Digital twin-based analysis of volumetric error mapping procedures

The evaluation of the volumetric accuracy of a machine tool is an open challenge in the industry, and a wide variety of technical solutions are available in the market and at research level. All solutions have advantages and disadvantages concerning which errors can be measured, the achievable uncertainty, the ease of implementation, possibility of machine integration and automation, the equipment cost and the machine occupation time, and it is not always straightforward which option to choose for each application. The need to ensure accuracy during the whole lifetime of the machine and the availability of monitoring systems developed following the Industry 4.0 trend are pushing the development of measurement systems that can be integrated in the machine to perform semi-automatic verification procedures that can be performed frequently by the machine user to monitor the condition of the machine. Calibrated artefact based calibration and verification solutions have an advantage in this field over laser based solutions in terms of cost and feasibility of machine integration, but they need to be optimized for each machine and customer requirements to achieve the required calibration uncertainty and minimize machine occupation time.This paper introduces a digital twin-based methodology to simulate all relevant effects in an artefact-based machine tool calibration procedure, from the machine itself with its expected error ranges, to the artefact geometry and uncertainty, artefact positions in the workspace, probe uncertainty, compensation model, etc. By parameterizing all relevant variables in the design of the calibration procedure, this simulation methodology can be used to analyse the effect of each design variable on the error mapping uncertainty, which is of great help in adapting the procedure to each specific machine and user requirements. The simulation methodology and the analysis possibilities are illustrated by applying it on a 3-axis milling machine tool.     

Fabrication of barium titanate ceramics via digital light processing 3D printing by using high refractive index monomer

A digital light processing (DLP) technology has been developed for 3D printing lead-free barium titanate (BTO) piezoelectric ceramics. By comparing the curing and rheological properties of slurries with different photosensitive monomer, a high refractive index monomer acryloyl morpholine (ACMO) was chosen, and a design and preparation method of BTO slurry with high solid content, low viscosity and high curing ability was proposed. By further selecting the printing parameters, the single-layer exposure time was reduced and the forming efficiency has been greatly improved. Sintered specimens were obtained after a nitrogen-air double-step debinding and furnace sintering process, and the BTO ceramics fabricated with 80 wt% slurry shows the highest relative density (95.32 %) and piezoelectric constant (168.1 pC/N). Furthermore, complex-structured BTO ceramics were prepared, impregnated by epoxy resin and finally assembly made into hydrophones, which has significance for the future design and manufacture of piezoelectric ceramic-based composites that used in functional devices.     

A data-driven digital-twin prognostics method for proton exchange membrane fuel cell remaining useful life prediction

Prognostics and health management of proton exchange membrane fuel cell (PEMFC) systems have driven increasing research attention in recent years as the durability of PEMFC stack remains as a technical barrier for its large-scale commercialization. To monitor the health state during PEMFC operation, digital twin (DT), as a smart manufacturing technique, is applied in this paper to establish an ensemble remaining useful life prediction system. A data-driven DT is constructed to integrate the physical knowledge of the system and a deep transfer learning model based on stacked denoising autoencoder is used to update the DT with online measurement. A case study with experimental PEMFC degradation data is presented where the proposed data-driven DT prognostics method has applied and reached a high prediction accuracy. Furthermore, the predicted results are proved to be less affected even with limited measurement data.     

Context-free grammars to detect straight segments and a novel polygonal approximation method

A new method for the polygonal approximation is presented. The method is based on the search for break points through a context-free grammar, that accepts digital straight segments with loss of information, as well as the decrease in the error committed employing the comparison of a tolerable error. We present an application of our method to different sets of objects widely used, as well as a comparison of our results with the best results reported in the literature, proving that our method achieves better values of error criteria. Besides, a new way to find polygonal approximations, with context-free grammars to recognize digital straight segments without loss of pixels, it is also addressed.     

Evaluation of direct light processing for the fabrication of bioactive ceramic scaffolds: Effect of pore/strut size on manufacturability and mechanical performance

Bioactive ceramic scaffolds for bone regeneration consisting of a three-dimensional mesh of interpenetrating struts with square section were fabricated via Digital Light Processing (DLP). The ability of the technique to manufacture 3D porous structures from β-tricalcium phosphate (β-TCP) powders with different dimensions of struts and pores was evaluated, identifying the possibilities and limitations of the manufacturing process. Small pore sizes were found to seriously complicate the elimination of excess slurry from the scaffold’s innermost pores. The effect of the strut/pore size on the mechanical performance of the scaffolds under compressive stresses was also evaluated, but no significant influence was found. Under compressive stresses, the structures resulted weaker when tested perpendicularly to the printing plane due to interlayer shear failure. Interlayer superficial grooves are proposed as potential failure-controlling defects, which could also explain the lack of a Weibull size effect on the mechanical strength of the fabricated DLP scaffolds.     

Determinants of the intention to use non-medical insertable digital devices: The case of Chile and Colombia

In the past, thinking of carrying electronic devices inside our bodies was only posed by non-real scenarios. The emergence of insertable devices has changed this. Since this technology is still in its initial development stages, few studies have investigated factors that influence its acceptance. This paper analyzes the predictors of the intention to use non-medical insertable devices in two Latin American contexts. We used partial least squares structural equation modeling to examine whether six constructs predicted intention to use insertable devices. A questionnaire was administered to undergraduate students located in Colombia and Chile (n = 672). We also examined whether these predictors influenced intention differently for both of them. Four common constructs significantly and positively influenced both Chilean and Colombian respondents to use insertable devices (hedonic motivation, habit, performance expectancy, and social influence). Also, the habit has a complementary mediating effect on the relationship between social influence and behavioral intention. By contrast, effort expectations were a positive and significant predictor, but only among Chilean respondents. Findings suggest that when technologies are emerging, well-known predictors of intention (e.g., performance and effort expectations) are less influential than predictors related to self-efficacy (e.g., habit and hedonic motivation). The use of insertable devices has a significant impact on society. Thus, a better understanding of what motivates their use has implications for both academia and industry.     

Secure image encryption scheme using 4D-Hyperchaotic systems based reconfigurable pseudo-random number generator and S-Box

This paper introduces the design of a hardware efficient reconfigurable pseudorandom number generator (PRNG) using two different feedback controllers based four-dimensional (4D) hyperchaotic systems i.e. Hyperchaotic-1 and -2 to provide confidentiality for digital images. The parameter's value of these two hyperchaotic systems is set to be a specific value to get the benefits i.e. all the multiplications (except a few multiplications) are performed using hardwired shifting operations rather than the binary multiplications, which doesn't utilize any hardware resource. The ordinary differential equations (ODEs) of these two systems have been exploited to build a generic architecture that fits in a single architecture. The proposed architecture provides an opportunity to switch between two different 4D hyperchaotic systems depending on the required behavior. To ensure the security strength, that can be also used in the encryption process in which encrypt the input data up to two times successively, each time using a different PRNG configuration. The proposed reconfigurable PRNG has been designed using Verilog HDL, synthesized on the Xilinx tool using the Virtex-5 (XC5VLX50T) and Zynq (XC7Z045) FPGA, its analysis has been done using Matlab tool. It has been found that the proposed architecture of PRNG has the best hardware performance and good statistical properties as it passes all fifteen NIST statistical benchmark tests while it can operate at 79.101-MHz or 1898.424-Mbps and utilize only 0.036 %, 0.23 %, and 1.77 % from the Zynq (XC7Z045) FPGA's slice registers, slice LUTs, and DSP blocks respectively. Utilizing these PRNGs, we design two 16 × 16 substitution boxes (S-boxes). The proposed S-boxes fulfill the following criteria: Bijective, Balanced, Non-linearity, Dynamic Distance, Strict Avalanche Criterion (SAC) and BIC non-linearity criterion. To demonstrate these PRNGs and S-boxes, a new three different scheme of image encryption algorithms have been developed: a) Encryption using S-box-1, b) Encryption using S-box-2 and, c) Two times encryption using S-box-1 and S-box-2. To demonstrate that the proposed cryptosystem is highly secure, we perform the security analysis (in terms of the correlation coefficient, key space, NPCR, UACI, information entropy and image encryption quantitatively in terms of (MSE, PSNR and SSIM)).     

Feasibility study of large-scale mass customization 3D printing framework system with a case study on Nanjing Happy Valley East Gate

At present, the development and implementation of digital transformation are the keys to promoting high-quality industry development. The new digital fabrication method of robotic 3D printing is a research area being studied by many to tackle the issue of the declining productivity of traditional construction methods. Although many studies have been done, most of the current 3D printing projects are facing limitations in terms of scale. In order to bridge the gap, this article proposed a mass customization 3D printing framework system for large-scale projects. This article discusses how mass customization is made possible through the joint operation of the FUROBOT software and 3D printing hardware. By taking the east gate of Nanjing Happy Valley Plaza as a case study, the article demonstrates and studies the feasibility of the large-scale mass customization 3D printing framework system.     

Changes in accommodative micro-fluctuations after wearing contact lenses of different optical designs

PurposeAccommodative micro-fluctuations (AMF) are small dioptric changes during accommodation. The aim of this study was to evaluate and compare changes in AMF when wearing silicone hydrogel contact lenses of two different optical designs.MethodsA multi-centre, randomised, cross-over, non-dispensing study was conducted on 68 adapted contact lens wearers aged 25–35 years to compare AMF responses to a spherical and aspheric silicone hydrogel (comfilcon A) lens designs. A Righton Speedy “i” series Auto Refractometer in accommodation analyser mode was utilized before and after reading a standard text in font size 8 on an iPhone 5 for 20 min at a 25 cm viewing distance. Phone screen brightness was set by automatic adjustment mode and ambient illumination was controlled at all sites.ResultsMean ± SD AMF change from before to after the reading task was 2.25 ± 5.6 and 0.13 ± 5.7 (relative values) for the spherical and aspheric lens designs, respectively. The difference was statistically significant (P = 0.017, Paired t-test).ConclusionsThe smaller change in AMF when using an aspheric lens design suggests reduced ciliary muscle stress when reading print on a smart phone at a close distance for short periods (20 min). Contact lens wearers who frequently use digital devices and are experiencing eye strain may benefit from switching from a spherical design to one that incorporates aspheric optics.     

R-curves determination of ordinary refractory ceramics assisted by digital image correlation method

As a figure-of-merit, the rising ratio of crack propagation resistance to fracture initiation resistance indicates a reduction of the brittleness and enhances the thermal shock resistance of ordinary refractory ceramics. The significant nonlinear fracture behaviour is related to the development of a fracture process zone (FPZ). The universal dimensionless load–displacement diagram method is applied as a promising graphical method for the determination of R-curves for magnesia refractories showing different brittleness. By applying digital image correlation (DIC) together with the graphical method, the problems arisen with accurate determination of the fracture initiation resistance and the crack length are overcome. Meanwhile, the R-curve is subdivided with respect to the fracture processes, viz the fracture initiation, the development of FPZ and the onset of traction free macro-crack. With the simultaneous crack lengths evaluated from DIC, the contribution of each fracture process to the crack propagation resistance at certain loading stage is quantitatively presented.