Digital Manufacturing

Sandip Kunar, PhD, is an Associate Professor in the Department of Mechanical Engineering, Aditya Engineering College, Surampalem, Andhra Pradesh, India. He has published 12 books, 35 book chapters, one patent, and more than 50 research papers in reputed international journals and conferences. His research interests include non-conventional machining processes, micromachining processes, advanced manufacturing technology, and industrial engineering. Jagadeesha T., PhD is an Associate Professor in the Mechanical Engineering Department at the National Institute of Technology Calicut, Kerala, India with more than 25 years of experience. He has published seven textbooks, four patents, and more than 75 articles in international journals and conferences. His research interests include advanced machining, additive manufacturing, fluid power control, advanced materials, and vibration and noise control. Gurudas Mandal, PhD is an Assistant Professor in the Department of Metallurgical Engineering at Kazi Nazrul University, West Bengal, India. He has published nine book chapters, one patent, and more than 20 articles in international journals and conferences. His research focus is on alloy steel and cast iron, composite materials, magnetic materials, hydrogen energy, and archaeometallurgy.

• Preface xxvAcknowledgement xxixPart I: Overview 11 Introduction to Digital Manufacturing System 3Sandip Kunar and Gurudas Mandal1.1 Introduction 31.2 Manufacturing as Craft and Technique 51.3 Manufacturing Becoming a Science 51.4 Concepts and Research and Development Status of Digital Manufacturing 91.5 Definition of Digital Manufacturing 111.6 Features and Developments of Digital Manufacturing 161.7 Digital Manufacturing Science: Significance and Research Approach 191.8 Conclusion 222 Industrial Production through the Ages: A Historical Analysis and Forecast 25Sameeha Khan, Juveiria Khan, Abdul Ahad, Zehra Fatima and Faisal Talib2.1 Introduction 262.2 Industrial Production 512.3 Discussion 652.4 Conclusion 683 Technology Management in Digital Manufacturing Science 75D.V.S.S.S.V. Prasad, M. Sreenivasa Reddy and A. Ramesh3.1 Introduction 763.2 Technological Landscape of Digital Manufacturing 793.3 Strategic Management of Technology 833.4 Operational Management of Digital Manufacturing Technologies 873.5 Technology Integration and Interoperability 923.6 Human Capital and Skills Management 983.7 Case Studies and Best Practices 1023.8 Conclusion and Future Directions 1074 Design Methodologies and Approaches in Traditional and Additive Manufacturing Systems: A Comparative Study 111Noor Yamshi, Fiza Siddiqui, Sabih Ahmad Khan and Faisal Talib4.1 Introduction 1124.2 Conventional Manufacturing Design Methodologies 1154.3 AM Design Methodologies 1194.4 Comparative Analysis of Design Methodologies 1244.5 Challenges and Limitations 1274.6 Future Trends and Opportunities 1294.7 Conclusions 1315 Simulation and Process Optimization in Wire Arc Additive Manufacturing: A Review 137Ajithkumar Sitharaj, Arulmurugan B., M.D. Barath Kumar, Ganesh N., Dharani Kumar S. and Gokulkumar S.5.1 Introduction 1385.2 Heat Source Modeling for Numerical Simulation in WAAM 1405.3 Thermal and Mechanical Analysis in FEA for WAAM 1455.4 Future Scope 1545.5 Conclusion 1566 The Role of Polymer Materials and Their Properties in Shaping the Future of Additive Manufacturing 161Ganesh Nataraj, Ramesh Babu S., Ramu Murugan, Senthil Kumar A.P. and Ajithkumar Sitharaj6.1 Introduction 1626.2 Types of Polymer Materials Used in AM 1666.3 Material Properties and Their Influence on AM 1696.4 Processing Techniques in Polymer AM 1726.5 Design Considerations for Polymer AM 1756.6 Advanced Polymer Materials for AM 1766.7 Applications of Polymer Materials in AM 1796.8 Challenges and Limitations 1816.9 Future Trends in Polymer Materials for AM 1826.10 Conclusion 1837 Metal Additive Manufacturing 187Nebechi Kate Obiora, Chika Oliver Ujah, Sandip Kunar, Peter Apata Olubambi and Daramy Vandi Von Kallon7.1 Introduction 1887.2 Basic Principles of MAM 1937.3 MAM Processes 1967.4 Metals Used in AM 2067.5 Recent Advances and Future Outlook 2107.6 Conclusion and Recommendation 2157.7 Recommendations 2168 Advancement in Materials for Functional Three-Dimensional Printing 223Arhaan Nawab, Waquar Alam, Wasim Alam, Mohd. Hamza and Faisal Talib8.1 Introduction 2248.2 Materials and Methods 2278.3 Applications of Materials 2388.4 Conclusions 2439 Cross-Country Comparative Analysis of Digital Manufacturing Systems 249Sunita Routray, Rudra Narayan Mohapatro and Ranjita Swain9.1 Introduction 2509.2 Digital Technological Review for the Manufacturing Process 2539.3 Cross-Country Comparative Analysis of DMS 2559.4 Advances in DMS in Today’s World 2619.5 Future Prospects in the Manufacturing Industry 2649.6 Conclusion 27310 A Review and Analysis from Industry 4.0 Toward Industry 5.0 279Sandip Kunar, Jagadeesha T., Chika Oliver Ujah, Norfazillah Talib, Gurudas Mandal, K. Nagasuresh, N. Naresh, S. Rama Sree and M. Sreenivas Reddy10.1 Introduction 28010.2 Historical Overview 28310.3 Basic Driving Concepts of Industry 4.0 and Industry 5.0 28410.4 Review of Key Enablers in Practical Context of Industry 4.0 and Industry 5.0 28710.5 Discussion 29310.6 Are We Fear of Technology? The Role of Regulations 29410.7 Controlling AI 29510.8 Conclusions 29610.9 The Future 29711 Envisioning Industry 4.0: A Review 307Sumanta Banerjee and Anindita Kundu11.1 Introduction and Background 30811.2 Changes and Transformation of Manufacturing Ecosystems: A Review 31111.3 Smart Manufacturing Systems: Role of AI, IoT, and Big Data 31511.4 Intelligent Factories 32111.5 The Fourth Industrial Revolution (Industry 4.0) 32411.6 Industry 3.0 to Industry 4.0: Mapping the Transformation 32511.7 Impact of Industry 4.0: Technological Inference 32711.8 Impact of Industry 4.0: Socio-Cultural Impacts 32811.9 Impact of Industry 4.0: Business Prospects 32911.10 Conclusions and Present/Futuristic Trends 33012 Future Development of Digital Manufacturing Science 335Alok Kumar and Sachin Kumar12.1 Introduction 33612.2 Conventional Methodology of the DMS Process 33712.3 The Electrical Mechanical (Elec-Mech) System with DMS 33912.4 The Externalization of DMS 34512.5 The Environmental Protection of DMS 34912.6 Applications of DMS 35712.7 Conclusion 359Part II: Computing Applications 36513 Computing Manufacturing in Digital Manufacturing Science 367Dasari Madhusudhan, Rupa Srivani and Keerthi Prabhavathi13.1 Introduction 36813.2 Theoretical Foundations of Computing in Manufacturing 37213.3 Mathematical Methods 37713.4 Key Computing Technologies in Manufacturing 38113.5 Applications of Computing in Digital Manufacturing 38813.6 Case Studies 39513.7 Discussion and Analysis 40213.8 Conclusion 40513.9 Implications for Industry 40613.10 Suggestions for Future Research 40714 Unlocking the Potential of Intelligent Manufacturing Guide to Digital Manufacturing 413Adnan Zafar, Imad Ur Rehman, Jamal Abdullah Haider and Faisal Talib14.1 Introduction 41414.2 Progression of Manufacturing Innovations 41614.3 Case Studies 42114.4 Challenges and Barriers 42414.5 Conclusion 42615 Bionic Manufacturing in Digital Manufacturing Science 429Debjani Bhakta, Jyoti Bhattacharjee and Subhasis Roy15.1 Introduction 43015.2 Digital Technologies Used for Bionic Manufacturing 43515.2.1 Artificial Intelligence (AI) and Machine Learning 43515.3 Applications of Bionic Manufacturing 43615.4 Applications of Bionic Manufacturing in Digital Manufacturing Science 43815.5 Challenges and Future Directions 44415.6 Case Studies 44915.7 Conclusions 45416 Direct Digital Manufacturing for Biomedical Applications: Toward Efficient Healthcare 465Amey Dukle and M. Ravi Sankar16.1 Introduction 46616.2 Technological Foundations of DDM for Biomedical Applications 46816.3 Application of DDM for Biomedical Applications 47516.4 Challenges in Adoption of DDM for Biomedical Applications 48016.5 Conclusion and Future Outlook 48217 Digital Manufacturing and the Fifth Industrial Revolution 491Alok Kumar and Ravi Shankar Rai17.1 Digital Manufacturing 49217.2 Development of Industrial Revolutions 49817.3 Uses of Digital Manufacturing 50217.4 Characterizing Industry 5.0 50617.5 Applications of DM Sectors 51317.6 Conclusion 51518 Factories of the Future: Digital Manufacturing in the Manufacturing Industry 523Rasu Karunanithi, Mohammed Abdur Rahman and Gopal Rajesh18.1 Introduction 52418.2 Advanced Technologies Used in Digital Manufacturing 52518.3 Workforce Transformation: Skills Needed for Managing and Operating Digital Manufacturing Systems 53918.4 Case Studies 54118.5 Challenges and Barriers to Adoption 54618.6 Cost of Technology Upgrades and Maintenance 54718.7 Conclusion 54919 Business Models for Additive Manufacturing: A Consulting Services Perspective 559Yogeshwaran Kumarasamy, Prases Kumar Mohanty and Shubhajit Das19.1 Introduction 55919.2 Business Background 56019.3 Importance of Business Model 56219.4 Business Models for Consulting Services 56419.5 Requirements for Consulting Services 56619.6 Opportunities in Various Segments 57019.7 Challenges in Additive Manufacturing for Consulting Service 57319.8 Conclusion 57520 Integration of Additive Manufacturing with Digital Technologies for Future Manufacturing 579Ganesh Nataraj, Ramesh Babu S., Ramu Murugan, Senthil Kumar A.P. and Ajithkumar Sitharaj20.1 Introduction 58020.2 Understanding Additive Manufacturing 58120.3 The Intersection of Additive Manufacturing and Digital Transformation 58320.4 Impact of Additive Manufacturing on Supply Chains 58520.5 Sustainability in Additive Manufacturing 58720.6 Customization and Personalization in Digital Manufacturing 58820.7 Challenges and Opportunities 58920.8 Future Trends in Additive Manufacturing and Digital Transformation 59020.9 Conclusion 59321 Computational Approaches to Advanced Digital Manufacturing Practices 597D.V.S.S.S.V. Prasad, Akhilesh Kumar Singh, Marxim Rahula Bharathi. B., Yarrapragada K.S.S. Rao and V.V. Kamesh21.1 Introduction 59821.2 Foundations of Digital Manufacturing 60021.3 Overview of Computational Models in Manufacturing 60321.4 Data Management and Analytics 60621.5 Software and Tools 60921.6 Computing Architectures and Systems 61121.7 Challenges and Limitations 61521.8 Future Trends and Innovations 61921.9 Conclusion 623References 625Index 627