Intelligent scheduling of a feature-process-machine tool supernetwork based on digital twin workshop

Modern manufacturing enterprises are shifting toward multi-variety and small-batch production. By optimizing scheduling, both transit and waiting times within the production process can be shortened. This study integrates the advantages of a digital twin and supernetwork to develop an intelligent scheduling method for workshops to rapidly and efficiently generate process plans. By establishing the supernetwork model of a feature-process-machine tool in the digital twin workshop, the centralized and classified management of multiple data types can be realized. A feature similarity matrix is used to cluster similar attribute data in the feature layer subnetwork to realize rapid correspondence of multi-source association information among feature-process-machine tools. Through similarity calculations of decomposed features and the mapping relationships of the supernetwork, production scheduling schemes can be rapidly and efficiently formulated. A virtual workshop is also used to simulate and optimize the scheduling scheme to realize intelligent workshop scheduling. Finally, the efficiency of the proposed intelligent scheduling strategy is verified by using a case study of an aeroengine gear production workshop.     

Digital twin-based assembly data management and process traceability for complex products

Complex products such as satellites, missiles, and aircraft typically have demanding requirements for dynamic data management and process traceability. The assembly process for these complex products involves high complexity, strong dynamics, many uncertainties, and frequent rework and repair, especially in the model development stage. Achieving assembly data management and process traceability for complex products has always been a challenge. A recently proposed solution involves one-to-one mapping of the corresponding physical entity, also known as the digital twin method. This paper proposes a digital twin-based assembly data management and process traceability approach for complex products. First, the dynamic evolutionary process of complex product assembly data was analyzed from three dimensions: granularity, period and version. Then, a framework of digital twin-based assembly data management and process traceability for complex products was constructed. Some core techniques are: 1) workflow-based product assembly data organization and version management; 2) synchronous modeling of the product assembly process based on digital twin; and 3) hierarchical management and traceability of product assembly data based on digital twin. On this basis, an algorithm flowchart for generating a product assembly data package was created, which includes product assembly data management, assembly process traceability, and generation of a product assembly data package. Furthermore, the Digital Twin-based Assembly Process Management and Control System (DT-APMCS) was designed to verify the efficiency of the proposed approach. Some aerospace-related assembly enterprises are currently using DT-APMCS and achieving satisfactory results. Finally, a summary of our work is given, and the future research work is also discussed.     

Development and evaluation of sub-element testing of SiC/SiC ceramic matrix composites at elevated temperatures

SiC/SiC ceramic matrix composites (CMCs) are being developed for use in aero-engines to replace nickel superalloy components. Sub-element testing acts as the key stepping stone in bridging understanding derived from basic coupon testing and more complex component testing. This study presents the development of high temperature C-shape sub-element testing with the use of digital image correlation to study damage progression. The specimen is designed with a bias towards a mixed mode-stress state more similar to what a CMC component may see in service. Both monotonic and fatigue tests were completed on C specimens and compared with predicted behaviour from modelling. Test data from both test types suggested that specimens were failing once they reached a critical radial stress level. However evidence from fractography of specimens showed that in both monotonic and fatigue tests radial cracks (driven by hoop stresses) are initiating prior to circumferential cracks.     

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.     

Fabrication and properties of 3D printed zirconia scaffold coated with calcium silicate/hydroxyapatite

The scaffold of bone repair needs a variety of material combinations to meet its intended performance; a typical single material such as zirconia has excellent mechanical properties, while hydroxyapatite and calcium silicate are bioactive materials with different degradation rates. In this paper, porous zirconia scaffolds were fabricated using 3D printing technology. The surface of the scaffold was coated by dipping with different contents of calcium silicate and hydroxyapatite to improve the biological activity and mechanical properties. Mechanical tests show that the coating material can effectively fill the pores of the porous scaffold, increasing its compressive strength by an average of 55%. The simulated body fluid (SBF) test showed that the higher calcium silicate in the coating increased the degradation rate. Cell experiments showed that the coated scaffolds exhibited good cytocompatibility and were beneficial to the proliferation and differentiation of cells. In conclusion, coated scaffolds have potential applications in the field of bone repair.     

Microstructural,mechanical properties and strengthening mechanism of DLP produced β-tricalcium phosphate scaffolds by incorporation of MgO/ZnO/58S bioglass

The inherent brittleness of bioceramics restricts their applications in load-bearing implant, although they possess good biocompatibility and bioactivity. ZnO, MgO and 58S bioglass (BG) were incorporated as additives to further improve the mechanical properties and biocompatibility of β-TCP and ZnO/MgO/BG-β-TCP composite scaffolds were manufactured via digital light processing (DLP). The composite with the best comprehensive performance was selected for degradation behavior and biocompatibility evaluation. The effects of different proportions of ZnO/MgO/BG on mechanical strength were analyzed and ZnO0·5/MgO1/BG2-β-TCP (ZMBT) samples exhibited superior mechanical strength. The improvement by 272% and 99% respectively was achieved in fracture toughness and compressive strength with the optimal recipe. The enhancement effect is realized through phase transition, alterative sliding actions and transgranular fracture to effectively prevent the load transfer combining the functions of bioglass and metal oxide. ZMBT scaffolds exhibited a more desirable pH environment and an enhanced ability of apatite-mineralization formation, meanwhile Si⁴⁺, Mg²⁺ and Zn²⁺ were gradually released from scaffolds. Furthermore, in vitro evaluation indicated that ZMBT scaffolds presented not only excellent cell attachment, proliferation, alkaline phosphatase (ALP) activity, but they up-regulated osteogenic gene (ALP, OCN, Runx2). These results suggest that the addition of ZnO/MgO/BG to DLP-printed β-TCP scaffolds offer a smart strategy to fabricate porous scaffolds with conspicuously better biological and physicochemical properties including compressive strength, bioactivity, osteogenesis and osteogenesis-related gene expression. Metal-oxide and BG synergistically enhanced the mechanical and biological properties which make the ZMBT scaffolds a strong candidate for bone repair applications.     

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.     

Design and implementation of current mode circuit for digital modulation

This paper proposes a new current-mode digital modulation circuit. The proposed circuit is MOS only hence, easily integrable. It employs an Extra X Current Conveyor (EX-CCII), two MOS transistors as switches, and a two MOS transistor-based active resistor. The amplitude shift keying/phase shift keying/frequency shift keying (ASK/PSK/FSK) modulator is obtained by proper selection of carriers (I_C1, I_C2). This circuit provides the current output signal at high output impedance, which is favorable for cascading. Also, the circuit is employing only MOS transistors, so it can be monolithically IC implementable. The effects of non-idealities and parasitics of the active element on the circuit performance are also investigated in detail. The functionality of the proposed digital modulator is verified through the Cadence Virtuoso tool using 0.18 μm Generic Process Design Kits parameters with the ±0.9 V supply voltage. The total area of the layout is 968.75 μm². Also, the experimental results are verified by using the IC AD-844 and IC CD4007.     

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)).     

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.