BazTech - Yadda

1

Digital Twin in manufacturing. Part II. Case studies in removal and additive machining processes

Grzesik Wit

Mechanik

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2023

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R. 96, nr 2

6--14

EN

In this paper, a survey of the applications of digital twins (DTs) in removal and additive machining operations performed in smart manufacturing is presented. Some representative examples of virtual modelling in these manufacturing areas at different scales and complexity, including tools, fixtures, machines, equipment and manufacturing/production systems are presented and overviewed. Current experiences of research centres and machine tools companies, which develop and implement of DT technology in the context of control and optimization of machining processes performed on CNC machine tools, are highlighted. According to the author’s opinion this comprehensive survey would encourage to undertake this important manufacturing problem to implement new virtual tools for developing the I4.0 strategy.

PL

W artykule zaprezentowano przegląd zastosowań cyfrowego bliźniaka (DT) w skrawaniu i obróbce przyrostowej. Podano przykłady o różnym poziomie złożoności, z uwzględnieniem oprzyrządowania, maszyn, procesów i systemów wytwórczych/produkcyjnych. Omówiono doświadczenia ośrodków badawczych we wdrażaniu technologii DT w kontekście sterowania procesami obróbkowymi na obrabiarkach CNC i ich optymalizacji. Zdaniem autora artykuł powinien zachęcić do podjęcia problematyki wprowadzania nowych narzędzi informatycznych w rozwoju strategii Przemysłu 4.0.

2

Digital twin in manufacturing. Part I. State of the art, architecture and applications

Grzesik Wit

Mechanik

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2023

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R. 96, nr 1

8--13

EN

In this paper, some important achievements in the development of Industry 4.0 (I4.0) strategy based on the concept of advanced digitalization covering smart manufacturing activities using the Internet of Things (IoT) and corresponding digital twin (DT) solutions are highlighted. Some popular definitions and their practical meanings, modelling principles and possible applications are given. Some new trends and enabling technologies in smart (intelligent) manufacturing, i.e, complete digitalization of assets (units, machines, equipment, etc.), processes and systems based on the evolutionary development of DTs are discussed. This paper should encourage industry and academia to undertake this important problem more seriously, to implement its future potential in manufacturing and enhance the I4.0 strategy.

PL

W artykule dokonano przeglądu osiągnięć w zakresie rozwoju strategii Przemysłu 4.0, opartego na zaawansowanej cyfryzacji z wykorzystaniem internetu rzeczy (IoT) i cyfrowego bliźniaka (DT - digital twin). Podano definicje i zasady modelowania oraz przedstawiono możliwe obszary zastosowań cyfrowego bliźniaka. Omówiono trendy w inteligentnym wytwarzaniu, m.in. kompletną cyfryzację maszyn, procesów i systemów wytwórczych, oparte na ewolucyjnym rozwoju koncepcji cyfrowego bliźniaka. Artykuł powinien zachęcić do podjęcia problematyki wprowadzania nowych narzędzi informatycznych w rozwoju strategii Przemysłu 4.0.

3

Towards an Optimal Motor Mounting Bracket Using Topology Optimization Combined with Sustainability and Manufacturing Cost Analysis

Fassi Hicham Fihri, Aniyou Hadji

Management and Production Engineering Review

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2023

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Vol. 14, No. 4

109--116

EN

The engine is the most important component of a vehicle. It attaches to the main frame via the engine mounting bracket which supports weight and operating loads. The engine mount therefore plays a crucial role in the durability and comfort of the vehicle. This article contributes to the search for the most optimal model from the point of view of resistance, environmental impact, and manufacturing cost. This involves, on the one hand, optimizing the support by reducing its initial mass by 30%, and on the other hand, seeking suitable material and manufacturing process with the least environmental impact. To this end, topology optimization will be combined with an environmental assessment and a manufacturing cost analysis. Four materials will be tested and evaluated. Finally, a cost analysis will present a comparison between a conventional process and 3D printing.

4

Fastener manufacturing methods

Rokosz Zbigniew

Fastener : rynek elementów złącznych

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2023

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nr 1

64--66

EN

Fasteners are found in almost every industry. In fact, it is hard to imagine an industrial sector where no fasteners are used (starting with a nail, rivet, screw, and ending with a bolt and nut). Their shape, strength or types are therefore very different. However, most are produced in a similar way, in specialised metalworking facilities.

5

Evaluating the development path of manufacturing industry under carbon neutralisation

Li Ran

Ecological Chemistry and Engineering. S

|

2023

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Vol. 30, nr 4

581--593

EN

China’s manufacturing industry faces the dual imperatives of supporting economic growth while reducing emissions to achieve national carbon neutrality targets. This study analyses the potential for decarbonisation across manufacturing sub-sectors. Using factor analysis and fuzzy comprehensive evaluation, it assesses industries based on foundational advantages, growth prospects, and sustainability. The results rank sub-sectors and identify promising areas like eco-friendly equipment and agricultural processing. However, carbon-intensive industries require urgent transformation. To optimise China’s industrial structure for low-carbon development, coordinated efforts across policy, industry, and enterprise are needed. Supportive regulations, industrial integration, and technology adoption can incentivise green manufacturing. By strategically promoting circular economy models, China can enhance quality and efficiency, convert waste into value, and contribute to global climate action. This study provides insights into aligning manufacturing growth with carbon neutrality in the new economic era.

6

Energy and labor intensity of manufacturing processes progressing toward sustainable development: A systematic literature review and SWOT analysis for a steel manufacturing company

Depczyński Radosław

Zeszyty Naukowe Akademii Morskiej w Szczecinie

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2022

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nr 72 (144)

201--210

EN

Manufacturing, as one of the main pillars of a civilized lifestyle, will be strongly affected by sustainability issues, and it will play an important role in establishing a sustainable future. Within the area of sustainability issues, some specific issues are pointed out, such as the energy and labor intensity of manufacturing processes. The main aims of this paper are a systematic literature review and the evaluation of the energy and labor intensity of manufacturing processes in an industrial enterprise while proposing changes toward sustainable development. In the research, 163 scientific publications (77 related to China) were taken from the Web of Science (WoS) database based on selected keywords describing the studied phenomenon. The analyzed publications were divided into five areas (clusters). In terms of evaluating the energy and labor intensity of manufacturing processes, twelve production processes were selected, which were then grouped according to their most important areas of similarity (automation, ergonomics, and discomfort). The systematic literature review was carried out using the VOSviewer software, version 1.6.14. This article also uses the methodology of a case study with a simplified SWOT analysis based on interviews with employees and expert panels. The subject of the research is an industrial enterprise representing the steel manufacturing sector in Poland.

7

Biologicalisation of manufacturing processes. State of the art, principles and developing trends

Grzesik Wit

Mechanik

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2022

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R. 95, nr 11

8--13

EN

In this paper, a survey of new achievements in the area of biologically inspired design and manufacturing and fundamental rules of biological transformation in manufacturing - also in relation to mechanical engineering - is provided. Some possible scenarios and several examples of the applications of biological transformation in manufacturing are presented. Some new trends, for instance, the way so-called Living Manufacturing Systems, which are based on advanced AI techniques, are discussed. Finally, some examples of a successful biologicalisation of manufacturing tools, i.e. injection moulds, machine tools, manufacturing processes, and systems are provided. This paper can motivate Polish engineers and researchers to undertake this topic in Poland.

PL

W artykule dokonano przeglądu osiągnięć w zakresie biologicznie inspirowanego projektowania i wytwarzania oraz zasad biologicznej transformacji tych podstawowych funkcji w inżynierii mechanicznej. Przedstawiono możliwe scenariusze i liczne przykłady wdrażania biologicznej transformacji w przemyśle wytwórczym. Omówiono nowe trendy, m.in. przejście do „żywych” systemów wytwórczych (living manufacturing systems) oparte na technikach AI samouczenia się. Zamiarem autora jest zainteresowanie inżynierów i naukowców w kraju tematem transformacji biologicznej.

8

IFC4precast - nowoczesny interfejs do wymiany danych na potrzeby produkcji prefabrykatów betonowych

Krzymowski Rafał

Materiały Budowlane

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2022

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nr 9

41--42

9

Doświadczenia z projektowania i produkcji betonów architektonicznych na bazie produktów RECKLI

Wójcik Andrzej

Materiały Budowlane

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2022

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nr 9

21--22

10

Analysis and perspectives on multivariate statistical process control charts used in the industrial sector: a systematic literature review

Ueda Renan M., Agostino Ìcaro R. S., Souza Adriano M.

Management and Production Engineering Review

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2022

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Vol. 13, No. 2

48--60

EN

The objective of this article is to carry out a systematic review of the literature on multivariate statistical process control (MSPC) charts used in industrial processes. The systematic review was based on articles published via Web of Science and Scopus in the last 10 years, from 2010 to 2020, with 51 articles on the theme identified. This article sought to identify in which industry the MSPC charts are most applied, the types of multivariate control charts used and probability distributions adopted, as well as pointing out the gaps and future directions of research. The most commonly represented industry was electronics, featuring in approximately 25% of the articles. The MSPC chart most frequently applied in the industrial sector was the traditional T2 of Harold Hotelling (Hotelling, 1947), found in 26.56% of the articles. Almost half of the combinations between the probabilistic distribution and the multivariate control graphs, i.e., 49.4%, considered that the data followed a normal distribution. Gaps and future directions for research on the topic are presented at the end.

11

Application of the pentagonal W-ECO model for manufacturing based on "SDGs"

Tanabe Ikuo

Journal of Machine Engineering

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2022

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Vol. 22, No. 1

25--42

EN

The Sustainable Development Goals (SDGs) were proposed to ensure the well-being of everyone on earth, a purpose to which all the fields, including manufacturing, must contribute. However, although industry is implementing this laudable concept in a piecemeal fashion, it is currently unlikely to achieve all 169 targets in the 17 Goals by the SDG deadline of 2030. Therefore, qualitative and quantitative achievement indicators and effective evaluation methods are needed to achieve the 17 goals of the SDGs when developing industrial products. Therefore, in this study, the manufacturing in response to the 17 goals and the 169 targets of the SDGs is considered, and the application of the pentagonal W-ECO model for manufacturing based on the SDGs was proposed. First, the current situation of manufacturing was considered from an environmental perspective, which is also important for the SGDs. Secondly, product’s lifespan which is deeply related to the environment, was discussed in terms of the correlation between time, technology and environment, and "Re" technology was proposed to extend product's lifespan and save resources. Then three cases of development for environmental conservation were introduced to understand the current situation, and it was confirmed that the new technologies in the three cases can contribute to the achievement of SDGs, however the degree of their contribution couldn't be evaluated quantitatively. Finally, the previous three cases using the proposed pentagonal W-ECO model quantitatively evaluated and confirmed that the results of the evaluation provide a quantitative indicator for achieving the SDGs. As a result, the effectiveness of the pentagonal W-ECO model for manufacturing based on SDGs is evaluated.

12

The acoustic emission (AE) controlling method of the electric sheet blanking process : a comparative study of selected data mining methods

Kochański Andrzej, Czyżewski Piotr, Moszczyński Leszek

Computer Methods in Materials Science

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2022

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Vol. 22, No. 4

189--200

EN

The article presents an experimental stand to assess the state of punch in the process of sheet blanking. Blanking trials were carried out on an eccentric press. During all the trials, there were recorded signals of acoustic emission (AE) that accompanied the process of blanking. For the recorded AE signals, the methodology of data preparation and analysis was presented. On that basis, the results of the assessment of the state of the punch were presented, and they employed five methods of visualization: Andrews curves, Principal Components Analysis, Linear Discriminant Analysis, a modified method of Stochastic Neighbor Embedding and Sammon Mapping. The aim of the work was to assess the possibility of using visualization methods to predict the condition of the tool on the basis of acoustic emission signals in processes carried out in extremely short times.

13

Soft modelling of the shaping of metal profiles in rapid tube hydroforming technology

Sadłowska Hanna, Kochański Andrzej

Computer Methods in Materials Science

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2022

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Vol. 22, No. 4

201--210

EN

The paper presents an approach to the impact of process parameters in innovative RTH (Rapid Tube Hydroforming) technology for shaping closed metal profiles in flexible and deformable dies. In order to implement the assumed deformation of the deformed profile, the RTH technology requires the monitoring and control of numerous technological parameters, including geometric, material, and technological variables. The paper proposes a two-stage research procedure considering hard modelling (constitutive) and soft modelling (data-driven). Due to the complexity of the technological process, it was required to develop a numerical finite element method FEM model focused on obtaining the adequate profile deformation measured by the ellipsoidality of the cylindrical profile. Based on the results of the numerical experiments, a preliminary soft mathematical model using ANN was developed. Analysing the soft model results, several statistical hypotheses were made and verified to investigate the significance of selected process parameters. Thanks to this, it was possible to select the most important process parameters, i.e., the properties of moulding sands used for RTH dies: the angle of internal friction and cohesion.

14

The study of co-design in the area of manufacturing

Krawczyk-Dembicka Elżbieta, Urban Wiesław, Łukaszewicz Krzysztof

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2022

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Vol. 70, nr 6

art. no. e143930

EN

The study is devoted to the co-design concept which is not widely studied in the manufacturing industry area. The concept is just practiced but not theorized and not investigated enough, although it greatly deserves it because of its perspectives and advantages potential in the technology changes era. This study aims to present an investigation of literature views on co-design in manufacturing operations, with the comparison to service literature where it is widely discussed; the study also aims at in-depth investigations of co-design occurrences in two industrial cases of product development to understand their nature and circumstances. In addition, the influence of Industry 4.0 technologies and their coexistence with the concept of sustainability will also be strongly taken into consideration in the empirical part of this study. The process of the individualized production of the industrial line for animal food packing and cardboard packaging production has been studied according to case study methodology. The study demonstrates that co-design could contribute to bettering the process of new product development and achieving products more accurate for the final users’ requirements. It goes hand in hand with one of the core ideas of sustainability, which is to have long-lasting products, exploited by the customer with a high level of satisfaction for a longer time. The study implies that the technologies of Industry 4.0 could support wider and more effective co-design exploitation by manufacturing entities.

15

Case Study of Composite Chassis Manufacturing Process Using Low Temperature Molds Tempered with Gradual Heat Annealing Process

Rządkowski Witold, Klik Przemysław, Tracz Jan, Kowalik Michał

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no 3

12--21

EN

This case study describes a manufacturing process of composite chassis also known as monocoque. The structure is made using carbon fibre reinforced polymers (CFRP) which are manufactured in out-of-autoclave (OOA) process from pre-impregnated carbon fabrics and aluminium alloy honeycomb core. Since the material cost is high the aim of the project was to reduce the cost of manufacturing process i.e. cost of models and moulds. Therefore, instead of high-temp models and moulds a cheaper alternative was used. It consisted of Styrofoam models made using polyurethane (PU) paste and moulds made from CFRP using wet layup process which were cured at room temperature. Such moulds had to be adapted to withstand high temperatures during pre-preg cure. This was done with gradual heat annealing process which increased the maximum service temperature from 45C to 90C. This was enough for the low-temp cure of pre-preg material, but it might be possible to increase the temperature even further. As a result, the cost of manufacturing process had been reduced by 50%.

16

Sposób wytwarzania recyklatów z produkcji wielowarstwowych membran na bazie polipropylenu oraz ich zastosowanie w osnowie kompozytów z udziałem haloizytu jako napełniacza

Gurdak Daniel, Stachowicz Krzysztof, Androshchuk Dmytro, Pietruszka Weronika, Czaja Krystyna

Przemysł Chemiczny

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2021

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T. 100, nr 6

591--595

PL

Opracowano sposób wytwarzania recyklatów z odpadów membran wielowarstwowych przy ograniczonym wpływie energii cieplnej. Oceniono możliwość wykorzystania otrzymanych recyklatów wraz z pierwotnym polipropylenem do wytwarzania kompozytów z udziałem napełniaczy glinokrzemianowych. Oceniano wpływ udziału recyklatów membranowych oraz haloizytu jako napełniacza na jednorodność otrzymanych materiałów oraz ich właściwości przetwórcze, termiczne i mechaniczne. Najlepszym materiałem okazał się kompozyt z dodatkiem 1% mas. haloizytu zawierający nawet 30% mas. odpadu membranowego. Charakteryzował się on nawet lepszą odpornością termiczną, lepszą udarnością, twardością oraz przetwarzalnością niż odpowiedni kompozyt z udziałem czystej osnowy polipropylenowej.

EN

The waste of multi-layer membranes was thermally stuck together and the obtained tapes were cut into small flakes. The obtained recyclates were used in a mixt. with polypropylene for the production of composites with Al-Si filler. Effect of the content of membrane waste and the halloysite on the homogeneity of the obtained composites and their processing, thermal and mech. properties was analyzed. The best material was a composite with the addn. of 1% by mass of halloysite and up to 30% by mass of membrane waste, which showed better thermal resistance, impact strength, hardness and processability compared to the composite obtained with the pure polypropylene.

17

Outsourcing effects and company size – a comparative analysis between the manufacturing and the services sector in Poland

Maziarczyk Anna

Organizacja i Zarządzanie : kwartalnik naukowy

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2021

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nr 1

57--66

EN

Introduction/background: The popularity of outsourcing as a management tool among Polish enterprises is increasing. Growing competition forces companies to look for new solutions for company management. Outsourcing is defined as a management tool to reduce costs in an enterprise. Aim of the paper: The aim of the study was to check whether there is a relationship between outsourcing and the size of the company. In the study, I list large companies and SMEs. Compares the relationships between the manufacturing and services sectors. Materials and methods: In this category, data from 250 companies from the Notoria database were used. In the first part of article, it compares the value of outsourcing across sectors using the Student T-test. In the next part of article, I examine the relationship between outsourcing and the size of companies. I compare the results between the vectors. Pearson's correlation test was used. It then compares the use of outsourcing between small and large companies. The student's T-test for independent programs was used. Results and conclusions: The results say there are differences in the use of outsourcing between the manufacturing and service sectors. I noticed that industrial companies use much more solutions provided by external suppliers. Moreover, I can see that outsourcing has a greater impact in manufacturing than in the service industry. As the company grows, the use of outsourcing increases. It also shows that large companies use outsourcing to a greater extent than smaller companies.

18

Gonty drewniane

Policińska-Serwa Anna

Materiały Budowlane

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2021

|

nr 6

28--30

19

Energooszczędne ściany z betonu komórkowego

Rolbiecka Beata, Langowska Monika

Materiały Budowlane

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2021

|

nr 4

10

20

Offline-online pattern recognition for enabling time series anomaly detection on older NC machine tools

Netzer Markus, Palenga Yannic, Goennheimer Philipp, Fleischer Juergen

Journal of Machine Engineering

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2021

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Vol. 21, No. 1

98--108

EN

Intelligent IoT functions for increased availability, productivity and component quality offer significant added value to the industry. Unfortunately, many old machines and systems are characterized by insufficient, inconsistent IoT connectivity and heterogeneous parameter naming. Furthermore, the data is only available in unstructured form. In the following, a new approach for standardizing information models from existing plants with machine learning methods is described and an offline-online pattern recognition system for enabling anomaly detection under varying machine conditions is introduced. The system can enable the local calculation of signal thresholds that allow more granular anomaly detection than using only single indexing and aims to improve the detection of anomalous machine behaviour especially in finish machining.