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Metals
Special Issues
Implementation of the Industry 4.0 Manufacturing—New Systems, Technologies and Outcomes
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Implementation of the Industry 4.0 Manufacturing—New Systems, Technologies and Outcomes

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: closed (31 July 2021) | Viewed by 16344

Special Issue Editors

Dr. Tomasz Trzepieciński

E-Mail Website
Guest Editor
Department of Manufacturing Processes and Production Engineering, Rzeszow University of Technology, Al. Powst. Warszawy 8, 39-959 Rzeszów, Poland
Interests: anisotropic plasticity; computational modeling; constitutive modeling; finite element method (FEM); friction; friction welding; manufacturing processes; sheet metal forming; tribology
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Francesco dell’Isola

E-Mail Website
Guest Editor
International Research Center on Mathematics and Mechanics of Complex Systems, University of L’Aquila, Via Giovanni Gronchi 18, 67100 L’Aquila, Italy
Interests: continuum mechanics; porous media; piezo-electro-mechanical structures; nonlinear elasticity; second gradient materials; metamaterials; mechanics of living tissue; smart materials; composite materials; experimental mechanics; numerical mechanics

Special Issue Information

Dear Colleagues,

Efforts to improve industrial output have resulted in the increased use of Industry 4.0 manufacturing techniques. The new digital industrial concept “Industry 4.0” makes it possible to gather and analyze data across machines, enabling faster, more flexible, and more efficient manufacturing processes. Several technology trends form the basis of Industry 4.0: additive manufacturing, augmented reality, autonomous robots, big data and analytics, cybersecurity, system integration, the cloud, the Internet of Things, and simulation. In additive manufacturing (AM), 3D Printing is also of great importance. AM methods can produce small batches of customized products that support the construction of complex lightweight designs. Augmented-reality-based systems support workers with real-time information to improve work procedures. Increasingly automated processes require innovative concepts for intralogistics. By involving the use of automation and data exchange in manufacturing environments, the actions of robots can be coordinated and automated to a greater extent than ever before. Big data analytics is the use of advanced analytic techniques against very large, data sets from different sources, and in different sizes. Growing numbers of manufacturers are using big data to support customer-management systems. Cybersecurity has become a vital component of the concept of Industry 4.0. It is the protection of business information and precious knowledge against abuse, unauthorized access, and cyber-attacks. The cloud is the key element of Industry 4.0, which makes it possible to develop a production strategy that is more effective and efficient by artificial intelligence and robotics. The industrial Internet of Things refers to machine communications, digitalization of the control quality process, automation systems, and sensor data.

During the last decade, the coupling of individual computational methods to provide both multiscale and multiphysics responses has proved to have enormous predictive capabilities. There has been a dynamic development of two- and three-dimensional numerical modeling of the industrial processes using the finite element method (FEM), boundary element method (BEM), finite difference method (FDM), computational fluid dynamics (CFD), finite volume method, neural networks, multi-grid and mesh-free methods, crystal plasticity finite element (CPFEM), discrete element method (DEM), extended finite element (XFEM), an arbitrary Lagrangian–Eulerian (ALE), cellular automata (CA), and fast Fourier transformation (FFT).

This Special Issue will present the latest achievements in several industrial application scenarios, leading to the so-called Industry 4.0 and the latest research related to the computational methods for a wide range of industrial applications. Both research and review articles focusing on new developments in the new digital industrial technology (Industry 4.0) are welcome for consideration of publication. We truly believe that this Special Issue will help the research community to enhance understanding of the present status and trends of the advanced digital technologies.

Topics of interest include (but are not limited to) the following:

  • Additive and hybrid manufacturing (3D printing, direct energy deposition, digital manufacturing, incremental forming, fused filament fabrication);
  • Automation of manufacturing process;
  • Autonomous systems, robotics, and computer-integrated manufacturing;
  • Big data analytics;
  • Cloud computing and manufacturing;
  • New approaches to computational methods in materials science;
  • Cybersecurity and cyber-physical systems;
  • Implementation of Industry 4.0 in the aerospace and automotive industries;
  • Internet of Things;
  • Machine learning for manufacturing;
  • Numerical modeling of the industrial processes (i.e., FEM, BEM, CFD, multi-grid and mesh-free methods, CPFEM, DEM, XFEM, ALE);
  • Smart factory;
  • Virtual reality in manufacturing 

Prof. Dr. Tomasz Trzepiecinski
Prof. Dr. Francesco dell’Isola
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. Metals is an international peer-reviewed open access monthly 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

  • 5G in manufacturing
  • additive manufacturing
  • advances in manufacturing processes
  • aerospace industry
  • aircraft industry
  • artificial vision
  • augmented and virtual reality
  • big data
  • big data analytics
  • cloud
  • cyber-physical systems
  • cybersecurity
  • deep analytics
  • deep learning
  • digital manufacturing platforms
  • digital transformation
  • fourth industrial revolution
  • Industry 4.0
  • intelligent vision systems
  • internet of services
  • internet of things
  • computational methods (finite element method, boundary element method, finite difference method, computational fluid dynamics, finite volume method, neural networks, multi-grid and mesh-free methods, crystal plasticity finite element, discrete element method, extended finite element methods, an arbitrary Lagrangian–Eulerian, cellular automata, fast Fourier transformation)
  • machine monitoring
  • numerical modeling
  • robotics and autonomous systems
  • smart factory
  • smart manufacturing

Published Papers (3 papers)

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Research

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20 pages, 10089 KiB  
Article
Human-Centered Robotic Development in the Steel Shop: Improving Health, Safety and Digital Skills at the Workplace
by Valentina Colla, Ruben Matino, Antonius Johannes Schröder, Mauro Schivalocchi and Lea Romaniello
Metals 2021, 11(4), 647; https://0-doi-org.brum.beds.ac.uk/10.3390/met11040647 - 15 Apr 2021
Cited by 20 | Viewed by 3485
Abstract
Within the implementation of the Industry 4.0 paradigm in the steel sector, robots can play a relevant role in improving health and safety conditions at the workplace, by overtaking cumbersome, repetitive and risky operations. However, the implementation of robotics solutions in this particular [...] Read more.
Within the implementation of the Industry 4.0 paradigm in the steel sector, robots can play a relevant role in improving health and safety conditions at the workplace, by overtaking cumbersome, repetitive and risky operations. However, the implementation of robotics solutions in this particular sector is hampered by harsh operating conditions and by particular features of many procedures, which require a combination of force and sensitivity. Human–robot cooperation is a viable solution to overcome existing barriers, by synergistically combining human and robot abilities in the sense of a human-centered Industry 5.0. In this sense, robotics solution should be designed in a way to integrate and meet the end-users’ demands in a common development process for successfully implementation and widely acceptance. The paper presents the outcomes of the field evaluation of a robotic workstation, which was designed for a complex maintenance operation that is daily performed in the steel shop. The system derives from a co-creation process, where workers were involved since the beginning in the design process, according to the paradigm of social innovation combining technological and social development. Therefore, the evaluation aimed at assessing both system reliability and end-users’ satisfaction. The results show that the human-centered robotic workstations are successful in reducing cumbersome operations and improving workers’ health and safety conditions, and that this fact is clearly perceived by system users and developers. Full article
(This article belongs to the Special Issue Implementation of the Industry 4.0 Manufacturing—New Systems, Technologies and Outcomes)
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Review

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55 pages, 14374 KiB  
Review
Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals
by Tomasz Trzepieciński, Valentin Oleksik, Tomaž Pepelnjak, Sherwan Mohammed Najm, Imre Paniti and Kuntal Maji
Metals 2021, 11(8), 1188; https://0-doi-org.brum.beds.ac.uk/10.3390/met11081188 - 26 Jul 2021
Cited by 41 | Viewed by 7085
Abstract
Lightweight materials, such as titanium alloys, magnesium alloys, and aluminium alloys, are characterised by unusual combinations of high strength, corrosion resistance, and low weight. However, some of the grades of these alloys exhibit poor formability at room temperature, which limits their application in [...] Read more.
Lightweight materials, such as titanium alloys, magnesium alloys, and aluminium alloys, are characterised by unusual combinations of high strength, corrosion resistance, and low weight. However, some of the grades of these alloys exhibit poor formability at room temperature, which limits their application in sheet metal-forming processes. Lightweight materials are used extensively in the automobile and aerospace industries, leading to increasing demands for advanced forming technologies. This article presents a brief overview of state-of-the-art methods of incremental sheet forming (ISF) for lightweight materials with a special emphasis on the research published in 2015–2021. First, a review of the incremental forming method is provided. Next, the effect of the process conditions (i.e., forming tool, forming path, forming parameters) on the surface finish of drawpieces, geometric accuracy, and process formability of the sheet metals in conventional ISF and thermally-assisted ISF variants are considered. Special attention is given to a review of the effects of contact conditions between the tool and sheet metal on material deformation. The previous publications related to emerging incremental forming technologies, i.e., laser-assisted ISF, water jet ISF, electrically-assisted ISF and ultrasonic-assisted ISF, are also reviewed. The paper seeks to guide and inspire researchers by identifying the current development trends of the valuable contributions made in the field of SPIF of lightweight metallic materials. Full article
(This article belongs to the Special Issue Implementation of the Industry 4.0 Manufacturing—New Systems, Technologies and Outcomes)
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23 pages, 5713 KiB  
Review
Multiphysics Modeling and Numerical Simulation in Computer-Aided Manufacturing Processes
by Tomasz Trzepieciński, Francesco dell’Isola and Hirpa G. Lemu
Metals 2021, 11(1), 175; https://0-doi-org.brum.beds.ac.uk/10.3390/met11010175 - 19 Jan 2021
Cited by 9 | Viewed by 4484
Abstract
The concept of Industry 4.0 is defined as a common term for technology and the concept of new digital tools to optimize the manufacturing process. Within this framework of modular smart factories, cyber-physical systems monitor physical processes creating a virtual copy of the [...] Read more.
The concept of Industry 4.0 is defined as a common term for technology and the concept of new digital tools to optimize the manufacturing process. Within this framework of modular smart factories, cyber-physical systems monitor physical processes creating a virtual copy of the physical world and making decentralized decisions. This article presents a review of the literature on virtual methods of computer-aided manufacturing processes. Numerical modeling is used to predict stress and temperature distribution, springback, material flow, and prediction of phase transformations, as well as for determining forming forces and the locations of potential wrinkling and cracking. The scope of the review has been limited to the last ten years, with an emphasis on the current state of knowledge. Intelligent production driven by the concept of Industry 4.0 and the demand for high-quality equipment in the aerospace and automotive industries forces the development of manufacturing techniques to progress towards intelligent manufacturing and ecological production. Multi-scale approaches that tend to move from macro- to micro- parameters become very important in numerical optimization programs. The software requirements for optimizing a fully coupled thermo-mechanical microstructure then increase rapidly. The highly advanced simulation programs based on our knowledge of physical and mechanical phenomena occurring in non-homogeneous materials allow a significant acceleration of the introduction of new products and the optimization of existing processes. Full article
(This article belongs to the Special Issue Implementation of the Industry 4.0 Manufacturing—New Systems, Technologies and Outcomes)
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