Innovations in the Design, Simulation, and Manufacturing of Production Systems

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: 31 December 2024 | Viewed by 6103

Special Issue Editors


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Guest Editor
Department of Manufacturing Engineering, Machines and Tools, Sumy State University, 40007 Sumy, Ukraine
Interests: manufacturing technology; design engineering; manufacturing systems; product design and development
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Department of Computational Mechanics named after V. Martsynkovskyy, Sumy State University, 40007 Sumy, Ukraine
Interests: dynamics and strength of machines; numerical simulation; parameter identification; artificial neural networks; design engineering
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Design, simulation, and manufacturing are integral stages of a machine's production. Design engineering focuses on the creative process of developing innovative systems and units, ensuring process intensification, productivity, flexibility, and efficiency. The importance of this stage implies modern approaches in the CAx technologies, ensuring digitalization of the design process, which is an integral part of Industry 4.0. This Special Issue welcomes articles on innovative solutions in designing machine tools, mechatronic devices, robotic systems, flexible manufacturing systems, transport machines and systems, reconfigurable machines, fixture and tooling design, rotary machines and drive units, etc. Verification of the created products is mandatory before the manufacturing stage. The developed design should be checked in a virtual environment based on the operating conditions. For this purpose, numerical simulation and experimental studies can be applied. The reliability of the virtual and experimental studies should be justified in terms of quality requirements. The above-mentioned processes make it possible to proceed to the manufacturing stage. The production processes using advanced manufacturing technologies and intelligent systems could be implemented to overcome the challenges of Industry 4.0, considering sustainable development goals in machining processes, additive manufacturing technologies, etc.

Prof. Dr. Vitalii Ivanov
Prof. Dr. Ivan Pavlenko
Dr. Katarzyna Antosz
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Machines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • advanced manufacturing
  • AR/VR technology
  • collaborative system
  • condition monitoring
  • digital transformation
  • digital twin
  • drive units
  • finite element modeling
  • industrial growth
  • industrial robotics
  • industry 4.0
  • intelligent systems
  • machine tools
  • maintenance service
  • mechatronics
  • metalworking equipment
  • model-based systems engineering
  • numerical simulation
  • process innovation
  • product innovation
  • quality assurance
  • rotary machines
  • smart manufacturing
  • sustainable manufacturing
  • transport machines and logistics

Published Papers (6 papers)

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Research

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23 pages, 2410 KiB  
Article
A Study of Sliding Friction Using an Acoustic Emission and Wavelet-Based Energy Approach
by Sergey Sychev and Andre D. L. Batako
Machines 2024, 12(4), 265; https://doi.org/10.3390/machines12040265 - 16 Apr 2024
Viewed by 129
Abstract
The purpose of this work is to study the mechanism of running-in during friction and to determine the informative parameters characterizing the degree of its completion. During friction, contact interaction of rough surfaces causes various wave phenomena covering a wide range of frequencies, [...] Read more.
The purpose of this work is to study the mechanism of running-in during friction and to determine the informative parameters characterizing the degree of its completion. During friction, contact interaction of rough surfaces causes various wave phenomena covering a wide range of frequencies, the subsequent frequency analysis can provide information about the sizes of wave sources and thereby clarify the mechanism of interaction between surface roughness. The using of the wavelet transform for processing the signals of audible acoustic emission made it possible to determine the beginning and the end of the change in the frequency ranges of the interaction of roughness. The code developed by the authors was used to analyze the acoustic emission signals by using wavelet energy and entropy criteria. The mother wavelet was chosen by carefully evaluating the effectiveness of 54 preliminary candidates for the mother wavelet from 7 wavelet families, according to three criteria: (1) maximum wavelet energy; (2) Shannon entropy minimum; and (3) maximum energy-to-Shannon entropy ratio. Full article
21 pages, 7725 KiB  
Article
Novel Gesture-Based Robot Programming Approach with the Ability of Code Reuse
by Vladyslav Andrusyshyn, Kamil Židek, Vitalii Ivanov and Ján Piteľ
Machines 2024, 12(4), 217; https://doi.org/10.3390/machines12040217 - 25 Mar 2024
Viewed by 555
Abstract
Nowadays, there is a worldwide demand to create new, simpler, and more intuitive methods for the manual programming of industrial robots. Gestures can allow the operator to interact with the robot more simply and naturally, as gestures are used in everyday life. The [...] Read more.
Nowadays, there is a worldwide demand to create new, simpler, and more intuitive methods for the manual programming of industrial robots. Gestures can allow the operator to interact with the robot more simply and naturally, as gestures are used in everyday life. The authors have developed and tested a gesture-based robot programming approach for part-handling applications. Compared to classic manual programming methods using jogging and lead-through, the gesture control method reduced wasted time by up to 70% and reduced the probability of operator error. In addition, the proposed method compares favorably with similar works in that the proposed approach allows one to write programs in the native programming language of the robot’s controller and allows the operator to control the gripper of an industrial robot. Full article
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21 pages, 11275 KiB  
Article
Digital Ergonomics—The Reliability of the Human Factor and Its Impact on the Maintenance of Aircraft Brakes and Wheels
by Michal Hovanec, Peter Korba, Samer Al-Rabeei, Martin Vencel and Branislav Racek
Machines 2024, 12(3), 203; https://doi.org/10.3390/machines12030203 - 20 Mar 2024
Viewed by 623
Abstract
This paper presents the development and use of digital tools in the maintenance processes and ergonomics of work systems in the aerospace industry. The Industry 4.0 strategy aims to ensure the reliability of the human factor throughout the entire lifecycle of the maintenance [...] Read more.
This paper presents the development and use of digital tools in the maintenance processes and ergonomics of work systems in the aerospace industry. The Industry 4.0 strategy aims to ensure the reliability of the human factor throughout the entire lifecycle of the maintenance process in the aerospace industry. Based on the requirement placed on the digital model of the working environment obtained from the 3D scanner data, an advanced software solution from TECNOMATIX, namely the TX JACK software 16.1.0 module, was used. The investigated digital ergonomic model, with two variants of workers with anthropometrically different weights, is the subject of analysis and simulation of the maintenance work process in an aerospace organization. Furthermore, the research also shows how the workers of maintenance and repair organizations are willing to develop their own knowledge and skills. The aviation industry should invest in the development of reliable software and hardware, improve safety at the level of digital ergonomics and the quality of jobs involving digitalization, and offer appropriate training for safety and quality personnel. The aim of this paper is to ensure the reliability of the human factor in the maintenance process and, consequently, to ensure technical safety by means of innovative tools in practice. The findings suggest that the investigated TESTER-STEND model with high-end adjustable pistons will improve ergonomics, worker performance, and work safety as a whole. Full article
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26 pages, 9870 KiB  
Article
Contactless Method for Measurement of Surface Roughness Based on a Chromatic Confocal Sensor
by Natalia Lishchenko, Garret E. O’Donnell and Mark Culleton
Machines 2023, 11(8), 836; https://doi.org/10.3390/machines11080836 - 17 Aug 2023
Cited by 1 | Viewed by 1465
Abstract
The methodology for assigning and assessing the surface quality is used at various stages of the product life cycle: during the design and technological preparation of production, the production itself, and during the control (testing) of products. The development of advanced technologies requires [...] Read more.
The methodology for assigning and assessing the surface quality is used at various stages of the product life cycle: during the design and technological preparation of production, the production itself, and during the control (testing) of products. The development of advanced technologies requires in situ part control. A non-contact in situ surface roughness measuring system is proposed in this paper. The proposed system utilizes a chromatic confocal sensor, and profile data, waviness data, roughness data, Ra, and Rz parameters are generated in the developed data-processing software. The assembled measuring system based on the chromatic confocal laser sensor showed its performance in assessing the roughness parameter Ra, from 0.34 µm to more than 12 µm, which covers a common range of milling, turning, and grinding. In this range, measurement relative errors can be controlled within 10%. Frequency analysis and correlation analysis of profilograms were performed. Frequency analysis made it possible to establish the dominant frequency components that occur in the profilogram of the samples, while correlation analysis was used to develop a methodology for identifying the deterministic and random components of the processed surface profile signal. The results of the analysis can be further used to develop diagnostic functions for process monitoring based on profilogram estimates, such as the autocorrelation function and the power spectrum density. Full article
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Review

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37 pages, 9123 KiB  
Review
A Concise Review on Materials for Injection Moulds and Their Conventional and Non-Conventional Machining Processes
by André F. V. Pedroso, Naiara P. V. Sebbe, Francisco J. G. Silva, Raul D. S. G. Campilho, Rita C. M. Sales-Contini, Rúben D. F. S. Costa, Marta L. S. Barbosa and Francisca R. Nogueira
Machines 2024, 12(4), 255; https://doi.org/10.3390/machines12040255 - 11 Apr 2024
Viewed by 329
Abstract
Injection moulds are crucial to produce plastic and lightweight metal components. One primary associated challenge is that these may suffer from different types of failures, such as wear and/or cracking, due to the extreme temperatures (T), thermal cycles, and pressures involved [...] Read more.
Injection moulds are crucial to produce plastic and lightweight metal components. One primary associated challenge is that these may suffer from different types of failures, such as wear and/or cracking, due to the extreme temperatures (T), thermal cycles, and pressures involved in the production process. According to the intended geometry and respective needs, mould manufacturing can be performed with conventional or non-conventional processes. This work focuses on three foremost alloys: AMPCO® (CuBe alloy), INVAR-36® (Fe-Ni alloys, Fe-Ni36), and heat-treated (HT) steels. An insight into the manufacturing processes’ limitations of these kinds of materials will be made, and solutions for more effective machining will be presented by reviewing other published works from the last decade. The main objective is to provide a concise and comprehensive review of the most recent investigations of these alloys’ manufacturing processes and present the machinability challenges from other authors, discovering the prospects for future work and contributing to the endeavours of the injection mould industry. This review highlighted the imperative for more extensive research and development in targeted domains. Full article
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23 pages, 7286 KiB  
Review
Design, Modelling, and Control of Continuum Arms with Pneumatic Artificial Muscles: A Review
by Oleksandr Sokolov, Alexander Hošovský and Monika Trojanová
Machines 2023, 11(10), 936; https://doi.org/10.3390/machines11100936 - 30 Sep 2023
Cited by 1 | Viewed by 1885
Abstract
In this research paper, we present a comprehensive analysis of the current state of soft robots actuated with pneumatic artificial muscles and emphasise their distinct advantages over rigid robots, including exceptional flexibility, adaptability, and safety. Our study explores the design principles of soft [...] Read more.
In this research paper, we present a comprehensive analysis of the current state of soft robots actuated with pneumatic artificial muscles and emphasise their distinct advantages over rigid robots, including exceptional flexibility, adaptability, and safety. Our study explores the design principles of soft robots, drawing inspiration from biological systems and human hands, and identifies promising avenues for further development. The emergence of hybrid robots is also recognised as a significant advancement, particularly in scenarios requiring high precision. The article explores mathematical models encompassing kinematics, dynamics, and statics, as well as alternative model-free approaches. These theoretical frameworks are instrumental in understanding and manipulating the behaviour of soft robots. However, despite substantial progress, soft robots’ practical application and simulation face limitations, primarily due to the demanding requirements and implementation challenges associated with their deployment. Consequently, this paper highlights the need for continued research and advancements to bridge the gap between the theoretical potential and practical utilisation of soft robots. Full article
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