Modern Technologies and Manufacturing Systems

The impact phenomena of solid micro-particles have gathered increasing interest across a wide range of fields, including space debris protection and cold-spray additive manufacturing of large, complicated structures. Effective motion monitoring is essential to understanding the impact behaviors of micro-particles. Consequently, a convenient and efficient micro-particle motion monitoring solution is proposed based on continuous single-frame multiple-exposure imaging technology. This method adopts a camera with excellent low-light performance coupled with high-frequency light-emitting diode (LED) flashes to generate short interval illumination. This technology can, in theory, achieve 1 million effective frames per second (fps) and monitor particles as small as 10 microns with speeds up to 12 km/s. The capabilities of the proposed method were validated by a series of micro-particle motion monitoring experiments with different particles sizes and materials under varying camera configurations. The study provides a feasible and economical solution for the velocity measurement and motion monitoring of high-speed micro-particles. Full article

Currently, classical methods for the creation of various shapes and bending angles of metal sheet parts are applied. They are represented by the so-called all-metal forming tools. Non-standard methods, which in some cases exceed conventional technical solutions, are used in the practice to a minor extent. This is an area of interest from the point of view of ecology, because the shaping process performed in this way does not burden the environment in any considerable way. The knowledge presented in this work is obtained based on experiments in laboratory conditions. The list of literature contains mainly works from the recent period. The research represents a contribution to the great mosaic of magnetism. The aim of the current paper is to also verify the possibilities of the suitability of a special tool in the formation of metal sheet specimens using the application of the so-called forming with a free core. Additional benefits of the experimental work and their results are anticipated. The contribution is complemented by detailed calculations and diagrams. The practical contribution and research is that the device used for forming has been successfully tested. It turns out that the presented method is suitable for further development. The method has proven that is it suitable for industrial applications where simple shapes are produced. Full article

Background: In this study, L-cysteine-capped silver nanoparticles (Cys-AgNPs) were successfully linked in a cotton textile, being attached in a covalent way to the cotton fibers via esterification with the hydroxyl groups from the cellulose. The AgNPs were strongly adhered to the fiber surface through coordination bonds with the thiol groups from the L-cys. In addition, they were compared with biogenic silver nanoparticles produced from fungi (bio-AgNPs). Materials and methods: The characterization of the Cys-AgNP and the bio-AgNP solutions were accomplished by UV−visible (UV−Vis), Z-potential, and X-ray diffraction (XRD). After the attachment of the Cys-AgNPs and the bio-AgNPs to the raw cotton, the textile surface was characterized by variable pressure scanning electron microscopy (VP-SEM), energy dispersive X-ray (EDX), and Fourier transform infrared spectroscopy (FT-IR). The antibacterial activity was performed by disk diffusion analysis. Results: The results of the UV−Vis analysis showed the presence of AgNPs in the Cys-AgNPs and the bio-AgNPs solutions, showing the Surface Plasmon resonance (SPR) for the AgNPs among 380–420 nm. In addition, they exhibited a Z-potential of −27 and −24 mV, respectively, with the presence of elemental silver shown by the XRD analysis. The VP-SEM images from the cotton fabrics covered in Cys-AgNPs and bio-AgNPs showed the presence of spherical AgNPs on their surface, and EDX analysis revealed the presence of peaks associated with the presence of Ag, C, and O. Furthermore, FT-IR analysis exhibited peaks associated with the presence of L-cysteine (SH-) and carboxylic acid arising from the esterification reaction among the cellulose from cotton and the carboxylic acid in the L-Cys molecules. Finally, the cotton textile exhibited antibacterial activity against Escherichia coli and Staphylococcus aureus. Conclusions: This study demonstrates the ability of Cys-AgNPs to bind to the cellulose from cotton fabric so as to produce antibacterial fabrics with enhanced durability, opening a wide range of options to be further used in healthcare and other industries. Full article

Regarding decision planning in the electronic manufacturing industry, this paper designs a green closed-loop manufacturing-recycling network for multiperiod production planning for multiple products. The network considers the tradeoff between production costs and environmental pollution induced by production scraps. Therefore, a mixed integer programming model with a dual objective is designed to achieve environmental protection and reduce production costs through resource recovery and utilization. At the same time, the recycled materials are considered to be treated, not entirely new, which could affect the manufacturing qualified rate. Thus, material attributes are proposed to distinguish new raw materials from recycled (second-hand) ones through the closed-loop manufacturing-recycling process to enhance the manufacturing qualified rate. In order to solve the dual-objective optimization model and realize optimal decisions, an epsilon constraint is designed to generate a nonextreme solution set by changing the original feasible region. The results show its ability to obtain a more balanced solution in terms of cost and environmental factors compared with the fuzzy-weighted method. Meanwhile, the analysis proves that the dual-objective optimization model with distinguishing material attributes can improve the efficiency of the manufacturing qualified rate and achieve a win-win situation for production and environmental protection during enterprise production. Full article

For a blood pump, the blood flow channel and impeller parameters directly affect the performance of the pump and the resulting blood circulation. The flow channel in particular has a great impact on the hydraulic performance of the pump (e.g., flow and pressure), which directly determines the overall performance of the blood pump. Traditional bearing-supported blood pumps can cause mechanical damage to blood cells, leading to hemolysis and thrombosis. In this study, therefore, we designed a conical spiral axial blood pump with magnetic levitation. The blood pump was supported by electrodynamic bearings in the radial direction and electromagnetic bearings in the axial direction. The impeller and the front and rear hubs were integrated to minimize blood stagnation and reduce the formation of thrombosis. The hub had a conical spiral flow channel design, which not only reduced the size of the impeller but also increased blood flow and pressure while meeting the design requirements. Computational fluid dynamics (CFD) analysis was used to analyze the flow field of the axial blood pump, a power function model was used to establish a hemolysis prediction model, and the particle tracking method was used to obtain the flow trajectories of individual blood cells, thereby predicting hemolysis-related performance of the blood pump. The simulation results showed that the main high shear stress area in the blood pump was located in the impeller inlet and the clearance between the top of the impeller and the inner chamber of the blood pump. When the hub taper angle of the blood pump was 0.72° and the clearance was 0.3 mm, the average hemolysis prediction value was 0.00216. This prediction value was smaller than that of traditional axial blood pumps. These findings can provide an important reference for the structural design of axial blood pumps and for reducing the hemolysis prediction value. Full article

In the study, an investigation was made into the hydrolytic degradation behavior of the microporous polylactide (PLA) in the initial stage in three biological buffer solutions with various pH-simulating body fluids in comparison with pure PLA. Studies also include the analysis of selected mechanical properties and physical structures. A microporous PLA was obtained by melt extrusion using a chemical blowing agent. The rate of Mw decrease induced by hydrolysis over 35 days of microporous PLA was roughly comparable to the pure material. The rate of depolymerization was slightly accelerated at an acid pH due to acid-catalyzed hydrolysis at the end of the observed period. The mechanical analysis showed the influence of various pH on the obtained results. Full article

The thermal load that occurs during grinding can be reduced with the aid of an optimized metalworking fluid (MWF) supply. In previous work, mainly the free jet was considered for the determination of the conditions required for an optimized MWF supply. An investigation of the interaction area between the MWF and the grinding wheel has not yet been carried out due to the lack of suitable measurement techniques. In the presented work, both the free jet and the interaction area are analyzed with the aid of new metrological analysis and evaluation methods based on high-speed records (shadowgraphy and shadogram imaging velocimetry) in order to assess the free jet geometry and velocities, as well as the velocity distribution and the MWF amount in the interaction area. Using this approach, the following main results were derived: (1) The free jet velocity remains approximately constant in a defined free jet cross-section even at high distances from the nozzle outlet. (2) The velocity distribution in the interaction area is mainly influenced by the flow rate. (3) A new image parameter (black pixel fraction) was derived for the evaluation of the MWF supply to the contact zone. Full article

Bottleneck identification is of great interest in discrete manufacturing fields, as they limit the system’s throughput. However, the bottlenecks are difficult to accurately identify due to the instability and complexity of discrete manufacturing systems. This paper proposes a dynamic bottleneck identification method (DBI-BS) that is based on effective buffers and fine-grained machine states to identify bottlenecks accurately. First, the complex manufacturing system (CMS) with strong coupling between elements is decoupled into several independent parts under the guidance of the effective buffer theory. Then, the machine activity duration method is improved through further fine-grained division, and the machine states are described by the timing flow model. The method to quantify the degree of bottleneck that restricts the system throughput (TH) is proposed on the basis of the turning point theory, and the one-to-one mapping relationship between the simulated and authentic complex manufacturing systems is also studied. Simulation results show that the DBI-BS can effectively identify dynamic bottlenecks in complex manufacturing processes, and the decoupling of complex systems can effectively improve the accuracy of dynamic bottleneck identification. Full article

Heat generation is a critical issue in grinding. If the grinding point generates significant heat, dimensional and shape accuracy may decrease due to thermal deformation, and the machined surface may deteriorate due to grinding burn. Therefore, monitoring the temperature during grinding is important to obtain ideal machining results. In this research, we develop a new method to measure the grinding surface and grinding wheel surface temperature during in-process machining. The proposed method measures the temperature of the grinding surface through small holes in a rotating grinding wheel. Using this method, we measured the temperature of the grinding surface during the dry grinding of carbon fiber reinforced plastics (CFRP). Temperature of the grinding surface was measured every 1/4 rotation of the grinding wheel at any depth of cut, assuming precision grinding, rough grinding, and high-efficiency grinding. The measurement value changed depending on the temperature measurement position of the infrared thermometer from numerical analysis of the grinding surface temperature. We also found that when the cut depth was small, the temperature, including the surface of the workpiece before machining, was measured at a specific temperature measurement position. The newly developed temperature measurement method was capable of in-process measurement of the grinding surface temperature and of detecting temperature rise when the grinding wheel was clogged. Full article

This article describes a methodical framework that combines two specific methods of Lean management, namely the ABC method and the MRP planning method. The article further argues that combining the ABC inventory method with subsequent MRP planning is beneficial if the combination is implemented in practice. To demonstrate the benefits, the framework is tested using a case study company. The presented case-study problem is to reduce the number of changeover downtimes in the environment of an engineering production company. The researched company deals with the problem of setting up production lines in a way to minimize the number of downtimes within one work shift. Within the solution, four possible variants of the production plan are presented. By combining the ABC and MRP methods, up to four changeovers can be saved, which in financial terms represents a saving of about EUR 450,000 per year. Full article

A frequent change in the manufacturing program caused by a change in customer requirements requires a logistics system in the company that can respond flexibly to these changes. In order for business logistics to respond flexibly and optimally to the tasks created, a tool is needed to verify the functionality of the entire process. This article, at its core, deals with the use of emulation in a mixed environment of the real and virtual worlds as a tool for optimising automatic guided vehicle (AGV) routes. The main objective of the article is the design of a system that allows verification of AGV routes using computer emulation. The solution was created and programmed in the Tecnomatix Plant Simulation program, in cooperation with AGV logistics supply tractors, and tested on a logistic test circuit. The results show that the main area of application of such a solution is mainly in the area of the capacity utilisation of the AGVs that are used in internal logistics processes. This solution helps to cut down on the time it takes to design and optimise logistics operations as well as on the time it takes to test logistics systems at full capacity before commencing production. Full article

This study proposes a design for unmanned chemical factories and implementation based on ultra-low-cost Internet of Things technology, to combat the impact of COVID-19 on industrial factories. A safety and private blockchain network architecture was established, including a three-layer network structure comprising edge, fog, and cloud calculators. Edge computing uses a programmable logic controller and a single-chip microcomputer to transmit and control the motion path of a four-axis robotic arm motor. The fog computing architecture is implemented using Python software. The structure is integrated and applied using a convolutional neural network (CNN) and a fractional-order proportional-integral-derivative controller (FOPID). In addition, edge computing and fog computing signals are transmitted through the blockchain, and can be directly uploaded to the cloud computing controller for signal integration. The integrated application of the production line sensor and image recognition based on the network layer was addressed. We verified the image recognition of the CNN and the robot motor signal control of the FOPID. This study proposes that a CNN + FOPID method can improve the efficiency of the factory by more than 50% compared with traditional manual operators. The low-cost, high-efficiency equipment of the new method has substantial contribution and application potential. Full article

A number of scientific methods are used to support productivity growth in companies, aimed at reducing waste, balancing assembly lines and supporting the introduction of automation into assembly processes. Their use in industrial practice is widespread, especially in large and medium-sized enterprises, and small businesses that use scientific methods to a limited extent. The aim of the research is to show the assembly process of throttle valves implemented in a small company, the effects of balancing the current assembly line and the effects of proposals of variant solutions on the automated assembly line and on the amount of hourly assembly production and costs per product. Within costs, two cost types are monitored: namely the hourly labor costs, and hourly machine costs. The sum of the hourly assembly line costs is determined by their sum. In the results section, the main sources of waste in the assembly process are identified, and eight proposals leading to the elimination of waste are processed. In the discussion, the individual proposals are evaluated in terms of the cost of one product, the hourly production of assembly and the tact times of assembly lines. The proposal that is evaluated as the best process is compared with the current state. The purpose of this article is to point out the advantages of the implementation of scientific methods in industrial practice, the achieved savings in the solved problem, and thus, to support those scientific methods in the management of assembly processes which are beginning to be used in greater extents by small businesses. Full article

Machining of difficult-to-cut materials such as titanium alloys, stainless steel, Inconel, ceramic, glass, and carbon fiber-reinforced plastics used in the aerospace, automobile, and medical industries is being actively researched. One non-traditional machining method involves the use of an abrasive waterjet, in which ultra-high-pressure water and abrasive particles are mixed and then ejected through a nozzle, and the thin jet stream cuts materials. The nozzle greatly affects the machining quality, as does the cutting tool of general machining, so it is very important to monitor the nozzle condition. If the nozzle is damaged or worn, or if the bore size increases or the bore becomes clogged with abrasive, the material may not be cut, or the surface quality of the cut may deteriorate. Here, we develop a nozzle monitoring system employing an acoustic emission sensor that detects the nozzle condition in real time. Full article

This paper provides an analytical formula for the theoretical stress concentration factor in a common type of excavation repair for large forgings and castings. Mechanical components obtained with these processes are often subjected to superficial defects. As the rejection of such pieces is out of question, given the relevant size and costs associated with them, usual industrial practice consists in the removal of the defect and a portion of the surrounding material through milling processes. The authors have selected a reference geometry of the excavation to be left on the mechanical pieces, which can be easily controllable in practice by three operating parameters. Then, the domain of existence of such a repair was investigated on a sequence of discrete points, by means of FEA, obtaining for each, the values of the stress concentration factor K_t. Finally, through polynomial regression, the K_t functions have been accurately approximated by a sixth degree polynomial formulation, which, given a triplet of dimensional geometric parameters, is able to compute the stress concentration factor K_t, with an error that never exceeds 8%. Full article

The article presents the results of machine backup designing in reconfigurable industrial processes. The development of manufacturing systems is moving towards intelligent, automated, autonomous, and reconfigurable manufacturing systems. Factories that want to ensure long-term sustainable and competitive manufacturing processes must be designing their processes to respond flexibly to changing changes in customer requirements. The article’s introduction characterizes concepts such as cold backup and warm backup machines and indicators relationship as the time between faults and repairs. The materials and methods describes prerequisites as the creation of the product family creation and resource availability with many formulas, simulation models, and its verification for the creation of the family products in the results of this article. The results describes the results from the calculations of the backups and family products of their use in reconfigurable manufacturing systems. The developed methodology for line design uses the principles of reconfiguration in designing configurations regarding advanced approaches in factories. A significant milestone will be the rapid integration of disruptive technologies and approaches into manufacturing systems. The complexity of future manufacturing systems in the Factories of the Future will only be possible with new innovative factory technologies using the digital twin. Full article

In this paper, we publish the algorithm to create a dual image manifested in the infrared and visible spectrum. To distinguish the information in the two light spectra, twin dyes are introduced for the inkjet plotter and printing realization for garment and canvas items. The graphics, invisible to the naked eye, are designed for the near infrared (NIR) spectrum and are suitable for urban security where surveillance cameras with IR detectors are installed. The duality of dyes is presented in tables, and the analysis is a basis for programming and developing new algorithms for the application of “Infrared Dyeing” on different materials and printing technologies. Through spectroscopy, this innovative solution demonstrates twin colorants by printing in one pass through the plotter such that one image remains visible, while the other one is hidden to the bare eye. The uniform and the school bag cover presented in this paper are kept simple in design because they incorporate information hidden to the naked eye but visible with surveillance cameras and all the other infrared detectors. The article provides mathematical models of duality coloring as a basis for programming the graphic prepress that merges both of the images, the visual one and the infrared one. A topic is the fusion of two images with colors that represent two graphs, with independent contents for the visual and near-infrared spectrum. Full article

The paper presents the results of research on the influence of the granulometric composition on the rheological properties of granulates from soft waste produced in the manufacturing of ceramic tiles using the Lamgea and Continua methods in terms of the possibility of their reuse. The composition of the granulates was modified by removing individual grain fractions in three measurement series. Comparatively, the measurement samples for the production granulates were prepared in the same way. Microscopic observations and granulometric analysis showed significant differences in the grain shape and grain size distribution of granulates. The soft waste granulates also showed much worse flow ability than the production granulates. It was shown that the removal of the smallest fractions significantly improved the rheological properties of soft waste granulates. This tendency was also observed in the case of measurements of changes in the bulk density. A Brookfield powder analyzer was used for rheological tests, and a flow analysis was performed using the numerical Jenike classification. Full article

The spent liquid glass mixture, which is widely used in foundries as a binder after knocking out of moldings, contains pieces of different sizes and strengths, and there is a strong silicate film on the sand grains themselves. The proposed regeneration plants, which provide for the removal of the silicate film by scrubbing, have low productivity and lead to abrasion of the grains themselves. For this reason, the knocked-out mixture is taken to the dump. As a result of the study of the state of the spent liquid glass mixture in the dump, it was found that, in the spent mixture that had lain for 8–10 years, under prolonged exposure to atmospheric precipitation at plus and minus temperatures, part of the silicate film dissolves and almost all monolithic pieces are destroyed. Further use of hydraulic regeneration allows us to reduce the film thickness and thereby reduce the percentage of liquid glass from 5–5.5% to 0.8–1.2%. This made it possible to select the composition of the molding sand for an automatic line, using the AlpHaset-process, which consists of 22–29% of liquid glass mixture from a dump, 65–72% of liquid glass, 5.5% of liquid glass, and a hardener in the amount of 0.55%. Full article

We present a noninvasive procedure that measures the flow velocity of a fluid by using polarized hydrogen nuclei in the fluid. The measurement procedure is based on a time-of-flight method where magnetic information is applied on the fluid with a permanent magnet and an RF-pulse. In contrast to other methods, this magnetic-marking method works without tracers. The read-out of the magnetic information is performed by optically pumped magnetometers downstream. In order to function, the magnetometers have to be operated in a magnetic shield with magnetic field strengths lower than 100 nT, i.e., in the zero-to-ultra-low-field regime. In this regime, the magnetometers are capable of detecting induced magnetic signals of 10 pT or less with an inline-flow setup. The results presented in this paper demonstrate the viability of optically pumped magnetometers for flow metering. The first metering results yielded an average accuracy of 3% at flow velocities between 13 cm/s and 22.4 cm/s. Full article

The paper deals with the issue of cutting zone and chip compression. The aim was to analyse the microstructure transverse section of the cutting zone on a metallographic cut, due to determined values of chip compression and plastic deformation, which affect the cutting process efficiency. The tested cutting tool material was coated with cemented carbide. The selected workpiece materials were C45 medium carbon steel of ISO grade and 62SiMnCr4 tool steel of ISO (W.Nr. 1.2101) grade. In the experiments, a DMG CTX alpha 500 turning centre was used. The cutting speed and feed were varied, and the depth of the cut was kept constant during the turning. The plastic deformation and chip compression determine the efficiency of the cutting process. The higher compression requires more work to perform the process and, therefore, it requires more energy for doing so. With the increase of the cutting speed, the deformation for C45 steel is decreased. The rapid deformation reduction was observed when the cutting speed was increased from 145 m/min to 180 m/min. Generally, deformation is decreasing with the increase of the feed. Only at a cutting speed of 145 m/min was the deformation elevation observed, when the feed was increased from 0.4 mm to 0.6 mm. During the turning of the 62SiMnCr4 tool steel we observed an error value at a cutting speed of 145 m/min and a feed of 0.4 mm was the middle cutting parameter. However, feed dependence was clear: With an increase of the feed, the plastic deformation was decreasing. This decreasing was more rapid with the increasing of the cutting speed. Besides plastic deformation, there was analysed chip compression as well. With the increasing of the cutting speed, there was a decrease of the chip compression. Due to a lack of information in the area of the chip compression and the plastic deformation in the cutting process, we decided to investigate the cutting zone for the turning of tool steels 62SiMnCr4, which was compared with the reference steel C45. The results could be applied to increase the efficiency of the process and improvement of the surface integrity. Full article

In this paper, we propose a new method to estimate the hole expansion ratio (HER) using an integrated analysis system. To precisely measure the HER, three kinds of analysis methods (computer vision, punch load, and acoustic emission) were utilized to detect edge cracks during a hole expansion test. Cracks can be recognized by employing both computer vision and a punch load analysis system to determine the moment of crack initiation. However, the acoustic emission analysis system has difficulty detecting the instant of crack appearance since the magnitude of the audio signal is drowned out by noise from the press, which interrupts the differentiation of crack configuration. To enhance the accuracy for determining the HER, an integrated analysis system that combines computer vision with punch load analysis, and improves on the shortcomings of each analysis system, is newly suggested. Full article

As the use of composite materials increases, the search for suitable automated processes gains relevance for guaranteeing production quality by ensuring the uniformity of the process, minimizing the amount of scrap generated, and reducing the time and energy consumption. Limitations on production by traditional means such as hand lay-up, vacuum bagging, and in-autoclave methods tend not to be as efficient when the size and shape complexity of the part being produced increases, motivating the search for alternative processes such as automated tape laying (ATL). This work aims to describe the process of modelling and simulating a composite ATL with in situ consolidation by characterizing the machine elements and using the finite differences method in conjunction with energy balances in order to create a digital twin of the process for further control design. The modelling approach implemented is able to follow the process dynamics when changes are made to the heating element and to predict the composite material temperature response, making it suitable for use as a digital twin of a production process using an ATL machine. Full article

Box girder is an important bearing and force transmitting component in the gondola car body; the rationality of its structure directly affects the life of the whole car body. In order to solve disadvantage of the traditional box girder optimization method, which mainly depends on design experience, the combined method of orthogonal experimental design and the genetic algorithm-back propagation (GA-BP) algorithm is used for the structural optimization of bolster beam in this paper. Nine groups of parameters were established by orthogonal experiment, which can give typical samples for GA-BP optimization. Then, the bolster beam is optimized by the GA-BP algorithm, and the new gondola car body model is established with the optimized parameters. The finite element analysis results show that the minimum stress is found by using the GA-BP algorithm, which is basically consistent with the simulation results. Finally, the results show that the combined method of orthogonal experimental design and GA-BP algorithm is feasible to the box girder optimization of the gondola car body. Meanwhile, the optimization results of bolster beam will provide a reference for the structural design of the heavy haul wagon body. Full article

At present, most of the incoming liquids from the oilfield combined stations are not pre-separated for natural gas, which makes the subsequent process of oil-water separation less effective. Therefore, it is necessary to carry out gas-liquid separation. A new type of axial flow gas-liquid separator was proposed in this paper. The numerical simulation was carried out by CFD FLUENT software, and the changes of concentration field, velocity field and pressure field in the axial flow gas-liquid separator were analyzed. It was found that there were gas-liquid separation developments and stabilization segments in the inner cylinder of the separator. The axial velocity will form a zero-speed envelope in the inner cylinder, and the direction of the velocity in front of and behind the zero-speed envelope was opposite. The tangential velocity showed a “W” shape distribution in the radial position of the inner cylinder. The pressure on the left wall of the guide vane was higher than that on the right side. Therefore, the left wall was more likely to be damaged than the right wall. Full article

In Industry 4.0, data are sensed and merged to drive intelligent systems. This research focuses on the optimization of selective assembly of complex mechanical products (CMPs) under intelligent system environment conditions. For the batch assembly of CMPs, it is difficult to obtain the best combinations of components from combinations for simultaneous optimization of success rate and multiple assembly quality. Hence, the Taguchi quality loss function was used to quantitatively evaluate each assembly quality and the assembly success rate is combined to establish a many-objective optimization model. The crossover and mutation operators were improved to enhance the ability of NSGA-III to obtain high-quality solution set and jump out of a local optimal solution, and the Pareto optimal solution set was obtained accordingly. Finally, considering the production mode of Human–Machine Intelligent System interaction, the optimal compromise solution is obtained by using fuzzy theory, entropy theory and the VIKOR method. The results show that this work has obvious advantages in improving the quality of batch selective assembly of CMPs and assembly success rate and gives a sorting selection strategy for non-dominated selective assembly schemes while taking into account the group benefit and individual regret. Full article

Low-altitude unmanned aerial vehicle (UAV) photogrammetry combined with structure-from-motion (SFM) algorithms is the latest technological approach to imaging 3D stereo constructions. At present, derivative products have been widely used in landslide monitoring, landscape evolution, glacier movement, volume measurement, and landscape change detection. However, there is still a lack of research into the accuracy of 3D data positioning based on the structure-from-motion of unmanned aerial vehicle (UAV-SFM) technology, itself, which can affect the measurable effectiveness of the results in further applications of this technological approach. In this paper, validation work was carried out for the DJI Phantom 4 RTK UAV, for earth observation data related to 3D positioning accuracy. First, a test plot with a relatively stable surface was selected for repeated flight imaging observations. Specifically, three repeated flights were performed on the test plot to obtain three sorties of images; the structure from motion and multi-view stereo (SFM-MVS) key technology was used to process and construct a 3D scene model, and based on this model the digital surface model (DSM) and digital orthophoto map (DOM) data of the same plot with repeated observations were obtained. In order to check the level of 3D measurement accuracy of the UAV technology itself, a window selection-based method was used to sample the point cloud set data from the three-sortie repeat observation 3D model. The DSM and DOM data obtained from three repeated flights over the surface invariant test plots were used to calculate the repeat observation 3D point errors, taking into account the general methodology of redundant observation error analysis for topographic surveys. At the same time, to further analyze the limits of the UAV measurement technique, possible under equivalent observation conditions with the same processing environment, a difference model (DOD) was constructed for the DSM data from three sorties, to deepen the overall characterization of the differences between the DSMs obtained from repeated observations. The results of the experimental study concluded that both the analysis of the 3D point set measurements based on window sampling and the accuracy evaluation using the difference model were generally able to achieve a centimeter level of planimetric accuracy and vertical accuracy. In addition, the accuracy of the surface-stabilized hardened ground was better, overall, than the accuracy of the non-hardened ground. The results of this paper not only probe the measurement limits of this type of UAV, but also provide a quantitative reference for the accurate control and setting of an acquisition scheme of the UAV-based SfM-MVS method for geomorphological data acquisition and 3D reconstruction. Full article

Conventional design of jigs and fixtures has become unsuitable given the requirements of modern technology and complexity and diversity in the production with the rapid update of products. Computer-aided design (CAD) of jigs and fixtures is an effective solution in this direction. The current paper focuses on a computer-aided design of the traditional jigs and fixtures and developed a system containing tailor-made software, created using the Visual Basic programming language and installed on it the viewer screen to show the part. The developed system has been built by connecting Visual Basic programming language to the SolidWorks software on which the part is drawn and saved as STEP AP-203 file format, and the system reads and extracts the data from the STEP AP-203 file. Heuristic rules of feature recognition are pre-prepared for checking the extracted geometric data and deciding which data shape will represent the machining feature; then, the system provides the optimum design of the traditional jigs and fixtures for a group of hollow cylindrical parts that contain a group of cross-holes on the cylinder body, whether perpendicular or offset from the cylinder’s axis, (inclined or inclined offset, or blind or through, by applying pre-prepared heuristic rules for the design of traditional jigs and fixtures. Full article

An innovative axial hydrocyclone separator was designed in which a guide vane was installed to replace a conventional tangential inlet, potentially aggravating inlet turbulence. The characteristics of velocity distribution, concentration distribution, and pressure distribution inside the separator were obtained through the numerical simulation of the turbulent flow of oil and water. The results showed that the flow field presented good symmetry, which eliminated the eccentric turbulence phenomenon in the conventional hydrocyclone separators and was beneficial for the oil–water separation. Full article

An ultrasonic spray pyrolysis (USP) device consists of an evaporation and two reaction zones of equal length, into which an aerosol with a precursor compound enters, and where nanoparticles are formed in the final stage. As part of this research, we simulated the geometry of a side inlet, where the reaction gas (H₂) enters into the reaction tube of the device by using numerical methods. Mixing with the carrier gas (N₂) occurs at the entry of the H₂. In the initial part, we performed a theoretical calculation with a numerical simulation using ANSYS CFX, while the geometries of the basic and studied models were prepared with Solidworks. The inlet geometry of the H₂ included a study of the position and radius of the inlet with respect to the reaction tube of the USP device, as well as a study of the angle and diameter of the inlet. In the simulation, we chose the typical flows of both gases (N₂, H₂) in the range of 5 L/min to 15 L/min. The results show that the best geometry is with the H₂ side inlet at the bottom, which the existing USP device does not allow for. Subsequently, temperature was included in the numerical simulation of the basic geometry with selected gas flows; 150 °C was considered in the evaporation zone and 400 °C was considered in the other two zones—as is the case for Au nanoparticle synthesis. In the final part, we performed an experiment on a USP device by selecting for the input parameters those that, theoretically, were the most appropriate—a constant flow of H₂ 5 L/min and three different N₂ flows (5 L/min, 10 L/min, and 15 L/min). The results of this study show that numerical simulations are a suitable tool for studying the H₂ flow in a UPS device, as the obtained results are comparable to the results of experimental tests that showed that an increased flow of N₂ can prevent the backflow of H₂ effectively, and that a redesign of the inlet geometry is needed to ensure proper mixing. Thus, numerical simulations using the ANSYS CFX package can be used to evaluate the optimal geometry for an H₂ side inlet properly, so as to reconstruct the current and improve future USP devices. Full article

Universal design, as an important concept in product development, has been gradually implemented in various industries and firms, but most of the applications are aimed at the incremental innovation of product design. However, considering the differentiation of product types, the design factors are varied and not precise, which makes it difficult to effectively implement the existing universal-design principles in specific product designs when facing architecturally innovative product development, which leads to an increasing amount of time and resources. This study, with an umbrella stand as an example, proposes to design a new universal-design scale by combining the attributes of the umbrella stand, the existing universal-design principles and the usability principles at the beginning of the design. Then, through interviews and user surveys, cluster analysis is used to screen the products and refine the design factors. In addition, with the Quantification Type I, the universal-design principles and design factors are matched effectively in order to obtain the weight differences of the product design factors and eliminate unsuitable design factors, in order to guide product design. Finally, the universal umbrella-stand-design case is completed for verification. The results show that the universal umbrella stand has been significantly improved in the evaluation of universal-design principles. In the future design, architecturally innovative products with inaccurate design factors can also use this process to complete the design and development of the target product, and to significantly enhance the universal-design evaluation of the product. Full article

We report on an ultrarapid (6 s) consolidation of binder-less WC using a novel Ultrahigh temperature Flash Sintering (UFS) approach. The UFS technique bridges the gap between electric resistance sintering (≪1 s) and flash spark plasma sintering (20–60 s). Compared to the well-established spark plasma sintering, the proposed approach results in improved energy efficiency with massive energy and time savings while maintaining a comparable relative density (94.6%) and Vickers hardness of 2124 HV. The novelty of this work relies on (i) multiple steps current discharge profile to suit the rapid change of electrical conductivity experienced by the sintering powder, (ii) upgraded low thermal inertia CFC dies and (iii) ultra-high consolidation temperature approaching 2750 °C. Compared to SPS process, the UFS process is highly energy efficient (≈200 times faster and it consumes ≈95% less energy) and it holds the promise of energy efficient and ultrafast consolidation of several conductive refractory compounds. Full article

The present research aimed to synthesize ketoprofen prodrugs and to demonstrate their potentiality for oral treatment to treat chronic inflammation by reducing its hepatotoxicity and gastrointestinal irritation. Methyl 2-(3-benzoyl phenyl) propanoate, ethyl 2-(3-benzoyl phenyl) propanoate and propyl 2-(3-benzoyl phenyl) propanoate was synthesized by esterification and identified by nuclear magnetic resonance (¹HNMR) and infrared (IR) spectrometric analysis. In silico SwissADME and ProTox-II analysis stated methyl derivative as ideal candidate for oral absorption, having a >30-fold LD50 value compared to ketoprofen with no hepatotoxicity. Moreover, in vivo hepatotoxicity study demonstrates that these ester prodrugs have significantly lower effects on liver toxicity compared to pure ketoprofen. Furthermore, ex vivo intestinal permeation enhancement ratio was statistically significant (* p < 0.05) compared to ketoprofen. Likewise, the prodrugs were found to exhibit not only remarkable in vitro anti-proteolytic and lysosomal membrane stabilization potentials, but also significant efficiency to alleviate pain induced by inflammation, as well as central and peripheral stimulus in mice model in vivo. These outcomes recommend that ketoprofen ester prodrugs, especially methyl derivative, can be a cost-effective candidate for prolonged treatment of chronic inflammatory diseases. Full article

Concerning the use of modern technologies and manufacturing systems in the production of high-stress components from Ni-base superalloys and the optimization of the production process, knowledge of the microstructure–mechanical properties relationship is very important. The microstructure of Ni-base superalloys is very closely related to the chemical composition. With the high number of alloying elements, various phases are presented in the structure of Ni-base superalloys, which have a predominantly positive effect on the mechanical properties, but also phases that reduce, in particular, the heat resistance of these materials. The aim of the presented paper is the quantification of structural parameters of two types of cast alloys, ZhS6K and IN738, where the effect of dwell at 10 and 15 h at 800 °C on the change in morphology and volume fraction of the γ′-phase precipitate was studied. The detected changes were verified by the Vickers hardness test. The IN718 superalloy was chosen as a representative of the wrought superalloy. This alloy was also annealed for 72 h at a temperature of 800 °C, and the quantification of structural parameters was performed by EDS mapping and TEM analysis. Another partial goal was to assess the effect of changes in the volume fraction of the γ′-phase and δ-phase on the change in the high-cycle fatigue life of superalloy IN 718. This superalloy was tested by dynamic cyclic loading with cycle asymmetry parameter R = −1 at an ambient temperature of 22 ± 5 °C and at a temperature of 700 ± 5 °C and with cycle asymmetry parameter R < 1 (three-point bending load) after annealing at 700 °C/72 h. The results of the quantitative analyses and fatigue tests will be further used in optimizing the design of Ni-base superalloy components by modern technologies such as additive technologies for the production of turbine blades and implemented within the philosophy of Industry 4.0. Full article

The performance of cutting tools can be significantly enhanced by matching the cutting edge rounding to the process and material properties. However, the conventional cutting edge rounding design is characterized by a significant number of experimental machining studies, which involve considerable cost, time, and resources. In this study, a novel approach to cutting edge rounding design using FEM-based chip formation simulations is presented. Based on a parameterized simulation model, tool temperatures, stresses and relative velocities can be calculated as a function of tool microgeometry. It can be shown that the external tool loads can be simulated with high agreement. With the help of these loads and the use of wear models, the resulting tool wear and the optimum cutting edge rounding can be determined. The final experimental investigations show a qualitatively high agreement to the simulation, which will enable a reduced effort design of the cutting edge in the future. Full article

This paper studies the production process of a shipbuilding enterprise. The company suffers from long manufacturing cycle, low utilization rate of personnel and an unbalanced production line. To solve these problems, the lean shipbuilding mode, mainly divided into shipbuilding work breakdown, production plan and virtual flow operation in this paper, is put forward, which combines the lean production and modern information management technology with shipbuilding. Supported by the theory of work breakdown structure and task package scheduling, the shipbuilding task package is reasonably divided. The priority of task package manufacturing is determined by calculating the task package manufacturing sequence coefficient, and a reasonable number of operators is calculated to ensure the continuity of segmented manufacturing. After determining the manufacturing priority of the task pack and the number of allocable personnel, the corresponding work can be scheduled. Production planning drives all production activities of the shipbuilding enterprise, and just-in-time production is achieved through the reasonable arrangement of these production plans, thus reducing the waste of personnel and time. Then, the virtual flow operation is carried out, which can achieve high efficiency of flow production and high flexibility of fixed workstation production during the production process of large-scale and heavy-duty products. The virtual assembly production system of the workshop is established according to the characteristics of shipbuilding operation and the actual production situation. On this basis, a lean shipbuilding manufacturing execution system for small and medium-sized shipbuilding enterprises is developed to achieve lean production in a shipbuilding workshop. Through the implementation of the lean shipbuilding mode based on task package scheduling and its manufacturing execution system, compared with the original data, the ship production cycle is reduced to 76.7%, the number of workers is reduced by 16.7% and the production balance rate is up to 81%. Full article

The cold bending method is a type of curved glass curtain wall construction method that has been used in practical engineering for a short time. It has the advantages of simple operation, high efficiency and low cost. However, the mechanical response and properties of glass panes caused by cold bending have not been solved effectively. To study the mechanical response and the properties of cold formed laminated tempered glass panes after applying with a wind load, cold bending and load tests of 9 laminated tempered glass panes were conducted by the orthogonal experimental design method. The effects of cold bending curvature, glass pane thickness and interlayer thickness were considered. In this paper, the response law of cold bending stress to the curvature and the relationship among the influencing factors were analyzed. The variation process of stress, the deflection of cold-formed glass panes under uniform load and the characteristics affected by cold-formed stress and deformation were studied. The results show that the cold bending stress is distributed in a saddle shape, and the curvature has the greatest influence on the cold bending stress, followed by the thickness of the glass panes. The influence of the interlayer thickness is small. The maximum stress appears near the corner of the short side direction adjacent to the cold bending corner. The cold bending stress increases linearly with increasing cold bending curvature. The cold bending stress and deformation have little effect on the change process of the later stage load effect. Full article

In modern chemical and oil refining complexes, separation processes are among the most popular and energy-intensive. Installations for their implementation should be equipped with nodes for creating vapor (evaporators) and liquid (deflegmators) irrigation. Evaporators of any type (film, thermosiphon, gas lift, cubic) belong to this class of devices. For example, in cubic evaporators, the gas flow is completely formed from flux bubbles that originate on the heat-conducting surface and float in the volume of the cubic liquid located in the apparatus. Due to the accompanying mass exchange, the bubbles are enriched with volatile components during ascent and noticeably increase in volume, and the growth of the bubble is determined, among other things, by the total flow. At the same time, in real bubbling-type equipment, the total mass transfer surface exceeds the cross-section of the device itself by more than two orders of magnitude. Thus, according to, the ratio of the internal cross-sectional area of the apparatus to the developed mass transfer surface is 0.0015–0.002. Based on the analysis of the integral equation of the diffusion boundary layer, it is shown that the presence of a resultant flow of substance through the phase interface (non-equimolarity of the process) in a two-phase gas (vapor)–liquid system leads to the transformation of the structure of the traditional mass transfer equation itself. The use of a new structure obtained for both binary and multicomponent mixtures makes it possible to significantly simplify the approach to the description and generalization of arbitrary mass transfer processes. The innovativeness of the proposed approach lies in its universality for non-equimolar processes. This simplifies the creation of models of any mass transfer devices and entire production lines. In addition, the proposed approach is a good auxiliary tool for various researchers and experimenters. It should also be noted that the separation processes of many products of organic origin during heating are characterized by the appearance of undesirable side reactions (thermal decomposition, condensation, polycondensation, formation of harmful impurities, etc.), which occur most intensively in the heating zones. At the same time, the evaporation and distillation units are subject to requirements for the minimum hydraulic resistance of the structure, the maximum separation capacity (efficiency), and the minimum residence time of the product in the apparatus (equivalent to the minimum holding capacity of the structure). It was noted that the specified requirements are most fully met by film-type devices. Full article

Headlights’ development for the automotive industry is gaining a lot of volatility due to frequent changes in features, styling and design, hardware interfaces, and software upgrades required by the OEM, supplier, or new trends in regulations. Standard development models based on V-cycle compliant with CMMI are not responding with reactivity on constant changes. The article proposes an approach based on mixed development strategies over the different core domains with Lean, Scrum, Feature-Driven Development, and VDI to satisfy the APQP milestones, with a proposal of a canvas-type model, the rapid delivery of headlights is portrayed. The efficiency and effectiveness of the model are assessed based on the assumed number of changes for new high-end headlights, based on experience and real cases. A delivery baseline LED-based Headlight development—planned versus actual—chart is presented and explained. Full article

Over the last few decades, advanced manufacturing and additive printing technologies have made incredible inroads into the fields of engineering, transportation, and healthcare. Among additive manufacturing technologies, 3D printing is gradually emerging as a powerful technique owing to a combination of attractive features, such as fast prototyping, fabrication of complex designs/structures, minimization of waste generation, and easy mass customization. Of late, 4D printing has also been initiated, which is the sophisticated version of the 3D printing. It has an extra advantageous feature: retaining shape memory and being able to provide instructions to the printed parts on how to move or adapt under some environmental conditions, such as, water, wind, light, temperature, or other environmental stimuli. This advanced printing utilizes the response of smart manufactured materials, which offer the capability of changing shapes postproduction over application of any forms of energy. The potential application of 4D printing in the biomedical field is huge. Here, the technology could be applied to tissue engineering, medicine, and configuration of smart biomedical devices. Various characteristics of next generation additive printings, namely 3D and 4D printings, and their use in enhancing the manufacturing domain, their development, and some of the applications have been discussed. Special materials with piezoelectric properties and shape-changing characteristics have also been discussed in comparison with conventional material options for additive printing. Full article

The process of agricultural robot design is a complex system requiring the cooperation and integration of agricultural, machinery, automation, and information technology. These demands create great challenges for the innovative design of agricultural robots. Meanwhile, more than 95% of the latest inventions and creations in the world are recorded in the patent literature. In order to make effective use of the information and data resources of patents, shorten the design cycle, and provide knowledge for the designers, according to the operation’s objectives, an agricultural robot technology knowledge graph (TKG) was established for innovative designs. By analyzing the patent information, a patent IPC co-classification network (IPCNet) for adaptive design process recognition was put forward to meet the requirements of the different operation objectives and operation links. Through the extraction of the technology keywords and efficacy keywords, based on the word co-occurrence network (WCONet), a technology–efficacy map (TEM) was constructed. Through the integration of the adaptive design process and the TEM, the agricultural robot design TKG was constructed for determining technological recommendations for agricultural robot design. The case of the citrus picking robot design was realized to implement the design process. With the technology recommendation results, the moving system, body, and end-effector for the citrus picking robot were designed to verify the results of the recommendation. Full article

The electro-hydrostatic actuator (EHA) is a type of highly integrated, compact, closed pump control drive system composed of a servo motor, a metering pump, a hydraulic cylinder and other components. Compared with the traditional valve control system, the electro-hydrostatic actuator has the advantages of a high power-to-weight ratio, high integration, environmental friendliness, and superior efficiency and energy saving. However, due to the complex mechanical–hydraulic coupling mechanism of the system and the existence of non-linear multi-source disturbances, the dynamic and static performance of the system is limited, particularly the pressure pulsation phenomenon under low-speed conditions, which seriously affects the high precision control requirements of the system. In order to address the low-speed pressure pulsation problem of the electro-hydrostatic actuator, first, the mathematical models of the servo motor, metering pump and hydraulic cylinder are established, and the simulation model of the EHA system is created based on MATLAB/Simulink. Second, from aspects of the servo motor and the quantitative piston pump, the causes of the pressure pulsation under low-speed working conditions are analyzed, and the parameter selection method of the accumulator is proposed to eliminate the pressure pulsation based on ${\omega }_n$ and $\zeta$ of the EHA system. Finally, the optimal charging pressure of the accumulator is simulated and experimentally analyzed. The simulation and experimental results show that the charging pressure range of the accumulator calculated with this method can effectively improve the pressure pulsation phenomenon of the EHA system under low-speed working conditions, and it plays a positive role in the engineering popularization and application of the EHA system. Full article

Scientific moulding, also known as decoupled injection moulding, is a production methodology used to develop and determine robust moulding processes resilient to fluctuations caused by variation in temperature and viscosity. Scientific moulding relies on the meticulous collection of data from the manufacturing process, especially inputs of time (fill, pack/hold), temperature (melt, barrel, tool), and pressure (injection, hold, etc.). This publication presents a use case where scientific moulding was used to enable the transfer and optimisation of an injection moulding process from an Arburg 221M injection moulding machine to an Arburg 375 V model. The part was an endovascular aneurysm repair dilator device where a polypropylene hub was moulded over a high-density polyethylene dilator insert. Upon transfer, multiple studies were carried out, including material rheology study during injection, gate freeze study, cavity balance of the moulding tool, and pressure loss analysis. A design of experiments was developed and carried out on the process with a variety of effects and responses. The developed process cycle time was compared to that achieved theoretically using mathematical modelling and the original process cycle time. The studies resulted in the identification of optimum parameters for injection speed, holding time, holding pressure, cooling time, and mould temperature. The process was verified by completing a 32-shot study and recording part weights and dimensional measurements to confirm repeatability and consistency of the process. The output from the study was a reduction in cycle time by 12.05 s from the original process. A cycle time of 47.28 s was theoretically calculated for the process, which is within 6.6% of the practical experiment results (44.15 s). Full article

The purpose of this study was to analyze the functioning of the vacuum distillation unit of a mini-refinery and to develop recommendations for improving the vacuum overhead system with the aim to reduce the cost of creating and maintaining a vacuum in the fuel oil separation column. A calculation model of the vacuum unit was developed in the Unisim Design R451 software package, which was identified by comparing the calculated data with the data from an industrial study for two operating modes of the installation. Replacing the existing steam-ejector pump with a liquid-ring vacuum pump was proposed. A numerical experiment was carried out on the developed model, the purpose of which was to determine the “bottlenecks” of the scheme. The peculiarity of the experiment was that the vacuum column and the vacuum overhead system were considered as a single whole. As a result, it was determined that the “bottleneck” is the condenser, which was proposed to be replaced. During the technical and economic analysis, two possible vacuum overhead system schemes were considered; according to the results, it was determined that the vacuum overhead system scheme based on a liquid-ring vacuum pump will help reduce operating costs by 78%. Full article

We aimed to increase the processing area of the roll-to-roll (R2R) nanoimprint lithography (NIL) process for high productivity, using a long roller. It is common for a long roller to have bending deformation, geometric errors and misalignment. This causes the non-uniformity of contact pressure between the rollers, which leads to defects such as non-uniform patterning. The non-uniformity of the contact pressure of the conventional R2R NIL system was investigated through finite element (FE) analysis and experiments in the conventional system. To solve the problem, a new large-area R2R NIL uniform pressing system with five multi-backup rollers was proposed and manufactured instead of the conventional system. As a preliminary experiment, the possibility of uniform contact pressure was confirmed by using only the pressure at both ends and one backup roller in the center. A more even contact pressure was achieved by using all five backup rollers and applying an appropriate pushing force to each backup roller. Machine learning techniques were applied to find the optimal combination of the pushing forces. In the conventional pressing process, it was confirmed that pressure deviation of the contact area occurred at a level of 44%; when the improved system was applied, pressure deviation dropped to 5%. Full article

Magnetic abrasive finishing (MAF) shows a high potential for use on computerized numerical control (CNC) machine tools as a standard tool to polish workpieces directly after the milling process. This paper presents a new MAF tool with a single, large permanent magnet and a novel top cover structure for finishing the plain ferromagnetic workpieces. The top cover structure of the MAF tool, combined with an optimized working gap, ensures the effect of mechanical powder compaction, which leads to a significant increase in process capability and surface roughness reduction. The influence of the process parameters such as feed rate, equivalent cutting speed, working gap (including for three grain sizes) and the gap to the magnet was investigated. In addition, the influence of the initial surface after face milling, end milling, ball end milling and grinding on the surface quality after MAF was investigated. Furthermore, three typical surfaces after milling and MAF were analyzed. By magnetic abrasive finishing, a significant surface quality improvement of the initial milled surfaces to roughness values up to Ra = 0.02 µm and Rz = 0.12 µm in one processing step could be achieved. Full article

This paper builds an infinity shaped (“∞”-shaped) laser scanning welding test platform based on a self-developed motion controller and galvanometer scanner control gateway, takes the autogenous bead-on-plate welding of 304SS with 3 mm thick specimens as the experimental objects, designs the experimental parameters by the Latin hypercube sampling method for obtaining different penetration depth welded joints, and presents a methodology based on the neuroevolution of augmenting topologies for predicting the penetration depth of “∞”-shaped laser scanning welding. Laser power, welding speed, scanning frequency, and scanning amplitude are set as the input parameters of the model, and welding depth (WD) as the output parameter of the model. The model can accurately reflect the nonlinear relationship between the main welding parameters and WD by validation. Moreover, the normalized root mean square error (NRMSE) of the welding depth is about 6.2%. On the whole, the proposed methodology and model can be employed for guiding the actual work in the main process parameters’ preliminary selection and lay the foundation for the study of penetration morphology control of “∞”-shaped laser scanning welding. Full article

Rupture discs, also called bursting discs, are widely used in pressure vessels, pressure equipment, and pressure piping in process industries, such as nuclear power, fire protection, and petrochemical industries. To explore the relationship between the burst pressure of reverse-acting rupture discs and their production, two common manufacturing methods, air pressure moulding and hydraulic moulding, were compared in this study. Reverse-acting rupture discs that complied with the form recommended by API 520-2014 were prepared with four release diameters, and burst pressure tests were carried out. These results showed an obvious negative correlation between the forming pressure of rupture discs and their actual burst pressure for all experimental samples. Further study showed that the main reason for this correlation was a reduction in thickness at the top of the rupture disc caused by large plastic deformation during compression moulding. To explore the relationship between the thickness reduction effect and moulding method, this study defined the “relative ratio of thickness reduction” and concluded that the effect of decreasing the thickness of the rupture disc was more obvious for rupture disc substrates with less flexural rigidity. The above conclusions have important significance for guiding the control of the burst pressure of rupture discs. Full article

Tool wear and cutting parameters have a significant effect on the surface layer properties in milling. Since the relation between tool wear, cutting parameters, and surface layer properties is mostly unknown, the latter cannot be controlled during production and may vary from part to part as tool wear progresses. To account for this uncertainty and to prevent premature failure, components often need to be oversized or surface layer properties need to be adjusted in subsequent manufacturing processes. Several approaches have been made to obtain models that predict the surface layer properties induced by manufacturing processes. However, those approaches need to be calibrated with a considerable number of experimental trials. As trials are time-consuming and surface layer measurements are laborious, no industrial applications have been realized. Complex models have one major drawback. They have to be re-parameterized as soon as process characteristics change. Therefore, manual experimental parameterization does not appear to be a feasible approach for industrial application. A highly automated approach for the machine learning of the relation between tool wear, cutting parameters and surface layer properties is presented in this paper. The amount of obtained measurement data allows a fundamental analysis of the approach, which paves the way for further developments. Full article

In order to attain high manufacturing productivity, industry 4.0 merges all the available system and environment data that can empower the enabled-intelligent techniques. The use of data provokes the manufacturing self-awareness, reconfiguring the traditional manufacturing challenges. The current piece of research renders attention to new consideration in the Job Shop Scheduling (JSSP) based problems as a case study. In that field, a great number of previous research papers provided optimization solutions for JSSP, relying on heuristics based algorithms. The current study investigates the main elements of such algorithms to provide a concise anatomy and a review on the previous research papers. Going through the study, a new optimization scope is introduced relying on additional available data of a machine, by which the Flexible Job-Shop Scheduling Problem (FJSP) is converted to a dynamic machine state assignation problem. Deploying two-stages, the study utilizes a combination of discrete Particle Swarm Optimization (PSO) and a selection based algorithm followed by a modified local search algorithm to attain an optimized case solution. The selection based algorithm is imported to beat the ever-growing randomness combined with the increasing number of data-types. Full article

This paper carried out the friction plug repair welding of 6082 aluminum alloy keyhole defects by using the method of friction heating between shaft shoulder and base material. In addition, a well-formed friction plug welding joint was obtained at different plug rotation speeds. In order to study the influence mechanism of plug rotation speeds on the microstructure of the weld nugget zone, EBSD technology was used to analyze the grain morphology, grain size and grain boundary characteristics of the weld nugget zone under different rotation speeds of the plug rod. The results show that in the nugget zone, the grain was fine and equated crystals refinement, and there was a preferred orientation. The deformation texture components in the welded nugget zone increased with the plug rotation speed from 1600 to 2000 rpm. However, the grain size first decreased and then increased, while the components in the High-Angle Boundary first increased and then decreased. Full article

The problem of damping torsional vibrations of the crankshaft of a multi-cylinder engine is very important from the point of view of the durability and operational reliability of the drive unit. Over the years, attempts have been made to eliminate these vibrations and the phenomena accompanying them using various methods. One of the methods that effectively increases the durability and reliability of the drive unit is the use of a torsional vibration damper. The torsional vibration damper is designed and selected individually for a given drive system. A well-selected damper reduces the amplitude of the torsional vibrations of the shaft in the entire operating speed range of the engine. This paper proposes a thermo-hydrodynamic model of a viscous torsional vibration damper that enables the determination of the correct operating temperature range of the damper. The input parameters for the model, in particular the angular velocities of the damper elements as well as the geometric and mass dimensions of the damper were determined on a test stand equipped with a six-cylinder diesel engine equipped with a factory torsional vibration damper. The damper surface operating temperatures used in model verification were measured with a laser pyrometer. The presented comparative analysis of the results obtained numerically (theoretically) and the results obtained experimentally allow us to conclude that the proposed damper model gives an appropriate approximation to reality and can be used in the process of selecting a damper for the drive unit. Full article

The large-scale application of volatile and highly water-soluble pesticides to guarantee crop production can often have negative impacts on the environment. The main loss pathways are vapor drift, direct volatilization, or leaching of the active substances. Consequently, the pesticide can either accumulate and/or undergo physicochemical transformations in the soil. In this scenario, we synthesized alginate nanoparticles using an inverse miniemulsion template in sunflower oil and successfully used them to encapsulate a hydrophilic herbicide, i.e., dicamba. The formulation and process conditions were adjusted to obtain a unimodal size distribution of nanohydrogels of about 20 nm. The loading of the nanoparticles with dicamba did not affect the nanohydrogel size nor the particle stability. The release of dicamba from the nanohydrogels was also tested: the alginate nanoparticles promoted the sustained and prolonged release of dicamba over ten days, demonstrating the potential of our preparation method to be employed for field application. The encapsulation of hydrophilic compounds inside our alginate nanoparticles could enable a more efficient use of pesticides, minimizing losses and thus environmental spreading. The use of biocompatible materials (alginate, sunflower oil) also guarantees the absence of toxic additives in the formulation. Full article

In the duplex steelmaking process, the oxygen flow rate is suppressed to reduce the increasing rate of the temperature in the molten bath, resulting in severe dynamic conditions. To improve the mixing effect of the molten bath, a Laval nozzle structure designed for combination gas has been proposed. In this research, five types of Laval nozzle structure have been built based on the combination gas content, and both numerical simulations and experiments are performed to analyze the flow field of the supersonic jet. The axial velocity and oxygen concentration were measured in the experiment, which agreed well with the numerically simulated data. The results show that both initial axial velocity and potential core length increase with the flow rate of combination gas. Further, applying a higher N₂ flow rate could improve the oxygen utilization rate at different ambient temperatures, but this issue increases the oxygen utilization rate; however, the latter can be reduced at higher ambient temperatures. Full article

This paper studies the evolution of the microstructure and microhardness in the G115 side of the G115/Sanicro25 dissimilar steel welded joint during the creep process. The joints were subjected to creep tests at 675 °C, 140 MPa, 120 MPa and 100 MPa. A scanning electron microscope equipped with an electron backscattering diffraction camera was used to observe the microstructure of the cross-section. The fracture position of the joint and the relationship between the cavity and the second phase were analyzed. The microstructure morphology of the fracture, the base metal and the thread end was compared and the composition and size of the Laves phase were statistically analyzed. The results show that the fracture locations are all located in the fine-grain heat-affected zone (FGHAZ) zone, and the microstructure near the fracture is tempered martensite. There are two kinds of cavity in the fracture section. Small cavities sprout adjacent to the Laves phase; while large cavities occupy the entire prior austenite grain, there are more precipitated phases around the cavities. The Laves phase nucleates at the boundary of the M₂₃C₆ carbide and gradually grows up by merging the M₂₃C₆ carbide. Creep accelerates the coarsening rate of the Laves phase; aging increases the content of W element in the Laves phase. Full article

In this paper, in order to improve the control characteristics of the centrifugal pump flow control system, a mathematical model of the centrifugal pump flow control system was established based on an analysis of the basic structures, such as the frequency converter, motor, and centrifugal pump. Based on the adaptive control theory, the recursive least squares algorithm with a forgetting factor was used to estimate the real-time parameters of the centrifugal pump control system, and the self-tuning PID control method was used to optimize the mathematical model of the centrifugal pump flow control system. The simulation results showed that the adjustment time of the optimized system was shortened by 16.58%, and the maximum overshoot was reduced by 83.90%, which improved the rapidity and stability of the transient response of the system. This showed that adaptive control had a significant effect on improving the robustness and anti-interference ability of the centrifugal pump control system. In order to further verify the accuracy of the self-tuning PID control method, a flow adaptive control system test platform was built. The test results showed that under the conditions of constant frequency and variable frequency, the actual flow rate of the centrifugal pump was always kept near the set flow rate, the error was small, and it had better real-time followability. The research results showed that adaptive control could revise the parameters in real-time according to changes to the centrifugal pump control system, which improved the stability and robustness of the system. Therefore, adaptive PID control could effectively improve the adaptability of centrifugal pumps to various complex working conditions and improve the working efficiency of centrifugal pumps. Full article

Microwave technology is widely used in different areas of advanced industry when energy must be provided to water-containing and other materials. The main barrier in the development of microwave devices is the possibility of efficient design by modelling a microwave system in a resonant state. For technical systems, the finite element method is widely used. However, the convergence process in the microwave finite element solver is sophisticated. The process itself and the influence of mesh granularity on the accuracy of modelling of microwave chambers in resonant states have not been investigated previously. The present paper aims to fill this gap. The resonance conditions of a microwave chamber were tested from the point of view of spatial resolution of the tetrahedral mesh used for open-source ELMER FEM software. The presented results experimentally determine the limits of accuracy of the geometry of microwave resonant chamber finite element method-based models. The determined values of microwave resonant chamber dimension tolerances should be considered for both open-source and commercial software for microwave modelling. Full article

The article discusses the influence of the post-process on the mechanical properties of elements produced with the use of the mask stereolithography (mSLA) method. Printed samples were subjected to the following post-process steps: Washing and post-curing, at various times. Then, static tensile and static bending tests were carried out, as well as Shore D hardness measurements for the inner and surface part of the sample, as well as profilographometric analysis of the surface. The post-curing time has been found to strongly affect the tensile and bending strength of printouts, and to improve their surface quality. Washing has an ambiguous effect on the strength of the printouts, but, in the end, it was found that extended washing slightly reduces the strength. Washing significantly affects the quality of the printout surface. A washing time that is too short results in a surface that strongly resembles the printing process, with high roughness. Increasing the washing time to 10 min lowers the roughness by one order of magnitude. Post-curing has also been shown to be beneficial for the cured sample with the application of shielding water. This approach results in an improvement in the flexural strength of the printouts. In general, the obtained research results indicate that, for printouts with cross-sectional dimensions of several mm, the optimal washing time is no more than 10 min and the post-curing time is at least 30 min. Full article

During air bending of sheet metals, the correction of punch stroke for springback control is always implemented through repeated trial bending until achieving the forming accuracy of bending parts. In this study, a modelling method for correction of punch stroke is presented for guiding trial bending based on a data-driven technique. Firstly, the big data for the model are mainly generated from a large number of finite element simulations, considering many variables, e.g., material parameters, dimensions of V-dies and blanks, and processing parameters. Based on the big data, two punch stroke correction models are developed via neural network and dimensional analysis, respectively. The analytic comparison shows that the neural network model is more suitable for guiding trial bending of sheet metals than the dimensional analysis model, which has mechanical significance. The actual trial bending tests prove that the neural-network-based punch stroke correction model presents great versatility and accuracy in the guidance of trial bending, leading to a reduction in the number of trial bends and an improvement in the production efficiency of air bending. Full article

Currently, some coffee production centers still perform classification manually, which requires a very long time, a lot of labor, and expensive operational costs. Therefore, the purpose of this research was to design and test the performance of a coffee bean classifier that can accelerate the process of classifying beans. The classifier used consisted of three main parts, namely the frame, the driving force, and sieves. The research parameters included classifier work capacity, power, specific energy, classification distribution and effectiveness, and efficiency. The results showed that the best operating conditions of the coffee bean classifier was a rotational speed of 91.07 rpm and a 16° sieve angle with a classifier working capacity of 38.27 kg/h: the distribution of the seeds retained in the first sieve was 56.77%, the second sieve was 28.12%, and the third sieve was 15.11%. The efficiency of using a classifier was found at a rotating speed of 91.07 rpm and a sieve angle of 16°. This classifier was simple in design, easy to operate, and can sort coffee beans into three classifications, namely small, medium, and large. Full article

Fertilizers are commonly used to improve the soil quality in both conventional and organic agriculture. One such fertilizer is dolomite for which soil application in granulated form is advantageous. These granules are commonly produced from ground dolomite powder in continuous pan transfer granulators. During production, the granulator’s operation parameters affect the granules’ properties and thereby also the overall performance of the fertilizer. To ensure product granules of certain specifications and an efficient overall production, process control and intensification approaches based on mathematical models can be applied. However, the latter require high-quality quantitative experimental data describing the effects of process operation parameters on the granule properties. Therefore, in this article, such data is presented for a lab-scale experimental setup. Investigations were carried out into how variations in binder spray rate, binder composition, feed powder flow rate, pan inclination angle, and angular velocity affect particle size distribution, mechanical stability, and humidity. Furthermore, in contrast to existing work samples from both, pan granules and product granules are analyzed. The influence of operation parameter variations on the differences between both, also known as trajectory separation, is described quantitatively. The results obtained indicate an increase in the average particle size with increasing binder flow rate to feed rate and increasing binder concentration and the inclination angle of the pan. Compressive strength varied significantly depending on the operating parameters. Significant differences in properties were observed for the product and the intermediate (pan) samples. In fact, for some operation parameters, e.g., binder feed rate, the magnitude of the separation effect strongly depends on the specific value of the operation parameter. The presented concise data will enable future mathematical modeling of the pan granulation process, e.g., using the framework of population balance equations. Full article

The paper presents the design and testing of a new servo drive for turning non-circular shapes. The presented solution is based on a commercially available piezoelectric drive unit with a stroke equal to 1000 µm and a resonant frequency of 150 Hz. The device was used in a conventional turning lathe and installed in a tool turret. The performance of the proposed tool was tested while turning multiple non-circular contours from a cylindrical shaft made of 6082 aluminum alloy. The machining accuracy was tested online using a laser sensor and offline with a coordinate measuring machine. The additional aim of those tests was also to verify if the application of an online transducer can allow a confident preliminary assessment of as-machined geometry. The drive positioning accuracy was compensated using 6th order polynomial what resulted in the fabrication of non-circular contours with an accuracy of no less than 39.8 µm when operating below the limit frequency of the drive (<9 Hz). It was found out that the deviations of the profile from ideal geometries increase linearly with frequency when turning at higher than the limit frequency. Full article

Low-rigidity thin-walled parts are components of many machines and devices, including high precision electric micro-machines used in control and tracking systems. Unfortunately, traditional machining methods used for machining such types of parts cause a significant reduction in efficiency and in many cases do not allow obtaining the required accuracy parameters. Moreover, they also fail to meet modern automation requirements and are uneconomical and inefficient. Therefore, the aim of provided studies was to investigate the dependency of cutting forces on cutting parameters and flank wear, as well as changes in cutting forces induced by changes in heating current density and machining parameters during the turning of thin-walled parts. The tests were carried out on a specially designed and constructed turning test stand for measuring cutting forces and temperature at specific cutting speed, feed rate, and depth of cut values. As part of the experiments, the effect of cutting parameters and flank wear on cutting forces, and the effect of heating current density and turning parameters on changes in cutting forces were analyzed. Moreover, the effect of cutting parameters (depth of cut, feed rate, and cutting speed) on temperature has been determined. Additionally, a system for controlling electro-contact heating and investigated the relationship between changes in cutting forces and machining time in the operations of turning micro-machine casings with and without the use of the control system was developed. The obtained results show that the application of an electro-contact heating control system allows to machine conical parts and semi-finished products at lower cutting forces and it leads to an increase in the deformation of the thin-walled casings caused by runout of the workpiece. Full article

The Kenics static mixer is one of the most widely studied static mixers, whose structure–function relationship has been studied by varying its aspect ratio and modifying the surface. However, the effect of the symmetric structure of the Kenics static mixer itself on twisting the fluid has been neglected. In order to study how the symmetrical structure of the Kenics static mixer impacts the fluid flow, we changed the center position of elements at twist angle 90° and introduced the eccentricity factor $\gamma$. We applied LHS-PLS to study this non-standard Kenics static mixer and obtained the statistical correlations of the aspect ratio, Reynolds number, and eccentricity factor on relative Nusselt number and relative friction factor. We analyzed the results by comparing the PLS model with the univariate analysis, and it was found that the underlying logic of the Kenics static mixer with an asymmetric structure became different. In addition, a non-standard Kenics static mixer with an asymmetric structure was investigated using vortex generation and dissipation through fluid flow simulation. The results demonstrated that the classical symmetric structure has a minor pressure drop, but the backward eccentric one has a higher thermal-hydraulic performance factor. It was found that the nature of the eccentric structure is that two elements with different aspect ratios are being combined at $\theta =90°$, and this articulation leads to non-standard Kenics static mixers with different underlying logic, which finally result in the differences between the PLS model and the univariate analysis. Full article

Aiming at the problems of over stacking, warping deformation and rapid adjustment of layer thickness in electron beam additive manufacturing, the 3D printing slicing algorithm and partition scanning strategy for numerical control systems are studied. The GPU (graphics processing unit) is used to slice the 3D model, and the STL (stereolithography) file is calculated in parallel according to the normal vector and the vertex coordinates. The voxel information of the specified layer is dynamically obtained by adjusting the projection matrix to the slice height. The MS (marching squares) algorithm is used to extract the coordinate sequence of the binary image, and the ordered contour coordinates are output. In order to avoid shaking of the electron gun when the numerical control system is forming the microsegment straight line, and reduce metal overcrowding in the continuous curve C⁰, the NURBS (non-uniform rational b-splines) basis function is used to perform curve interpolation on the contour data. Aiming at the deformation problem of large block components in the forming process, a hexagonal partition and parallel line variable angle scanning technology is adopted, and an effective temperature and deformation control strategy is formed according to the European-distance planning scan order of each partition. The results show that the NURBS segmentation fits closer to the original polysurface cut line, and the error is reduced by 34.2% compared with the STL file slice data. As the number of triangular patches increases, the algorithm exhibits higher efficiency, STL files with 1,483,132 facets can be cut into 4488 layers in 89 s. The slicing algorithm involved in this research can be used as a general data processing algorithm for additive manufacturing technology to reduce the waiting time of the contour extraction process. Combined with the partition strategy, it can provide new ideas for the dynamic adjustment of layer thickness and deformation control in the forming process of large parts. Full article

A digitalization of business process through utilizing Digital Twins is an approach that assists companies to align themselves with changes of technology development, and accordingly, improve their outcomes. To take full advantage of implementing Digital Twins, the importance of the creative phase role as pillars of this technology on the performance of the other parts and overall outcome should not be overlooked. This research addresses the lack of an integrated framework for setting up the creative phase of digital twins. To design the proper framework, by relying on a qualitative empirical method, an interview with persons who are experts in the Digital Twin area was organized to collect the information about all obvious and hidden aspects of this phase and manifest what kind of entities participate in this phase, what potential challenges and obstacles exist and what solution is effective to overcome them. The structural feature of the proposed framework continuously prepares the system for changes, aiming to adopt improvement within. The findings of this study can be used as instruction by all companies that want to take the first steps toward the digital representation of physical assets, or for those who deal with Digital Twin and want to improve their systems’ interactions. Full article

As the applications of heterogeneous materials expand, aluminum laminates of similar materials have attracted much attention due to their greater bonding strength and easier recycling. In this work, an alloy design strategy was developed based on accumulative roll bonding (ARB) to produce laminates from similar materials. Twin roll casting (TRC) sheets of the same composition but different cooling rates were used as the starting materials, and they were roll bonded up to three cycles at varying temperatures. EBSD showed that the two TRC sheets deformed in distinct ways during ARB processes at 300 °C. Major recrystallizations were significant after the first cycle on the thin sheet and after the third cycle on the thick sheet. The sheets were subject to subsequent aging for better mechanical properties. TEM observations showed that the size and distribution of nano-precipitations were different between the two sheet sides. These nano-precipitations were found to significantly promote precipitation strengthening, and such a promotive effect was referred to as hetero-deformation induced (HDI) strengthening. Our work provides a new promising method to prepare laminated heterogeneous materials with similar alloy TRC sheets. Full article

The article analyses and evaluates the ever-important topic of assessing geometric deviation of tolerated formations related to bases with the usage of coordinate measuring machines. The basic system for off-line simulation consists of the coordinate planes of a component’s coordinate system. At the beginning of the measurement, the coordinate system is created by the “3–2–1” alignment. Due to production deviations in real surfaces of the component, each measurement generates mutually different coordinate systems, which is well proven by the experiment on measuring with a coordinate measuring machine DEA Global Performance 12.22.10. An integral part of the article is also the quantification of geometric deviations of ideal tolerated formations related to bases, the estimate of the uncertainty of measurement arising from the placement of points in defining the base system, and the effect of such uncertainty upon the interval of satisfactory values in conformity with the STN EN ISO 14253-1 technical standard. The article also includes a proposal measure in order to ensure the reproducibility of defining the mutual position of coordinate systems. Full article