The last few decades have seen rapid growth in additive manufacturing (AM) technologies. AM has implemented a novel method of production in design, manufacture, and delivery to end-users. Accordingly, AM technologies have given great flexibility in design for building complex components, highly customized products, effective waste minimization, high material variety, and sustainable products. This review paper addresses the evolution of engineering design to take advantage of the opportunities provided by AM and its applications. It discusses issues related to the design of cellular and support structures, build orientation, part consolidation and assembly, materials, part complexity, and product sustainability.
Industry 4.0 (I4.0) has increasingly been adopted as an advanced manufacturing strategy to counter global competition. The capability of a company to compete on various manufacturing strategy outputs (MSOs) such as cost, quality, delivery, flexibility, performance and innovativeness play a significant role in motivating the whole company to take advantage of its competitors. I4.0 is comprised of various technologies, and how I4.0 technologies can influence the MSOs are still unclear, and it took less interest in the literature. This article aims to analyze the influence of the I4.0 technologies on MSOs to achieve market competitiveness from the perspective of academic and industry experts. To do so, the influence of the adoption of various I4.0 technologies on the MSOs was investigated. Expert opinions were gathered on the relationship between manufacturing competitive capabilities and I4.0 technologies. The identification of the influential relationships provides arguments for the proposed I4.0 technology selections, which will allow companies to gain a highly competitive advantage. The results showed that the performance (regarding the MSOs) had a high potential for integration with different I4.0 technologies.
The turning, which consists of the removal of metal from the outer diameter of a rotating cylindrical workpiece, is one of the most common techniques for cutting, especially when finishing the product. The values of the cutting parameters, such as feed rate, cutting speed, and depth of cut, in a turning operation must be selected carefully to improve the profit of operations by enhancing productivity and reducing the total manufacturing cost for each component. A high vibration leads to poor surface finish and reduced productivity and shortens the tool life; therefore, this parameter should be controlled. In this study, an experiment is conducted to investigate the effects of these cutting parameters in the turning process of a workpiece, composed of AISI 1040 steel, using the response surface method. Statistical tools were used to design the experiments. These parameters are optimized by using analysis of variance, regression, and optimization techniques to achieve the condition of minimum vibration and chip frequency, therefore improving the surface roughness after the turning process.
Electron beam melting (EBM) is a relatively new process in three-dimensional (3D) printing to enable rapid manufacturing. EBM can manufacture metallic parts with thin walls, multi-layers, and complex internal structures that could not otherwise be produced for applications in aerospace, medicine, and other fields. A 3D transient coupled thermomechanical finite element (FE) model was built to simulate the temperature distribution, distortion, and residual stresses in electron beam additive manufactured Ti-6Al-4V parts. This research enhances the understanding of the EBM-based 3D printing process to achieve parts with lower levels of residual stress and distortion and hence improved quality. The model used a fine mesh in the layer deposition zone, and the mesh size was gradually increased with distance away from the deposits. Then, elements are activated layer by layer during deposition according to the desired material properties. On the top surface, a Gaussian distributed heat flux is used to model the heat source, and the temperature-dependent properties of the powder and solid are also included to improve accuracy. The current simulation has been validated by comparing the FE distortion and temperature results with the experimental results and other reported simulation studies. The residual stress results calculated by the FE analysis were also compared with the previously reported simulation studies on the EBM process. The results showed that the finite element approach can efficiently and accurately predict the temperature field of a part during the EBM process and can easily be extended to other powder bed fusion processes.
Globalization has created a highly competitive and diverse market, an uncertain and risky business environment, and changing customer expectations. An effective manufacturing strategy reduces complexity and provides organizations with a well-organized manufacturing structure. However, existing research on manufacturing strategies appears scattered, lacking systematic understanding and finding no causal relationship between manufacturing strategies’ outputs (MSOs) and their importance. Therefore, this study is a pioneer in identifying the influential factors of MSOs in the adoption of Industry 4.0 (I4.0) technologies utilizing the decision-making trial and evaluation laboratory (DEMATEL) approach. This method is considered an effective method for identifying the cause-effect relationship of complex problems. It evaluates interdependent relationships among MSO factors from the perspective of academic and industry experts. Identifying cause and effect factors leads to increasing the market’s competitiveness and prioritizing them. To deal with the vagueness of human beings’ perceptions, this study utilizes fuzzy set theory and the DEMATEL method to form a structural model. Results show that customer satisfaction, cost per unit produced, and the number of advanced features are the main factors influencing MSOs.
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