This paper describes the analysis of continuous magnetic field-assisted double-sided incremental forming (M-DSIF), a derivation of magnetic field-assisted single-point incremental forming (M-SPIF). In M-DSIF, the driving magnet remains in contact with the workpiece and does not allow for relaxation between individual steps (called contours). M-DSIF enables forming of truncated cones much faster and more accurately than M-SPIF. The number of revolutions per contour of the tool greatly impacts the resulting shape. The proposed two-step M-DSIF is a viable option for distributing material from the center toward the corners of the cone base, which minimizes localized strain in the corners.

Companies aim to adapt their shopfloors to increase the efficiency and effectiveness of their production activities, adding value to their shopfloor. However, it has become increasingly challenging to obtain an accurate and comprehensive overview of the shop floor and organisation, leading to difficulties in making operational, tactical, and strategic decisions. Existing methods to support such companies either restrict access to information or pre-determine the perspectives on the information for decision-making. This research employs a research-by-design approach to develop the digital twinning approach that can facilitate companies to develop a solution that can provide the appropriate information at the right moment and in the right perspective. To structure the digital twinning approach, key functions in the approach are outlined in a functional architecture. Two case studies demonstrate and verify the applicability and added value of the architecture in developing an information provisioning solution. The positive outcomes and experiences from these case studies highlight the potential of the digital twinning approach to facilitate companies in developing adaptable and company-specific solutions to enhance decision-making processes.

In the realm of production systems, determining the optimal segment allocation remains a central concern. While several existing models address this issue, a significant gap remains as many overlook the critical role of innovation and lack a holistic perspective. This paper presents a model that emphasizes innovation capabilities and introduces the concept of a “Technology Multiplier” underscoring the compounding influence of technology and innovation on production segment allocation decisions. Within this work, we focus on preliminary studies to establish the “Technology Multiplier” concept employing an Analytical Hierarchy Process (AHP) with sensitivity analysis. The validity of our approach is demonstrated through four case studies from three industries, illustrating the relevance of our elaborated metrics for the concept of “Technology Multipliers”. In particular, a leading automotive company uses our findings to reach a more appropriate strategic decision aligned with innovation and production growth, compared to its previous decisions. These results not only demonstrate a robust fit with our proposed metrics but also indicate that our framework lays the foundation for further research on the “Technology Multiplier”, enriching the decision-making process for production segment allocation.

The mechanistic approach is commonly implemented to predict and optimise the cutting forces in milling processes to prevent tool breakages, reduce tool wear, reduce form error, and improve surface quality. To implement this method, the cutting force coefficients (CFCs), that characterise the mechanics of the process, must be calculated. This study compares the accuracy of the predicted cutting forces for variable pitch and helix bull-nose milling tools using a rapid testing (RT) optimisation-based mechanistic CFC identification method that only requires a single angular cut with increasing radial engagement to the traditional mechanistic approach that requires several straight cuts. Along with developing a hybrid technique that combines variation in feed rate and radial engagement. The traditional radial, tangential, and axial (RTA) force model is also compared with the frictional and normal rake face (UV) force model that is independent of the local tool rake and inclination angles which is a necessary for bull nose tools. The RT and the developed hybrid CFC identification method with the UV force model predicted the average Fx, Fy and Fz cutting forces to within 7.1 %, 4.3 %, and 3.8 % error, respectively. These methods were slightly less accurate than the traditional method, however they have significant industrial benefits because they have can be used to identify CFCs with either a single cut, or from any tool-path with chip-load variation, respectively. The RTA force model predicted the average cutting forces similarly to the UV force model, however, the UV force model had lower errors using the rapid RT testing method at the extreme corners of the experimental design space.

This paper presents an innovative digital tooth surface precision control model(DTS-PCM) for spiral bevel gears, focusing on the contact parameters derived from the surface synthesis method(SSM) and the pinion tooth surface contact control parameters under Gleason expert manufacturing system(GEMS). This model enables the direct derivation of tooth cutting adjustment parameters for Gleason machine tools, facilitating a seamless integration of design theory with practical processing. Firstly, a novel method for accurately determining the curvature parameters of pinion tooth surfaces, based on predefined contact parameters, has been developed using ease-off topology. Then, based on the pinion gear cutting pitch cone model, a coupled tooth line vector transformation model is proposed to calculate the principal curvature parameters of the nodes. Additionally, a set of equations for the pinion tooth surface contact control parameters is derived, and a formula for calculating the pinion gear cutting adjustment parameters is provided. Finally, two sets of pinion tooth surface contact control parameters were obtained using DTS-PCM: the calculated tooth contact analysis(TCA) and ease-of-topology results. The findings demonstrate that the proposed method is largely consistent with the outcomes of the GEMS calculations, thereby validating the accuracy of DTS-PCM. This indicates that the method can be directly integrated with GEMS software, facilitating practical applications that shorten the design and processing cycle.

The 5G mobile communication standard can potentially meet the networking requirements for different industrial use cases simultaneously due to the promised low latency, high bandwidth, and high device density while providing a high quality of service. These capabilities enable the realization of digital twins (DTs) that are based on edge computing for time- and safety-critical wireless applications. However, the investigation of the applicability of 5G for DTs in real-world manufacturing scenarios is still lacking. In this work, we have evaluated a DT based on edge-computing and 5G mobile communication using extensive experiments. We have focused on the communication technology and requirements needed to enable functionalities on edge devices. The key contribution of this paper is a comprehensive experimental study on 5G performance characteristics in an existing manufacturing system. Moreover, the influence of 5G on the functionality of the edge-based DT is evaluated and discussed. Full factorial experiments with different network configurations are designed and conducted. The performance of communication characteristics (latency, jitter) is evaluated as well as the impact on the continuity between real and digital processes. The results are also compared with the WiFi standard by experimental evaluation. At last, the limits of current 5G networks for manufacturing are discussed.

The Battery Thermal Management System rely heavily on cold plates. Manufacturing cost effective, highly productive cold plates having integrated channels is promising solution for thermal management. Friction Stir Channeling is a newly developed and promising manufacturing process for the formation of integrated functional channels on metal blocks for cold plate applications. This research presents the solution to control over channel surface roughness, catering to thermal management system requirements, and shows that it is achievable by manipulating factors like heat input, plasticization effect, and process pitch (v/ω). The study establishes the correlations between important channel features and secondary parameters like pseudo heat index (PHI), flow stress (σf), and changes in thermal history. Notably, the study highlights the pivotal role of channel roughness as a key determinant of corrosion initiation within the channel through an electrochemical corrosion test. Additionally, the FSC process is found to impart lower compressive residual stresses adding to the advantages of the process.

The use of Virtual Machining models may be a valuable approach in the designing stage of a machining operation as long as the models are sufficiently accurate. When vibration risks are suspected, stability analysis approaches to predict regenerative chatter phenomena are generally used. However, although these approaches, when applicable, allow efficient numerical optimization of the process around an operating point, they often require other strong assumptions such as neglecting transient phenomena or oversimplifying kinematics. On the other hand, time domain approaches with detailed matter removal modelling allow to monitor the continuous evolution of cutting conditions and represent various phenomena that the models can reproduce (regenerative chatter, forced vibrations, non-linear behaviours). The amount of data produced is, however, considerable and often costly to analyse. It may therefore be interesting to deduce, from these data, scalar indicators allowing easier and more relevant analysis of the simulation results.In this work, the modal work of the cutting forces upon the workpiece vibratory displacements is proposed as an indicator to discriminate different tool paths. A one degree of freedom theoretical problem and a face milling operation on extruded aluminum profiles extracted from automotive structural part are used to explain and show the relevance of such indicator.

On-axis single point diamond turning experiments were performed on (111)CaF2 to investigate the effect of the resulting force system on the single crystal response. The cutting and thrust forces were measured and the resulting surface topography was characterized. The Schmid factors and fracture factors were calculated, and their ratio SfFf*was determined as a function of cutting direction and resultant force angle. It was found that this approach can be used to predict the number and location of resulting fracture lobes on the surface with respect to the lattice orientation. Two regimes with different topography were predicted when turning (111)CaF2, depending on the resultant force angle.