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In the era of Industry 4.0, the idea of 3D printed products has gained momentum and is also proving to be beneficial in terms of financial and time efforts. These products are physically built layer-by-layer based on the digital Computer Aided Design (CAD) inputs. Nonetheless, 3D printed products are still subjected to defects due to variation in properties and structure, which leads to deterioration in the quality of printed products. Detection of these errors at each layer level of the product is of prime importance. This paper provides the methodology for layer-wise anomaly detection using an ensemble of machine learning algorithms and pre-trained models. The proposed combination is trained offline and implemented online for fault detection. The current work provides an experimental comparative study of different pre-trained models with machine learning algorithms for monitoring and fault detection in Fused Deposition Modelling (FDM). The results showed that the combination of the Alexnet and SVM algorithm has given the maximum accuracy. The proposed fault detection approach has low experimental and computing costs, which can easily be implemented for real-time fault detection.

The Fourth Industrial Revolution drives industries from traditional manufacturing to the smart manufacturing approach. In this transformation, existing equipment, processes, or devices are retrofitted with some sensors and other cyber-physical systems (CPS), and adapted towards digital production, which is a blend of critical enabling technologies. In the current scenario of Industry 4.0, industries are shaping themselves towards the development of customized and cost-effective processes to satisfy customer needs with the aid of a digital twin framework, which enables the user to monitor, simulate, control, optimize, and identify defects and trends within, ongoing process, and reduces the chances of human prone errors. This paper intends to make an appraisal of the literature on the digital twin (DT) framework in the domain of smart manufacturing with the aid of critical enabling technologies such as data-driven systems, machine learning and artificial intelligence, and deep learning. This paper also focuses on the concept, evolution, and background of digital twin and the benefits and challenges involved in its implementation. The Scopus and Web of Science databases from 2016 to 2021 were considered for the bibliometric analysis and used to study and analyze the articles that fall within the research theme. For the systematic bibliometric analysis, a novel approach known as Proknow-C was employed, including a series of procedures for article selection and filtration from the existing databases to get the most appropriate articles aligned with the research theme. Additionally, the authors performed statistical and network analyses on the articles within the research theme to identify the most prominent research areas, journal/conference, and authors in the field of a digital twin. This study identifies the current scenarios, possible research gaps, challenges in implementing DT, case studies and future research goals within the research theme.

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An increase in unplanned downtime of machines disrupts and degrades the industrial business, which results in substantial credibility damage and monetary loss. The cutting tool is a critical asset of the milling machine; the failure of the cutting tool causes a loss in industrial productivity due to unplanned downtime. In such cases, a proper predictive maintenance strategy by real-time health monitoring of cutting tools becomes essential. Accurately predicting the useful life of equipment plays a vital role in the predictive maintenance arena of industry 4.0. Many active research efforts have been done to estimate tool life in varied directions. However, the consolidated study of the implemented techniques and future pathways is still missing. So, the purpose of this paper is to provide a systematic and comprehensive literature survey on the data-driven approach of Remaining Useful Life (RUL) estimation of cutting tools during the milling process. The authors have summarized different monitoring techniques, feature extraction methods, decision-making models, and available sensors currently used in the data-driven model. The authors have also presented publicly available datasets related to milling under various operating conditions to compare the accuracy of the prediction model for tool wear estimation. Finally, the article concluded with the challenges, limitations, recent advancements in RUL prognostics techniques using Artificial Intelligence (AI), and future research scope to explore more in this area.

The mechanical, physical and interfacial properties of aluminum alloys are improved by reinforcing the silicon carbide particles (SiCp). Machinability of such alloys by traditional methods is challenging due to higher tool wear and surface roughness. The objective of research is to investigate the machinability of SiCp reinforced Al6061 composite by Wire-Electrical Discharge Machining (wire-EDM). The effect of wire-EDM parameters namely current (I), pulse-on time (Ton), wire-speed (Ws), voltage (Iv) and pulse-off time (Toff) on material removal rate (MRR) is investigated and their settings are optimized for achieving the high MRR. The experiments are designed by using Taguchi L16 orthogonal arrays. The MRR obtained at different experiments are analyzed using statistical tools. It is observed that all the chosen process parameters showed significant influence of on the MRR with contribution of 27.39%, 22.08%, 21.32%, 15.76% and 12.94% by I, Iv, Toff, Ton and Ws, respectively. At optimum settings, the Wire-EDM resulted in MRR of 65.21 mg/min and 62.41 mg/min for samples with 4% and 8% SiCp. The results also indicated reinforcing SiCp upto 8% showed marginally low influence on MRR. Microstructural investigation of the cut surface revealed the presence of craters with wave pattern on its surface. The top surface of the crater is featured by the recast layers connecting adjacent craters. Further, the statistical model is developed using linear regression to predict the MRR (?2—73.65%) and its predicting accuracy is verified by the confirmation trials. The statistical model is useful for predicting the MRR for different settings of the process parameters. The optimized settings can be used to improve the machining productivity by increasing the MRR while machining of Al6061-SiCp (upto 8 wt. %) alloy by wire-EDM industries.

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