Additive manufacturing (AM) is one of the fastest-growing industrial techniques, bringing many innovative solutions to different manufacturing problems. In AM, a sliced image of the 3D model is ...layered together to make a 3D object. The main reason for the exponential growth of AM is its numerous advantages over conventional methods, such as high-cost efficiency, less material wastage, a very high degree of freedom, and lesser material constraints. One of the biggest contributors to this growth is the aerospace industry. It is due to the ease of making complex structures and alloys with a very high strength-to-weight ratio (S:W). The authors have comprehensively reviewed the use of AM in the aerospace industry in this review. This review mainly focuses on the metal AM of complex components used in the Aerospace industry. The other topics in this review are an in-depth study of the different AM techniques, a classification of different AM processes, a comparison between conventional and AM techniques, an advantage of AM techniques, and the future scope of AM techniques. The material characterization and microstructure of the components and the different process parameters concerning the cost and irrespective of cost are also briefly discussed.
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There has been significant development in metal additive manufacturing (MAM) technology over the past few decades, and considerable progress has been made in understanding how various processes and ...their parameters influence the properties of printed metallic parts. Despite this, the knowledge concerning its characteristics has been dispersed across a variety of publications and sources, making it difficult to gain a comprehensive understanding of the entire field, especially for businesses interested in additive manufacturing (AM). In order to bridge this gap, periodic reviews encompassing state-of-the-art as the whole are necessary. Therefore, this article provides a comprehensive overview of the essential features of MAM techniques based on the most recent scientific knowledge. It explores emerging research on four of the most significant technologies, including material extrusion (ME), binder jetting (BJ), powder bed fusion (PBF), and directed energy deposition (DED). As well as providing an outline of fundamental process characteristics, ongoing efforts to optimize them and current challenges, it also highlights gaps in understanding and future research and development needs. A significant feature of this review is the provision of substantial documentation regarding the mechanical properties of materials processed by a variety of commercial systems, including a variety of novel hybrid additive manufacturing (HAM) machines. This is accompanied by an investigation into the most recent works done to characterize the environmental impact along with a conceptual framework for improving the energy efficiency (EE) of the manufacturing process. As a result of reporting on both the characteristics of several MAM processes along with their sustainability features in one integrated article, it is anticipated that this information will serve as a valuable resource for both the academic and manufacturing communities to better appreciate and understand what differentiates MAM from traditional manufacturing (TM) processes, thus facilitating its future advancement and adoption.
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Providing a solid foundation of knowledge in modeling remanufacturing systems, this book addresses the design, planning, and processing issues faced by decision-makers in the field. With easy-to-use ...mathematical or simulation modeling to demonstrate solutions for each remanufacturing issue, it helps practitioners understand how a particular issue can be effectively modeled and how to choose the appropriate solution methodology. The book also discusses how increasingly stringent environmental regulations and decreasing natural resources influence manufacturers toward more environmentally conscious manufacturing and product recovery initiatives.
Tool condition monitoring is critical in ultraprecision manufacturing in order to optimize the performance of the overall process, while maintaining the desired part quality. Recently, deep learning ...has been successfully applied to numerous classification tasks in manufacturing, often to forecast part quality. In this paper, a novel deep learning data-driven modeling framework is presented, which includes a fusion of multiple stacked sparse autoencoders for tool condition monitoring in ultraprecision machining. The proposed computational framework consists of two main structures. First, a training model that is designed with the ability to process multiple parallel feature spaces to learn the lower-level features. Second, a feature fusion structure that is used to learn the higher-level features and associations to tool wear. To achieve this learning structure, a modified loss function is utilized that enhances the feature extraction and classification tasks. A dataset from a real manufacturing process is used to demonstrate the performance of the proposed framework. Experimental results and simulations show that the proposed method successfully classifies the ultraprecision machining case study with over 96% accuracy, while also outperforming comparable methodologies.
Manufacturing Process Selection Handbook provides engineers and designers with process knowledge and the essential technological and cost data to guide the selection of manufacturing processes early ...in the product development cycle. Building on content from the authors' earlier introductory Process Selection guide, this expanded handbook begins with the challenges and benefits of identifying manufacturing processes in the design phase and appropriate strategies for process selection. The bulk of the book is then dedicated to concise coverage of different manufacturing processes, providing a quick reference guide for easy comparison and informed decision making. For each process examined, the book considers key factors driving selection decisions, including: * Basic process descriptions with simple diagrams to illustrate * Notes on material suitability * Notes on available process variations * Economic considerations such as costs and production rates * Typical applications and product examples * Notes on design aspects and quality issues Providing a quick and effective reference for the informed selection of manufacturing processes with suitable characteristics and capabilities, Manufacturing Process Selection Handbook is intended to quickly develop or refresh your experience of selecting optimal processes and costing design alternatives in the context of concurrent engineering. It is an ideal reference for those working in mechanical design across a variety of industries and a valuable learning resource for advanced students undertaking design modules and projects as part of broader engineering programs. * Provides manufacturing process information maps (PRIMAs) provide detailed information on the characteristics and capabilities of 65 processes in a standard format * Includes process capability charts detailing the processing tolerance ranges for key material types * Offers detailed methods for estimating costs, both at the component and assembly level
Peer-reviewed extended papers selected from the 25th International Conference on Material Forming (ESAFORM 2022)Peer-reviewed extended papers selected from the 25th International Conference on ...Material Forming (ESAFORM 2022), April 27-29, 2022, Portugal.
Outlines the correct procedures for doing FMEAs and how to successfully apply them in design, development, manufacturing, and service applications There are a myriad of quality and reliability tools ...available to corporations worldwide, but the one that shows up consistently in company after company is Failure Mode and Effects Analysis (FMEA). Effective FMEAs takes the best practices from hundreds of companies and thousands of FMEA applications and presents streamlined procedures for veteran FMEA practitioners, novices, and everyone in between. Written from an applications viewpoint—with many examples, detailed case studies, study problems, and tips included—the book covers the most common types of FMEAs, including System FMEAs, Design FMEAs, Process FMEAs, Maintenance FMEAs, Software FMEAs, and others. It also presents chapters on Fault Tree Analysis, Design Review Based on Failure Mode (DRBFM), Reliability- Centered Maintenance (RCM), Hazard Analysis, and FMECA (which adds criticality analysis to FMEA). With extensive study problems and a companion Solutions Manual, this book is an ideal resource for academic curricula, as well as for applications in industry. In addition, Effective FMEAs covers: * The basics of FMEAs and risk assessment * How to apply key factors for effective FMEAs and prevent the most common errors * What is needed to provide excellent FMEA facilitation * Implementing a "best practice" FMEA process Everyone wants to support the accomplishment of safe and trouble-free products and processes while generating happy and loyal customers. This book will show readers how to use FMEA to anticipate and prevent problems, reduce costs, shorten product development times, and achieve safe and highly reliable products and processes.
Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing deals with various aspects of joining materials to form parts. Additive Manufacturing (AM) is an automated ...technique for direct conversion of 3D CAD data into physical objects using a variety of approaches. Manufacturers have been using these technologies in order to reduce development cycle times and get their products to the market quicker, more cost effectively, and with added value due to the incorporation of customizable features. Realizing the potential of AM applications, a large number of processes have been developed allowing the use of various materials ranging from plastics to metals for product development. Authors Ian Gibson, David W. Rosen and Brent Stucker explain these issues, as well as: Providing a comprehensive overview of AM technologies plus descriptions of support technologies like software systems and post-processing approaches Discussing the wide variety of new and emerging applications like micro-scale AM, medical applications, direct write electronics and Direct Digital Manufacturing of end-use components Introducing systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing is the perfect book for researchers, students, practicing engineers, entrepreneurs, and manufacturing industry professionals interested in additive manufacturing.
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