Innovation in manufacturing through digital technologies and applications: Thoughts and Reflections on Industry 4.0

The rapid pace of developments in digital technologies offers many opportunities to increase the efficiency, flexibility and sophistication of manufacturing processes; including the potential for easier customisation, lower volumes and rapid changeover of products within the same manufacturing cell or line. A number of initiatives on this theme have been proposed around the world to support national industries under names such as Industry 4.0 (Industrie 4.0 in Germany, Made-in-China in China and Made Smarter in the UK). This book presents an overview of the state of art and upcoming developments in digital technologies pertaining to manufacturing. The starting point is an introduction on Industry 4.0 and its potential for enhancing the manufacturing process. Later on moving to the design of smart (that is digitally driven) business processes which are going to rely on sensing of all relevant parameters, gathering, storing and processing the data from these sensors, using computing power and intelligence at the most appropriate points in the digital workflow including application of edge computing and parallel processing. A key component of this workflow is the application of Artificial Intelligence and particularly techniques in Machine Learning to derive actionable information from this data; be it real-time automated responses such as actuating transducers or informing human operators to follow specified standard operating procedures or providing management data for operational and strategic planning. Further consideration also needs to be given to the properties and behaviours of particular machines that are controlled and materials that are transformed during the manufacturing process and this is sometimes referred to as Operational Technology (OT) as opposed to IT. The digital capture of these properties and behaviours can then be used to define so-called Cyber Physical Systems. Given the power of these digital technologies it is of paramount importance that they operate safely and are not vulnerable to malicious interference. Industry 4.0 brings unprecedented cybersecurity challenges to manufacturing and the overall industrial sector and the case is made here that new codes of practice are needed for the combined Information Technology and Operational Technology worlds, but with a framework that should be native to Industry 4.0. Current computing technologies are also able to go in other directions than supporting the digital ‘sense to action’ process described above. One of these is to use digital technologies to enhance the ability of the human operators who are still essential within the manufacturing process. One such technology, that has recently become accessible for widespread adoption, is Augmented Reality, providing operators with real-time additional information in situ with the machines that they interact with in their workspace in a hands-free mode. Finally, two linked chapters discuss the specific application of digital technologies to High Pressure Die Casting (HDPC) of Magnesium components. Optimizing the HPDC process is a key task for increasing productivity and reducing defective parts and the first chapter provides an overview of the HPDC process with attention to the most common defects and their sources. It does this by first looking at real-time process control mechanisms, understanding the various process variables and assessing their impact on the end product quality. This understanding drives the choice of sensing methods and the associated smart digital workflow to allow real-time control and mitigation of variation in the identified variables. Also, data from this workflow can be captured and used for the design of optimised dies and associated processes

Large-Eddy Simulations of Flow and Heat Transfer in Complex Three-Dimensional Multilouvered Fins

The paper describes the computational procedure and results from large-eddy simulations in a complex three-dimensional louver geometry. The three-dimensionality in the louver geometry occurs along the height of the fin, where the angled louver transitions to the flat landing and joins with the tube surface. The transition region is characterized by a swept leading edge and decreasing flow area between louvers. Preliminary results show a high energy compact vortex jet forming in this region. The jet forms in the vicinity of the louver junction with the flat landing and is drawn under the louver in the transition region. Its interaction with the surface of the louver produces vorticity of the opposite sign, which aids in augmenting heat transfer on the louver surface. The top surface of the louver in the transition region experiences large velocities in the vicinity of the surface and exhibits higher heat transfer coefficients than the bottom surface.Air Conditioning and Refrigeration Project 9

Summary of the 1st AIAA Geometry and Mesh Generation Workshop (GMGW-1) and Future Plans

The 1st AIAA Geometry and Mesh Generation Workshop (GMGW-1) was held in conjunction with the AIAA Aviation Forum and Exposition 2017 and in collaboration with the 3rd AIAA Computational Fluid Dynamics (CFD) High Lift Prediction Workshop (HiLiftPW-3). As the first AIAA workshop on these topics, GMGW-1's broad objectives were to assess the current state-of-the art in geometry preprocessing and mesh generation technology as well as software as applied to aircraft and spacecraft systems. The workshop was intended to identify and develop understanding of areas of needed improvement in terms of performance, accuracy, and applicability. It was also to provide a foundation for documenting best practices for geometry preprocessing and mesh generation. The genesis of GMGW-1 is found in the indictments levied against geometry preprocessing and mesh generation - not undeservedly - by the NASA CFD Vision 2030 Study. In order to create a reference against which future progress in geometry preprocessing and mesh generation can be measured, the organizers of GMGW-1, with the assistance of the organizers of HiLiftPW- 3, focused GMGW-1 on generation of meshes of the NASA High Lift Common Research Model (HL-CRM). Some of the generated meshes were provided for use by the participants in HiLiftPW-3. All meshes and the processes by which they were generated were analyzed by GMGW-1 as a first assessment of state of the art practices. The results of GMGW-1 added quantitative detail to known problem areas including geometry modeling, data interoperability, and amount of human intervention. They do provide a clear path toward a vision of geometry preprocessing and mesh generation in the year 2030. The next milepost along this path will be a second workshop

Flow and turbulent structures around simplified car models

External car aerodynamics study has great importance in overall car efficiency and ride stability, being a key element in successful automotive design. The flow over car geometries shows three dimensional and unsteady turbulent characteristics. Additionally, vortex shedding, flow reattachment and recirculation bubbles are also found around the bluff body. These phenomena greatly influence the lift and drag coefficients, which are fundamental for ride stability and energy efficiency, respectively. The aim of the present study is focused on the assessment of different LES models (e.g. VMS or SIGMA models), as well as to show their capabilities of capturing the large scale turbulent flow structures in car-like bodies using relative coarse grids. In order to achieve these objectives, the flow around two model car geometries, the Ahmed and the Asmo cars, is simulated. These generic bluff bodies reproduce the basic fluid dynamics features of real cars. First, the flow over both geometries is studied and compared against experimental results to validate the numerical results. Then, different LES models are used to study the flow in detail and compare the structures found in both geometries.Peer ReviewedPreprin

CFD-Simulations in the Early Product Development

AbstractA growing range of products shifts the product development in focus. Especially the early design phase defines the costs and quality. Thus, to ensure the quality of the products, different concepts are designed and evaluated. A tool for the evaluation of the different designs is simulation due to being fast and cost efficient. But simulation in the early phase still remains a problem. This results of the basic and fast changing concepts, which take too much effort to be converted into a simulation model. To get around these circumstances, we propose a method for an online modelling in the design process. Instead of defining the simulation model at once, the method modificates the simulation model during simulation run time. Furthermore, the functionality is shown in a CFD simulation using the meshless Smoothing Hydrodynamics method. Using the GPU to achieve real-time simulation, the method allows a WYSIWYG design-simulation development helping to raise the quality of products

State-of-the-art in aerodynamic shape optimisation methods

Aerodynamic optimisation has become an indispensable component for any aerodynamic design over the past 60 years, with applications to aircraft, cars, trains, bridges, wind turbines, internal pipe flows, and cavities, among others, and is thus relevant in many facets of technology. With advancements in computational power, automated design optimisation procedures have become more competent, however, there is an ambiguity and bias throughout the literature with regards to relative performance of optimisation architectures and employed algorithms. This paper provides a well-balanced critical review of the dominant optimisation approaches that have been integrated with aerodynamic theory for the purpose of shape optimisation. A total of 229 papers, published in more than 120 journals and conference proceedings, have been classified into 6 different optimisation algorithm approaches. The material cited includes some of the most well-established authors and publications in the field of aerodynamic optimisation. This paper aims to eliminate bias toward certain algorithms by analysing the limitations, drawbacks, and the benefits of the most utilised optimisation approaches. This review provides comprehensive but straightforward insight for non-specialists and reference detailing the current state for specialist practitioners