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Recent Industry and Engineering Achievements and Their Impact on Material and Manufacturing Processes

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 December 2023) | Viewed by 8190

Special Issue Editors

Dr. Aleksander Gwiazda

E-Mail Website
Guest Editor
Department of Engineering Processes Automation and Integrated Manufacturing Systems, Faculty of Mechanical Engineering, Silesian University of Technology, Konarskiego 18A, 44-100 Gliwice, Poland
Interests: designing machine systems; material design; the combination of mechanical engineering and material engineering; the modeling of processes and systems; computer analysis
Dr. Iwona Paprocka

E-Mail Website
Guest Editor
Department of Engineering Processes Automation and Integrated Manufacturing Systems, Faculty of Mechanical Engineering, Silesian University of Technology, Konarskiego 18A Str., 44-100 Gliwice, Poland
Interests: predictive scheduling; maintenance scheduling; artificial intelligence; metaheuristic; production control; production scheduling; industry 4.0
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The Special Issue is dedicated to the Fourth Industrial Revolution and aims to promote new intelligent technologies in the field of material processes automation, robotization, control and monitoring, as well as promoting innovative approaches to manufacturing processes and applications of material solutions in technical systems. One of the dimensions of the Fourth Industrial Revolution is the advanced combination of virtual and real tools and tests to improve the efficiency of modern engineering science. On the other hand, due to intelligent, autonomous company systems, the manufacturing processes from design, through processing and transportation, to disassembly and material recovery are more transparent and controllable. Analyses of the influence of parameters of materials, machines, processes and systems on the key success factors of engineering projects are welcomed. In addition, it is interesting to use mathematical modeling, simulation, machine learning, optimization and control to estimate the obtained material properties and improve system parameters in terms of reliability, stability and sustainability, including but not limited to the following topics: intelligent and innovative processing and production systems (including 3D printing, additive technologies, vacuum molding, etc.); the modeling and simulation of material, machining and production processes as well as logistics processes (including reverse logistics), taking into account virtual and virtual–real research approaches.; optimization of material and process parameters, including advances in material and manufacturing processes. The monitoring of material, technological and production parameters, as well as fault diagnoses (including Big Data processing, cloud computing, blockchain technology, etc.); innovative approaches to material protection as well as machine maintenance and self-awareness; and new methods for the testing and measurement of material and process parameters. It is our pleasure to invite you to submit a manuscript for this Special Issue.

Dr. Aleksander Gwiazda
Dr. Iwona Paprocka
Guest Editors

Manuscript Submission Information

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

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

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • 3D printing
  • additive technologies
  • vacuum molding
  • modeling and simulation of material and production processes
  • monitoring of technological and production parameters
  • optimization of material and process parameters
  • logistics processes
  • reverse logistics
  • monitoring of material processes
  • fault diagnosis
  • machine maintenance

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Published Papers (4 papers)

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Research

25 pages, 6773 KiB  
Article
Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al–PE) Using Taguchi Orthogonal Array Design
by Bekir Yalçın, Ali Yüksel, Kubilay Aslantaş, Oguzhan Der and Ali Ercetin
Materials 2023, 16(13), 4528; https://doi.org/10.3390/ma16134528 - 22 Jun 2023
Cited by 14 | Viewed by 1521
Abstract
Aluminum Matrix Composite (AMC) represents an innovative class of materials that is extensively utilized in industries such as automotive, defense, aerospace, structural engineering, sports, and electronics. This study investigates the thrust force, exit burr formation, changes in the micro-tool, and drilled hole diameters [...] Read more.
Aluminum Matrix Composite (AMC) represents an innovative class of materials that is extensively utilized in industries such as automotive, defense, aerospace, structural engineering, sports, and electronics. This study investigates the thrust force, exit burr formation, changes in the micro-tool, and drilled hole diameters during the micro-drilling of an aluminum-polyethylene composite panel (Al–PE). The panel consists of 3501 series aluminum skin materials bonded to a polyethylene (PE) core. Micro-drilling test parameters were designed using Taguchi’s L16 (42 23) orthogonal array. Tests were conducted with five control parameters: cutting speed with four levels (10 m/min, 20 m/min, 30 m/min, 40 m/min), feed rate with four levels (0.5 µm/rev, 1 µm/rev, 2 µm/rev, 4 µm/rev), the tool diameter with two levels (0.7 mm, 1 mm), and tool point angle with two levels (100°, 140°) using both AlTiN-coated and uncoated drills. The maximum thrust force (Fz), maximum burr height, and changes in both the drill tool and hole diameters were measured for analysis of variance (ANOVA). The results showed that, in terms of impact on Fz, tool point angle had the highest positive influence (64.54%) on the micro-drill at the entrance of composite (upper aluminum plate). The cutting speed had the highest positive influence (45.32%) on the tool in the core layer (PE core layer). The tool point angle also had the highest positive influence (68.95%) on the micro-drill at the lower layer of the composite (the lower aluminum plate). There was noticeable chip adhesion on the major cutting edge and nose area under micro-drilling conditions with higher thrust forces and burr height. The AlTiN coating had a positive effect on tool wear and hole diameter deviations, but it adversely affected the burr height. Full article
(This article belongs to the Special Issue Recent Industry and Engineering Achievements and Their Impact on Material and Manufacturing Processes)
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21 pages, 3628 KiB  
Article
Integration of Discrete Simulation, Prediction, and Optimization Methods for a Production Line Digital Twin Design
by Damian Krenczyk and Iwona Paprocka
Materials 2023, 16(6), 2339; https://doi.org/10.3390/ma16062339 - 14 Mar 2023
Cited by 9 | Viewed by 2377
Abstract
The integration of discrete simulations, artificial intelligence methods, and the theory of probability in order to obtain a high flexibility of the production system is crucial. In this paper, the concept of a smart factory operation is proposed along with the idea of [...] Read more.
The integration of discrete simulations, artificial intelligence methods, and the theory of probability in order to obtain a high flexibility of the production system is crucial. In this paper, the concept of a smart factory operation is proposed along with the idea of data exchange architecture, simulation creation, performance optimization, and predictive analysis of the production process conditions. A Digital Twin for a hybrid flow shop from the automotive industry is presented as a case study. In the paper, the Ant Colony Optimization (ACO) algorithm is developed for multi-criteria scheduling problems in order to obtain a production plan without delays and maximum resource utilization. The ACO is compared to the immune algorithm and genetic algorithm. The best schedules are achieved with low computation time for the Digital Twin. By predicting the reliability parameters of the limited resources of the Digital Twin, stable deadlines for the implementation of production tasks are achieved. Mean Time To Failure and Mean Time of Repair are predicted for a real case study of an electric steering gear production line. The presented integration and data exchange between the elements of the smart factory: a Digital Twin, a computing module including an optimization, prediction, and simulation methods fills the gap between theory and practice for Industry 4.0. The paper presents measurable benefits of integration of discrete simulation tools, historical data analysis, and optimization methods. Full article
(This article belongs to the Special Issue Recent Industry and Engineering Achievements and Their Impact on Material and Manufacturing Processes)
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12 pages, 5900 KiB  
Article
Susceptibility of High-Manganese Steel to High-Temperature Cracking
by Gabriela Fojt-Dymara, Marek Opiela and Wojciech Borek
Materials 2022, 15(22), 8198; https://doi.org/10.3390/ma15228198 - 18 Nov 2022
Cited by 7 | Viewed by 1825
Abstract
Tests were carried out on two high-Mn steels: 27Mn-4Si-2Al-Nb with Nb microaddition and 24Mn-3Si-1.5Al-Nb-Ti with Nb and Ti microadditions. High-manganese austenitic steels, due to their good strength and plastic properties belong to the AHSS (Advanced High-Strength Steel) group and are used in the [...] Read more.
Tests were carried out on two high-Mn steels: 27Mn-4Si-2Al-Nb with Nb microaddition and 24Mn-3Si-1.5Al-Nb-Ti with Nb and Ti microadditions. High-manganese austenitic steels, due to their good strength and plastic properties belong to the AHSS (Advanced High-Strength Steel) group and are used in the automotive industry. The main difficulties faced during the casting of the steel and hot working are hot cracks, which can appear in the surface of the ingot. Cracks on the edges of the sheet after hot rolling are the reason for cutting the edges of the sheet and increasing production costs and material losses. The main reason for the formation of hot cracks is the decrease in metal ductility in the high-temperature brittleness range (HTBR). The width of the HTBR depends on mechanical properties and microstructural factors, i.e., non-metallic inclusions or intermetallic phases at austenite grain boundaries. In this paper, a hot tensile test was performed. The research was performed on the GLEEBLE 3800 thermomechanical simulator. This test allows us to determine the width of the high-temperature brittleness range (HTBR), the Nil Strength Temperature (NST), the Nil Ductility Temperature (NDT), and the Ductility Recovery Temperature (DRT). Hot ductility was determined from the value of the reduction in area R(A). The obtained results make it possible to determine the temperature of the beginning of hot working from the tested high-Mn steels. Fractographic research enabled us to define mechanisms of hot cracking. It was found that hot cracks form as a result of disruptions in the liquid film on crystals’ boundaries. Full article
(This article belongs to the Special Issue Recent Industry and Engineering Achievements and Their Impact on Material and Manufacturing Processes)
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15 pages, 5808 KiB  
Article
Effect of the Mass Fraction of NiTi–TiB2 SHS-Particles on the Phase Composition, Structure, and Mechanical Properties of Inconel 625–NiTi–TiB2 Composites Produced by Direct Laser Deposition
by Alexey Matveev, Vladimir Promakhov, Nikita Schulz, Vladislav Bakhmat, Artem Babaev, Artem Semenov and Alexander Vorozhtsov
Materials 2022, 15(19), 6861; https://doi.org/10.3390/ma15196861 - 2 Oct 2022
Cited by 4 | Viewed by 1725
Abstract
This paper studies the impact of the mass fraction of NiTi–TiB2 particles obtained by the method of self-propagating high-temperature synthesis (SHS) on the phase composition, structure, and mechanical properties of composites made by direct laser deposition from an Inconel 625–NiTiz–TiB2 powder [...] Read more.
This paper studies the impact of the mass fraction of NiTi–TiB2 particles obtained by the method of self-propagating high-temperature synthesis (SHS) on the phase composition, structure, and mechanical properties of composites made by direct laser deposition from an Inconel 625–NiTiz–TiB2 powder mixture. Composites were obtained from a powder mixture with the mass fraction of particles at 5–10 wt%, and they consisted of an Inconel 625 metal matrix wherein ceramic inclusions of titanium diboride TiB2 were distributed. Increasing the mass fraction of SHS-produced NiTi particles from 30 to 95 wt% led to the emergence of a NiTi intermetallide phase in the matrix material as well as an increase in the average TiB2 particle size and formation of their agglomerates. In addition, an increase in the microhardness of the materials was observed. The graph of tensile strength of Inconel 625–NiTi–TiB2 samples has a parabolic shape with a maximum at 1000 MPa (when the mass fraction of SHS-produced NiTi–TiB2 particles is at 30 wt%). A further increase in the mass fraction of NiTi–TiB2 led to a decrease in the tensile strength down to 400 MPa. Here the deformation of samples decreases linearly as the ratio of composite particles in the initial mixture increases. From a comparative analysis of the results obtained, the optimal mass fraction of composite NiTi–TiB2 particles in the Inconel 625-NiTi–TiB2 powder mixture was found to be 5 wt%. Full article
(This article belongs to the Special Issue Recent Industry and Engineering Achievements and Their Impact on Material and Manufacturing Processes)
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