attacks. However, such solutions can be more effectively devised if a thorough understanding of the nature of various attacks is achieved first. To develop effective solutions against cyber-manufacturing attacks, it is of utmost important to understand motivations of the attacker, behaviors of the attacks, patterns of the attack, and impacts of these attacks. The comprehensive analysis of cyber-manufacturing attacks can be achieved by conducting an in-depth investigation of the attacks, identifying vulnerabilities caused by the attacks, and experimenting the attacks in a controlled CMS environment. This research presents how a cyber-manufacturing testbed can be utilized to achieve the above goal. It contributes toward the goal by accomplishing four tasks. First, it established a cyber-manufacturing system testbed. Second, the research identified attack surfaces in the designed testbed and performed an in-depth investigation for cyber-attacks that can infiltrate the established testbed. Based on the second task, it developed a ranking system. Finally, based on the ranking system, high-impact attack scenarios have been identified, demonstrated and analyzed on the cyber-manufacturing testbed.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"21 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130744399","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In dies used to cure preformed material, the top die is actuated to significant force levels. To ensure repeatability, three external V-grooves are used to guide so that the two halves are located accurately in the plane perpendicular to the designed approach direction. The kinematics of this assembly process is revealed by analysis. Infinitesimal screw theory describing the instantaneous motion, or the velocity and the corresponding reciprocal space, that of the possible force system are used to characterize the motion of the top die. Dynamic simulation with force input equations governing the local trajectory of the top die as it progressively engages with the grooves is established. We record the excursion of the top die in the plane normal to the nominal approach direction to characterize the motion. The two die halves mating before the V-grooves form line contacts is seen to be a necessary condition for self-alignment. We show that on reassembly from randomly perturbed initial conditions, only on specific design of the V groove system, the CG is moved towards a fixed position by the nesting force.
{"title":"Assembly for Enhanced Repeatability Under Planar Constraints","authors":"J. Bordoloi, J. P. Khatait, Shubhabrata Mukherjee","doi":"10.1115/imece2022-95641","DOIUrl":"https://doi.org/10.1115/imece2022-95641","url":null,"abstract":"\u0000 In dies used to cure preformed material, the top die is actuated to significant force levels. To ensure repeatability, three external V-grooves are used to guide so that the two halves are located accurately in the plane perpendicular to the designed approach direction. The kinematics of this assembly process is revealed by analysis. Infinitesimal screw theory describing the instantaneous motion, or the velocity and the corresponding reciprocal space, that of the possible force system are used to characterize the motion of the top die. Dynamic simulation with force input equations governing the local trajectory of the top die as it progressively engages with the grooves is established. We record the excursion of the top die in the plane normal to the nominal approach direction to characterize the motion. The two die halves mating before the V-grooves form line contacts is seen to be a necessary condition for self-alignment. We show that on reassembly from randomly perturbed initial conditions, only on specific design of the V groove system, the CG is moved towards a fixed position by the nesting force.","PeriodicalId":113474,"journal":{"name":"Volume 2B: Advanced Manufacturing","volume":"192 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121329825","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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