Integrated Manufacturing Research Articles

Innovative design and process simulation of aviation bracket based on topology optimization and additive manufacturing

Abstract In this paper, topology optimization(TO) and laser powder bed fusion (LPBF) technology were combined to explore the key technology of parts integration design and manufacturing oriented to performance, structure and manufacturing process. With the help of topology optimization(TO), the lightweight design of the aviation bracket achieved the weight loss goal of 87.69% in this work. The thermophysical properties of TC4 were calculated by thermodynamic calculation, and the temperatue interval of Laser Powder Bed Fusion for TC4 is 1800 ℃- 3000 ℃ was determined . Additionally, the LPBF macro-scale simulation was carried out. The results showed that the maximum temperature in the printing process is lower than 2500℃, and the maximum displacement is 4.87 mm, which only appears in the non-design space. Finally, the safety factor and maximum displacement of aviation bracket are 1.3 and 0.8 mm, and the maximum Mises stress is 654 MPa, all of which meet the design requirements.

Active and passive infrared emittance tuning using optically transparent unpatterned ITO thin films

Tailoring of thermal emittance has applications in smart radiators, camouflage, infrared (IR) scene generation, stealth, and thermal management. Various studies have explored avenues to achieve both passive and active emittance tuning using methods such as meta-surfaces, phase change materials, composites, nanostructure arrays and multi-layer stacks. Most of these methods often involve complex fabrication processes like multilayer depositions and micro/nano patterning, limiting their scalability for large-scale applications. This study presents a straightforward and scalable approach for passive and active emittance tuning using Indium Tin Oxide (ITO) films deposited on a high emissivity flexible polyethylene terephthalate (PET) substrate. By changing the deposition time, the thickness of the ITO film is controlled which changes the observed emissivity of the ITO/PET composite structure over a wide range (0.2–0.94) while maintaining optical transparency. Using this approach for passive emittance tuning, we demonstrate an IR scene generation application. As the ITO film is conducting, by applying voltage to the ITO/PET sheet, its temperature is changed using which active emittance tuning is also achieved. Compared to existing methods of emittance tuning, the presented approach is simpler, gives flexible films with optical transparency, and has the potential for large-scale integration, enabling cost-effective and scalable manufacturing of emittance-tuned surfaces.

High-speed, low-voltage, low-bit-energy silicon photonic crystal slow-light modulator with impedance-engineered distributed electrodes

Silicon modulators in optical transceivers feature high-density integration and low manufacturing cost, but they also need to deliver high speed and low power consumption to meet the demands of future data centers and high-performance computing. This paper demonstrates a significantly improved 64 Gbps silicon Mach–Zehnder modulator incorporating photonic crystal slow-light phase shifters. By employing distributed electrodes and engineering their impedance, electro-optic phase matching and electrical impedance matching were obtained simultaneously, and the driving voltage was reduced to 0.87 V, which is compatible with fin-type field effect transistors and eliminates the need for additional electrical amplifiers. The bit energy of as low as 59 fJ/bit is comparable to that of microring modulators, while this modulator does not require temperature control like that used for microring modulators, due to its wide working spectrum of 6 nm. These results indicate the potential for addressing power issues in next-generation data infrastructures.

Exploration and Research on the Diversified Collaborative Education Model of Intelligent Manufacturing Professional Groups under the Background of the Integration of Suzhou Wuxi Changzhou Urban Vocational Education Circle

With the rapid development of global economic integration and intelligent manufacturing, vocational education plays an important role in cultivating high-quality technical and skilled talents. As an important base for China’s economic development and intelligent manufacturing industry, the development of vocational education in the Suzhou Wuxi Changzhou metropolitan area is particularly crucial. This article analyzes the current development status and existing problems of the Suzhou Wuxi Changzhou Urban Vocational Education Circle, constructs a diversified collaborative education model for intelligent manufacturing professional groups, and verifies the effectiveness of this model in improving education quality and promoting industrial development through empirical research and case analysis. Finally, the possible challenges and response strategies in the implementation process are discussed.

Multi-Objective Optimization of Surface Integrity in the Grind-Hardening Process

Grind-hardening machining is a new integrated manufacturing technology that integrates the theory of material surface quenching and grinding machining. The surface integrity of grind-hardening directly affects the performance and reliability of the parts. Improving the grind-hardening quality has always been the focus and difficulty in this field. Based on the surface integrity theory and the characteristics of the grind-hardening process, this paper proposed four optimization criteria for grinding parameters according to the engineering application requirements of materials. Using the expectation function, the burr cross-sectional area, depth of the effective hardened layer, and surface roughness were comprehensively analyzed under each optimization criterion to obtain an optimal combination of grinding parameters. The results revealed a significant inconsistency in the optimized grinding parameters under each optimization criterion. When considering the depth of the effective hardened layer as the primary optimization parameter and ignoring the surface roughness and burr cross-sectional area, the highest overall desirability was 0.926395. In practical application, the optimization criteria should be reasonably selected according to the actual engineering requirements.

Effect of a process interruption on the mechanical properties of AlSi10Mg components produced by laser powder bed fusion (PBF-LB/M)

Due to various causes, process interruptions during powder bed fusion of metal with laser beam (PBF-LB/M) can occur. This can be performed deliberately, e.g. as part of sensor integration or hybrid manufacturing. However, unplanned interruptions are also possible, for example, due to a power outage. In particular, long-term interruptions may result in significant quality losses, making it necessary to cancel the build job. Depending on the extent of the print job and the location of the interruption, this can mean a major economic loss. Most of the previous studies have found only minor reduction of the mechanical properties. However, these studies often dealt with the effect of planned interruptions and relatively short interruptions of about 1 h. Significantly longer interruption times are also realistic, especially when they occur overnight or during weekends. The aim of this study is to investigate the effects on the component quality of a process interruption when the manufacturing process is continued several hours after the interruption. For this purpose, the effects of different interruption durations (1, 4, 10 and 16 h) on the microstructure, hardness, tensile strength and fatigue properties of the PBF-LB/M-fabricated components made of AlSi10Mg were investigated. In addition, the layer shift resulting from the interruption is measured and described geometrically. The results show that for AlSi10Mg specimens in which the layer shift was removed and which are not highly loaded, an unplanned long-term process interruption up to 10 h does not result in a significant loss of quality under the considered conditions. Furthermore, it is apparent that the procedure for restarting the process is very important for the resulting component quality.

Statistical data treatment for residence time distribution studies in pharmaceutical manufacturing

Residence time distribution (RTD) method has been widely used in the pharmaceutical manufacturing for understanding powder dynamics within unit operations and continuous integrated manufacturing lines. The dynamics thus captured is then used to develop predictive models for unit operations and important RTD-based applications ensuring product quality assurance. Despite thorough efforts in tracer selection, data acquisition, and calibration model development to obtain tracer concentration profiles for RTD studies, there can exist significant noise in these profiles. This noise can make it challenging to identify the underlying signal and get a representative RTD of the system under study. Such concerns have previously indicated the importance of noise handling for RTD measurements in literature. However, the literature does not provide sufficient information on noise handling or data treatment strategies for RTD studies. To this end, we investigate the impact of varying levels of noise using different tracers on measurement of RTD profile and its applications. We quantify the impact of different denoising methods (time and frequency averaging methods). Through this investigation, we see that Savitsky Golay filtering turns out to a good method for denoising RTD profiles despite varying noise levels. The investigation is performed such that the key features of the RTD profile (which are important for RTD based applications) are preserved. Subsequently, we also investigate the impact of denoising on RTD-based applications such as out-of-specification (OOS) analysis and RTD modeling. The results show that the degree of noise levels considered in this work do not significantly impact the RTD-based applications.

Anisotropic dynamic compression response of an ultra-high strength steel fabricated by laser hybrid additive manufacturing

Directed energy deposition (DED) is a technological innovation revolutionizing in-situ repair, hybrid manufacturing, and multi-material integration manufacturing, characterized by microstructural heterogeneity on a macro-scale. However, the overall performance of these DED-fabricated components under dynamic loading, particularly along different directions, remains uncharted. This work explores the anisotropic dynamic compression response of an ultra-high strength steel, namely 35CrMnSiA steel, fabricated using DED on a wrought substrate. The laser hybrid additive manufactured samples were subjected to split Hopkinson pressure bar testing along different directions. The results show the following: 1) hybrid manufactured 35CrMnSiA steel has an anisotropic dynamic compression response due to the mismatched properties of each subzone induced by microstructural heterogeneity, 2) low-strength DED part shows higher strain under compression along the build direction but behaves similarly to the wrought material when compressed along the transverse direction, 3) intergranular void/crack is the primary damage mechanism, cracks preferred formed in wrought substrate due to the martensite with poor plastic dissipation ability, 4) when the interface is subjected to parallel directional impact loads, the strain mismatch between the two side subzones leads to interface separation. This study provides comprehensive understanding of the dynamic behavior of DED-fabricated components with heterogenous microstructure, and new insight into demanding tailored strategies to ensure consistent and predictable behavior under various loading conditions.

Integrated Filtration and Washing Modeling: Optimization of Impurity Rejection for Filtration and Washing of Active Pharmaceutical Ingredients.

A digital design tool that can transfer material property information between unit operations to predict the product attributes in integrated purification processes has been developed to facilitate end-to-end integrated pharmaceutical manufacturing. This work aims to combine filtration and washing operations frequently using active pharmaceutical ingredient (API) isolation. This is achieved by coupling predicted and experimental data produced during the upstream crystallization process. To reduce impurities in the isolated cake, a mechanistic model-based workflow was used to optimize an integrated filtration and washing process model. The Carman-Kozeny filtration model has been combined with a custom washing model that incorporates diffusion and axial dispersion mechanisms. The developed model and approach were applied to two systems, namely, mefenamic acid and paracetamol, which are representative compounds, and various crystallization and wash solvents and related impurities were used. The custom washing model provides a detailed evolution of species concentration during washing, simulating the washing curve with the three stages of the wash curve: constant rate, intermediate stage, and diffusion stage. A model validation approach was used to estimate cake properties (e.g., specific cake resistance, cake volume, cake composition after washing, and washing curve). A global systems analysis was conducted by using the calibrated model to explore the design space and aid in the setup of the optimization decision variables. Qualitative optimization was performed in order to reduce the concentration of impurities in the final cake after washing. The findings of this work were translated into a final model to simulate the optimal isolation conditions.

Supply Chain Innovative Practices and Customer Satisfaction: Insights from Manufacturing SMEs

Abstract In today’s highly competitive business landscape, SMEs face the challenges of meeting customer demands and expectations. To remain competitive, attract and satisfy customers, manufacturing SMEs must adopt innovative practices within their supply chain. This research investigates the influence of supply chain innovative practices (SCIPs) on customer satisfaction within the context of manufacturing SMEs. A cross-sectional questionnaire survey was utilised to collect the data from 172 customers of manufacturing SMEs in Mwanza, Tanzania to gain comprehensive insights into the influence of SCIPs on customer satisfaction. Descriptive statistics and binary logistic regression (BLR) were used for data analysis. The research findings revealed that manufacturing SMEs adopt SCIPs, including digitalization and IoT integration, vendor-managed inventory, customisation, Just-In-Time, collaborative relationships, and lean manufacturing to a moderate extent. Moreover, the findings demonstrate a significant and positive correlation between SCIPs and customer satisfaction. We conclude that SMEs that successfully adopt SCIPs experience higher levels of customer satisfaction, which, in turn, positively influences customer loyalty and brand reputation. Therefore, manufacturing SMEs can capitalise on customer satisfaction, loyalty, and sustainable growth by strategizing SCIPs along their supply chain. The study contributes to the existing knowledge by providing valuable insights into the importance of SCIPs in improving customer satisfaction in manufacturing SMEs.

A MEMS Electrochemical Angular Accelerometer with Silicon-Based Four-Electrode Structure.

This paper presents a MEMS electrochemical angular accelerometer with a silicon-based four-electrode structure, which was made of thousands of interconnected microchannels for electrolyte flow, anodes uniformly coated on structure surfaces and cathodes located on the sidewalls of flow holes. From the perspective of device fabrication, in this study, the previously reported multi-piece assembly was simplified into single-piece integrative manufacturing, effectively addressing the problems of complex assembly and manual alignment. From the perspective of the sensitive structure, in this study, the silicon-based four-electrode structure featuring with complete insulation layers between anodes and cathodes can enable fast electrochemical reactions with improved sensitivities. Numerical simulations were conducted to optimize the geometrical parameters of the silicon-based four-electrode structure, where increases in fluid resistance and cathode area were found to expand working bandwidths and improve device sensitivity, respectively. Then, the silicon-based four-electrode structure was fabricated by conventional MEMS processes, mainly composed of wafer-level bonding and wafer-level etching. As to device characterization, the MEMS electrochemical angular accelerometer with the silicon-based four-electrode structure exhibited a maximum sensitivity of 1458 V/(rad/s2) at 0.01 Hz and a minimum noise level of -164 dB at 1 Hz. Compared with previously reported electrochemical angular accelerometers, the angular accelerometer developed in this study offered higher sensitivities and lower noise levels, indicating strong potential for applications in the field of rotational seismology.

The Electronics Resurgence Initiative 2.0 for U.S. Semiconductor Manufacturing

Abstract The second Electronics Resurgence Initiative (ERI 2.0), sponsored by the U.S. Defense Advanced Research Project Agency (DARPA) Microsystems Technology Office (MTO), is focused on driving next generation dual use microelectronics for national security and domestic needs. The initiative focuses on creating U.S. capability for three-dimensional heterogeneous integration (3DHI) manufacturing and pursuing focused research for the manufacture of complex 3D microsystems. This guest editorial describes the outcomes from a three-day summit (Seattle, Washington, August 2023) where the initiative was launched.

Design and Integration of a Flapping Wing Apparatus

Abstract In this paper, we presented the design, integration, and experimental verification of a flapping wing apparatus. The purpose for this apparatus is to provide a framework to study the applicability of various types of sensors on flapping wings in the presence of forward speed. This work is inspired by the discoveries of mechanosensory hairs on insect wings that perform like strain-gauge sensors. To design the apparatus, we started by kinematic analysis of a crank-slider mechanism to actuate the wings. After that, we constructed the equations of motion of the entire system to find the proper gear ratio, motor properties, and other geometric dimensions. For the aerodynamic modeling, we used a quasi-steady formulation and presented a closed-form solution for the aerodynamic torque. Then, we explained the integration process and manufacturing of the main parts and presented two prototypes for the apparatus. At the end, we showed the final constructed versions of the apparatus and presented the experimental response and compared them with the simulation.

Analyzing the role of Multi-Agent Technology in minimizing breakdown probabilities in Manufacturing Industries

Purpose Every company or manufacturing system is vulnerable to breakdowns. This research aims to analyze the role of Multi-Agent Technology (MAT) in minimizing breakdown probabilities in Manufacturing Industries.Design/methodology/approach This study formulated a framework of six factors and twenty-eight variables (explored in the literature). A hybrid approach of Multi-Criteria Decision-Making Technique (MCDM) was employed in the framework to prioritize, rank and establish interrelationships between factors and variables grouped under them.Findings The research findings reveal that the “Manufacturing Process” is the most essential factor, while “Integration Manufacturing with Maintenance” is highly impactful on the other factors to eliminate the flaws that may cause system breakdown. The findings of this study also provide a ranking order for variables to increase the performance of factors that will assist manufacturers in reducing maintenance efforts and enhancing process efficiency.Practical implications The ranking order developed in this study may assist manufacturers in reducing maintenance efforts and enhancing process efficiency. From the manufacturer’s perspective, this research presented MAT as a key aspect in dealing with the complexity of manufacturing operations in manufacturing organizations. This research may assist industrial management with insights into how they can lower the probability of breakdown, which will decrease expenditures, boost productivity and enhance overall efficiency.Originality/value This study is an original contribution to advancing MAT’s theory and empirical applications in manufacturing organizations to decrease breakdown probability.

Component integration manufacturing middleware for customized production

The cyber-physical production system requires continuous effort to integrate heterogeneous resources and code with frequent changes in components to support customized production for personalized consumer needs. First, we introduce the cloud-native concept to build component integration manufacturing middleware, to realize the unity of software and hardware components, including application, service, model, data, workflow, etc. On the edge and cloud, node services are deployed in containers to form a service mesh; microservices are orchestrated in the middleware; continuous integration and deployment are used at the frontground to design and produce. Second, by elaborating on the specific process of using the middleware for design and production, the improvement of the flexibility of customized production is demonstrated from three aspects: product, process, and resource. Last, the proposed approach is evaluated by building a customized production platform according to the middleware design concept. According to the need for different types of flexibility, corresponding experiments were designed and further verified. Experimental results show that the proposed middleware design approach can provide multiple flexibility for the production system, enabling the cyber-physical production system to support customized production.

Configurable hybrid integral manufacturing platform: subtractive-additive process with industrial robot arm, proof of concept results

Configurable hybrid integral manufacturing platform: subtractive-additive process with industrial robot arm, proof of concept results

Test Method of Secure and Controllable FPGA Chip Used in Flexible DC Transmission Control and Protection System

Flexible DC transmission control and protection system is a high-performance distributed computing system, which has the characteristics of high-speed data acquisition and fast processing, and uses a large number of high-performance FPGA (Field Programmable Logic Array) chips. FPGA has the characteristics of high integration and complex manufacturing process, and its security and controllability is faced with many challenges. The reliability of FPGA is an important standard to measure its performance, so reliability test fault screening is very important to ensure its normal operation. Although the automatic test equipment (ATE) can test the fault of FPGA, it is not convenient for field testing due to the price, test environment and other factors. In this paper, a design scheme of built-in self-test (BIST) for fault detection and fault diagnosis is proposed, which can detect faults of look-up table (LUT) and interconnection resources (wires and programmable switches). At the same time, considering the effect of rising temperature on fault probability, a controlled self-heating element (SHE) is constructed by using the internal resources of FPGA to provide the required temperature for BIST testing. Finally, an integrated layout scheme of BIST and SHE is proposed. An experiment of self-heating of FPGA chip is completed by TSINGHUA PGL22G, which verifies the correctness and feasibility of the theory.

Optimized bilateral ultrasonic surface rolling process assisting directed energy deposition of thin-walled medium-entropy alloy with high mechanical performance

Laser directed energy deposition (DED) offers significant advantages for the integral manufacturing of large-scaled thin-walled workpieces. Nevertheless, how to improve the yield strength (YS) and fatigue properties of thin-walled parts fabricated by DED is a crucial issue. As an advanced surface strengthening technology, ultrasonic surface rolling process (USRP) is aimed to improve the mechanical performances of additively manufactured workpieces. In this work, an optimized bilateral USRP parameter (including the load, repeated times, scanning speed, etc.) with high manufacturing efficiency and surface integrity was developed to fabricate thin-walled CoCrNi medium-entropy alloy (MEA) parts (~1.5mm thickness). Compared to the as-deposited sample, the sample treated by USRP shows a good strength-ductility balance (ultra-high YS and ductility with 1026.6MPa and 21.9%, respectively), as well as an impressive improvement in the high-cycle fatigue limit strength of 76.9%. The reasons for high mechanical performance are revealed through multi-scale characterization and calculation. Ultra-high strength is predominantly attributed to the high-density pre-existing dislocations and deformation twins (DTs); Good ductility is related with high hetero-deformation induced stress and the activation of multiple deformation substructures induced by high flow stress, such as dislocations, DTs and hexagonal close-packed phase. Further, the improvement in fatigue performance is ascribed to the closure of manufacturing defects in the surface or subsurface and inhibited surface roughening behavior from stable gradient nanotwinned layer. Finally, the work reveals the quantitative relationship among processing-properties-promotion mechanism (PPP), which provides a criterion to meet the specific mechanical performance of DEDed thin-walled components by precisely tuning the bilateral USRP parameters.

Preface

The International Conference on Artificial Intelligence and Industrial Technology Applications originates from 2021 and has attracted various promising researchers who are developing new directions in the field of artificial intelligence and industrial technology. The 2023 3rd International Conference on Artificial Intelligence and Industrial Technology Applications (AIITA 2023), held in Suzhou, China from March 24th to 26th, 2023, was meant to unite researchers, experts, professors and academic staff as well as a wide range of participants of professional community from China and other countries concerned.AIITA 2023, with about 150 participants, was held to further integrate artificial intelligence with industrial technologies, and promoted research and developmental activities in related fields as well as scientific information interchange between researchers, developers, engineers, students, and practitioners working all around the world.Highly eventful program of the Conference, the list of well-established organizations-participants and devoted engagement of many colleagues throughout all the stages of Conference preparation instill confidence in practical importance of mutual initiative. The framework of the Conference comprises keynote speeches, oral presentations, and academic investigation, discussing open and significant problems facing industrial technologies, proposing innovative ideas and approaches to solution of the problems, and considering the new possibilities of application and development of cutting-edge artificial intelligence with industrial technologies.The Conference has become one of the venues for demonstrating scientific achievements of international class by leading scientists and young scholars and would facilitate the strengthening of academic cooperation, meanwhile the Conference proceedings would be expressed in the form of international scientific publishing. Various topics of the papers, gone through a vigorous peer review process, are covered in the proceedings, including: Artificial Intelligence Algorithm, Information Retrieval and Fusion, Intelligent Mechatronics, Integrated Manufacturing System, Intelligent Service Machines, etc.On behalf of the Conference Organizing Committee, we would like to thank the referees for their efficient and thoughtful actions. We are grateful to the members of the Technical Program Committee for their efforts in making and shaping the program for AIITA 2023. Particularly, we acknowledge the publishing support from the members of Journal of Physics: Conference Series.We hope that the future AIITA will be as successful and stimulating, as indicated with the contributions presented in this volume.The Committee of AIITA 2023List of Committee Member are available in this pdf.

Zero programming robotics in additive manufacturing repairs

This document explains the implementation of an integral additive manufacturing system at the Canadian Centre for Welding and Joining (CCWJ). Highlighting its use to remanufacture high-value components with a streamlined workflow using an optical coordinate measuring machine and parametric programming. The resultant output robot code is embedded with control of dimensional accuracy, laser power, beam velocity, and powder feed rate. This approach centers its attention on the remanufacturing of parts and their inherent complex surface as well as the time-consuming task of programming the robot to construct tool paths for the cladding strategy. These issues are solved using a set of topologies implemented in software and hardware that deliver a system that integrates the control parameters and the tooltip toolpaths into a highly automated system offering versatility, scalability, and reproducibility. The results show the capacity of the system to directly repair worn-out parts from a 3D scanner and deliver short-time programming sequences with integrated process constraints, precision, and high dimensional accuracy.