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E-grāmata: Digital Twins in Manufacturing: Virtual and Physical Twins for Advanced Manufacturing

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Digital Twins in Manufacturing: Virtual and Physical Twins for Advanced ManufacturingPalielināt
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This book presents a guide to digital twin technologies and their applications within manufacturing. It examines key technological advances in the area of Industry 4.0, including numerical and experimental models and the Internet of Things (IoT), and explores their potential technical benefits through real-world application examples. This book presents digital models of advanced manufacturing processes dynamics that enable to control the cutting processes including experimental and simulation studies for brittle-ductile transition of ultra-precision machining materials assuring product quality. Innovative electrical power harvesting solutions from tool vibrations and wireless data transmission from confined and heavily cooled environment are also included. It explains the benefits of virtual and physical twins adapted to real systems, including the ability to shorten the product's path to the market, and enabling the transition to higher value-added manufacturing processes. Including numerous illustrations and clear solved problems, this book will be of interest to researchers and industry professionals in the fields of mechatronics, manufacturing engineering, computational mechanics.

1 The State-of-the-Art in the Theoretical and Practical Applications of the Digital Twins Components
1(10)
1.1 Numerical Modeling and Prediction of Manufacturing Processes
1(2)
1.2 Vibration Cutting for Smart Manufacturing
3(1)
1.3 Vibration Energy Harvesting
4(1)
1.4 Internet of Things Devices for Manufacturing Process Control
5(1)
1.5 The Relationship Between Edge and Cloud-Based Computing
6(5)
References
8(3)
2 Digital Twins for Smart Manufacturing
11(138)
2.1 Digital Twin Emphasis on Cutting Tool Vibration Control Through Design Parameters
11(14)
2.1.1 Optimally Designed Self-Exciting Drill for Vibration Cutting
11(7)
2.1.2 Modified Boring Tool Structures for Effective Cutting
18(7)
2.2 Cutting Tool Physical Entities and Their Virtual Counterparts Synchronization
25(19)
2.2.1 Simulation and Analysis of Vibration Turning Tool
26(8)
2.2.2 Evaluation of Workpiece Surface Roughness and Tool Wear
34(5)
2.2.3 Influence of Boundary Conditions on the Vibration Turning Tool Eigen Modes
39(5)
2.3 Evaluation of Technological Features of Macro-and Micro-drilling
44(31)
2.3.1 Virtual Twin of Vibration Drilling Tool
44(9)
2.3.2 Physical Twin of Vibration Drilling Tool
53(6)
2.3.3 Characterization of Vibration Drilling Process and Workpiece Surface Quality
59(3)
2.3.4 Drilling Process Simulation Using Smoothed Particle Hydrodynamics Method
62(3)
2.3.5 Micro-drill Stiffness Amplification by Buckling Mode Control
65(7)
2.3.6 Experimental Study of Micro-drill Physical Twin
72(3)
2.4 Quality Improvement of Grinding Operations
75(21)
2.4.1 An Excitation Approach to Ultrasonically Assisted Cylindrical Grinding
75(10)
2.4.2 Development of Actuator for Back Grinding
85(11)
2.5 Artificial Neural Networks Approaches for Quality Prediction in Robotized Incremental Sheet Forming
96(9)
2.5.1 Determination of Friction Force Between the Tool and Forming Sheet
96(1)
2.5.2 Evaluation Methodology of Metal Sheet Forming Process
97(7)
2.5.3 Cupping Test for the Material Model Calibration
104(1)
2.6 FE Simulations
105(44)
2.6.1 FE Simulations of Cupping Test for Material Model Calibration
106(1)
2.6.2 Numerical Simulations of SPIF Process
107(22)
2.6.3 Evaluation Methodology of Polymer Sheet Forming Process
129(16)
References
145(4)
3 Integration of Digital and Physical Data to Process Difficult-to-Cut Materials
149(54)
3.1 Digital Twin for Excited Cutting Tool
149(32)
3.1.1 Prevention of Chemical Interactions Between Tool and Workpiece Materials by Contact Time Reduction
149(17)
3.1.2 Vibration Milling for Surface Finish Improvement
166(8)
3.1.3 Vibration Drilling of Brittle Materials
174(7)
3.2 Physical Twin of Vibrationally Excited Workpiece Drilling
181(22)
3.2.1 Vibration Excitation of a Workpiece for Drilling Force Reduction
181(5)
3.2.2 Development of Actuator Enabling a Brittle-Ductile Transition of Warkpiece Material
186(14)
References
200(3)
4 Wireless Connectivity Options for Tool Condition Monitoring IoT Applications
203(64)
4.1 The New Principles of Energy Harvesting in Macro Level
203(52)
4.1.1 Virtual Twin of Piezoelectric Energy Harvester
203(31)
4.1.2 Enhanced Harvester Configuration
234(7)
4.1.3 Investigation of Optimized Cantilever Beam
241(9)
4.1.4 Appropriate Way to Extract the Low-Frequency Vibration Energy
250(5)
4.2 The New Principles of Energy Harvesting in Micro Level
255(12)
4.2.1 Enhanced Vibration Energy Harvesting Configuration
256(8)
References
264(3)
5 Digital Twin-Driven Technological Process Monitoring for Edge Computing and Cloud Manufacturing Applications
267
5.1 Edge Computing-Enabled Wireless Vibration Sensor Node
267(36)
5.1.1 Use Case of the Non-rotating Tool
267(17)
5.1.2 Use Case of the Rotating Tool
284(19)
5.2 Wireless IoT Vibration Sensor for Cloud Manufacturing Applications
303(45)
5.2.1 Virtual Twin of Piezoelectric Transducer
304(21)
5.2.2 Rotating Shank-Type Tool Condition Monitoring
325(23)
5.3 Tool Wear Status Recognition Based on Machine Learning
348
5.3.1 Support Vector Machines Algorithm Adaptation for Milling Force Prediction
352(5)
References
357
Prof. dr. Hab. Vytautas Ostasevicius is currently a director of the Institute of Mechatronics at Kaunas University of Technology (KTU), member of the Lithuanian and Royal Swedish Academies of sciences, expert of the European Commission for HORIZON-2020 for Factories of the Future and "Eurostars" applications, Eureka, Grand Solution Application(s) (Danemark) projects evaluation, and chairman of the International Federation of Theory of Machines and Mechanisms (IFToMM) national committee. He has conducted 10 international and 10 national research projects, and supervised 18 Ph.D. students. He is the author and coauthor of 300 scientific papers, 6 monographs (two of them edited in Springer), 45 patents/inventions. His current research interests include dynamics and optimization of structures, precision manufacturing technologies, Industry 4.0 applications, MEMS.
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