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Selected Papers from the 30th International Conference on Flexible Automation...
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Selected Papers from the 30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2020-2021)

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: closed (30 April 2022) | Viewed by 14385

Special Issue Editor

Prof. Dr. George-Christopher Vosniakos

E-Mail Website
Guest Editor
School of Mechanical Engineering, National Technical University of Athens, 15780 Athens, Greece
Interests: robotics in manufacturing; optimal process planning; VR in manufacturing; intelligence in Industry 4.0; 3D printer design and control; CNC machine tools
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue of the Journal of Manufacturing and Materials Processing includes selected papers presented at the 30th FAIM International Conference (FAIM 2020-2021), which was held in Athens, Greece, from 15–18 June 2021 (https://www.faimconference.org/).

Papers should discuss the recent advances and applications of different techniques and research methods used in manufacturing. Authors of selected high-quality works from the conference will be invited to submit extended versions of their original papers (50% expansion of the contents of the conference paper). Submissions should have a particular focus on one or more of the following topics:

  • Manufacturing processes;
  • Machine tools and manufacturing equipment.

Prof. Dr. George-Christopher Vosniakos
Guest Editor

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. Journal of Manufacturing and Materials Processing 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 1800 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.

Published Papers (5 papers)

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Research

16 pages, 4611 KiB  
Article
Heat Dissipation Plays Critical Role for Longevity of Polymer-Based 3D-Printed Inserts for Plastics Injection Moulding
by Vicente F. Moritz, Gilberto S. N. Bezerra, Michael Hopkins Jnr, Evert Fuenmayor, Suzan Günbay, Conor Hayes, John G. Lyons and Declan M. Devine
J. Manuf. Mater. Process. 2022, 6(5), 117; https://doi.org/10.3390/jmmp6050117 - 08 Oct 2022
Cited by 3 | Viewed by 2304
Abstract
Injection moulding is a polymer processing method of choice for making plastic parts on industrial scale, but its traditional mould is made from tooling steel with time-consuming and costly production. Additive manufacturing technologies arise as an alternative for creating mould inserts at lower [...] Read more.
Injection moulding is a polymer processing method of choice for making plastic parts on industrial scale, but its traditional mould is made from tooling steel with time-consuming and costly production. Additive manufacturing technologies arise as an alternative for creating mould inserts at lower costs and shorter lead times. In this context, this study describes a series of stereolithography (SLA)-printed injection mould inserts fabricated from two photopolymer resins, utilised to mould standard tensile specimens of a commercial-grade polypropylene, aiming to evaluate effects on the polymer’s thermal and mechanical properties. Our results demonstrated that the glass fibre-filled resin inserts withstood more moulding cycles before failure, had superior mechanical properties, higher Tg and greater thermal conductivity. Calorimetric data revealed that PP thermal properties and degree of crystallinity were little affected, while mechanical testing suggests a significant effect in the elongation at break. Thus, these findings highlight the importance of adequate heat extraction during injection moulding and endorse further application of SLA mould inserts for the manufacturing of injection-moulded plastic parts in the case of prototypes or small batches, provided suitable cooling is made available, contributing to the feasibility and affordability of employing this approach for an industrial setting. Full article
(This article belongs to the Special Issue Selected Papers from the 30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2020-2021))
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19 pages, 6209 KiB  
Article
Flange Wrinkling in Deep-Drawing: Experiments, Simulations and a Reduced-Order Model
by Kelin Chen, Adrian J. Carter and Yannis P. Korkolis
J. Manuf. Mater. Process. 2022, 6(4), 76; https://doi.org/10.3390/jmmp6040076 - 10 Jul 2022
Cited by 9 | Viewed by 4529
Abstract
Flange wrinkling is often seen in deep-drawing process when the applied blankholding force is too small. This paper investigates the plastic wrinkling of flange under a constant blankholding force. A series of deep-drawing experiments of AA1100-O blanks are conducted with different blankholding forces. [...] Read more.
Flange wrinkling is often seen in deep-drawing process when the applied blankholding force is too small. This paper investigates the plastic wrinkling of flange under a constant blankholding force. A series of deep-drawing experiments of AA1100-O blanks are conducted with different blankholding forces. The critical cup height and wrinkling wave numbers for each case is established. A reduced-order model of flange wrinkling is developed using the energy method, which is implemented to predict the flange wrinkling of AA1100-O sheet by incrementally updating the flange geometry and material hardening parameters during the drawing process. A deep-drawing finite element model is developed in ABAQUS/standard to simulate the flange wrinkling of AA1100-O blanks under constant blankholding force. The predicted cup height and wave numbers from the finite element model and reduced-order model are compared with the experimental results, which demonstrates the accuracy of the reduced-order model, and its potential application in fast prediction of wrinkling in deep-drawing process. Full article
(This article belongs to the Special Issue Selected Papers from the 30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2020-2021))
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21 pages, 3528 KiB  
Article
Understanding System Complexity in the Non-Destructive Testing of Advanced Composite Products
by Nikita Gandhi, Rob Rose, Anthony J. Croxford and Carwyn Ward
J. Manuf. Mater. Process. 2022, 6(4), 71; https://doi.org/10.3390/jmmp6040071 - 02 Jul 2022
Cited by 2 | Viewed by 2701
Abstract
Non-destructive testing (NDT) is a quality control measure designed to ensure the safety of products according to established variability thresholds. With the development of advanced technologies and a lack of formalised knowledge of the state-of-the-art, the National Composites Centre, Bristol, has identified that [...] Read more.
Non-destructive testing (NDT) is a quality control measure designed to ensure the safety of products according to established variability thresholds. With the development of advanced technologies and a lack of formalised knowledge of the state-of-the-art, the National Composites Centre, Bristol, has identified that the increasing complexity of composite products will lead to some severe inspection challenges. To address the apparent knowledge gap and understand system complexity, a formulaic approach to introduce intelligence and improve the robustness of NDT operations is presented. The systemic development of a high-fidelity knowledge base (KB) involves the establishment of a capability matrix that maps material, component, and defect configuration to the capabilities and limitations of selected detection methods. Population and validation are demonstrated through the experimental testing of reference standards and evaluated against an assessment criteria. System complexity in ultrasonic testing operations focusses on capturing the inherent risks in inspection and the designation of evidence-based path plans for automation platforms. Anticipated deployment of the validated applicability data within the KB will allow for road-mapping of the inspection technique development and will provide opportunities for knowledge-based decision making. Moreover, the KB highlights the need for Design for Inspection, providing measurable data that the methodology should not be ignored. Full article
(This article belongs to the Special Issue Selected Papers from the 30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2020-2021))
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16 pages, 4423 KiB  
Article
Tooling and Infusion Design Strategies to Reduce Trade-Offs in Forming and Infusion Quality of Multi-Textile CFRPs
by Nikita Budwal, Kent Kasper, Jon Goering and Carwyn Ward
J. Manuf. Mater. Process. 2022, 6(3), 62; https://doi.org/10.3390/jmmp6030062 - 09 Jun 2022
Viewed by 1738
Abstract
Achieving right-first-time-manufacture (RFTM) of co-infused textile assemblies is challenging, without improving the accessibility to design knowledge of trade-offs between different tooling and infusion strategies. As demonstrated in previous work, the choice between a flexible or rigid mould material can result in trade-offs between [...] Read more.
Achieving right-first-time-manufacture (RFTM) of co-infused textile assemblies is challenging, without improving the accessibility to design knowledge of trade-offs between different tooling and infusion strategies. As demonstrated in previous work, the choice between a flexible or rigid mould material can result in trade-offs between dimensional accuracy and geometrical precision. Similarly, the choice of an infusion strategy can result in trade-offs in infusion quality and time. Building on past work, an investigation into forming variability across the length of six co-infused multi-textile components, with three different tooling inserts and two infusions set-ups, was conducted. To quantitatively assess variation, a method adapting principles of statistical process control was employed to analyse the yarn crimp measured from high-resolution cross-sectional scans of the components. The results were compared to a geometrical and dimensional analysis of the manufactured parts presented in a previous work. The analysis represents a method for capturing forming differences in textile preforms, which can be used to inform designs for the manufacture of textile CFRPs. The results were used to improve a hybrid rigid-flexible tooling design for an infused multi-textile component. Full article
(This article belongs to the Special Issue Selected Papers from the 30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2020-2021))
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19 pages, 4628 KiB  
Article
On the Accurate Prediction of Residual Stress in a Three-Pass Slot Nickel-Base Repair Weld by Numerical Simulations
by Vasileios Akrivos, Ondrej Muransky, Lionel Depradeux, Michael C. Smith, Anastasia Vasileiou, Viorel Deaconu and Priyesh Kapadia
J. Manuf. Mater. Process. 2022, 6(3), 61; https://doi.org/10.3390/jmmp6030061 - 01 Jun 2022
Cited by 2 | Viewed by 2425
Abstract
The activities within a European network to develop accurate experimental and numerical methods to assess residual stresses in structural weldments are reported. The NeT Task Group 6 or NeT-TG6 project examined an Alloy 600 plate containing a three-pass slot weld made with Alloy [...] Read more.
The activities within a European network to develop accurate experimental and numerical methods to assess residual stresses in structural weldments are reported. The NeT Task Group 6 or NeT-TG6 project examined an Alloy 600 plate containing a three-pass slot weld made with Alloy 82 consumables. A number of identical specimens were fabricated and detailed records of the manufacturing history were kept. Parallel measurement and simulation round robins were performed. Residual stresses were measured using neutron diffraction via five different instruments. The acquired database is large enough to generate reliable mean profiles, to identify clear outliers, and to establish the systematic uncertainty associated with this non-destructive technique. NeT-TG6 gives a valuable insight into the real-world variability of diffraction-based residual stress measurements, and forms a reliable foundation against which to benchmark other measurement methods. The mean measured profiles were used to validate the accuracy achieved by the network in the prediction of residual stresses. Full article
(This article belongs to the Special Issue Selected Papers from the 30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2020-2021))
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