About the Book
Drive innovation and efficiency in your manufacturing processes with this comprehensive guide that explores the transformative impact of digital manufacturing technologies, from robotics to Industry 4.0.
Digital manufacturing refers to the use of a computer-based system consisting of various tools and software for simulation, analytics, 3D visualization, and business and manufacturing collaboration. Often, these tools and software programs are cloud-based. They enable a manufacturer to connect and integrate manufacturing operations into a streamlined whole. With this centralized computer system, manufacturers have a seamless, connected flow of data related to all their processes and products. This comprehensive volume explores the transformative impact of digital technologies on the manufacturing industry. It delves into the core concepts of digital manufacturing, including automation, additive manufacturing, robotics, digital twins, and Industry 4.0. Covering both the theoretical foundations and practical applications of these technologies, this book provides a detailed understanding of how these technologies are reshaping production processes, improving efficiency, and driving innovation. It highlights the challenges and opportunities of adopting these advancements in the context of modern manufacturing environments. With real-world case studies and insights from industry experts, this book serves as an essential resource for professionals, students, and researchers aiming to understand and implement digital manufacturing solutions.
Readers will find the volume:
Introduces technologies for successful improvement in advanced processes and applications of digital manufacturing;
Explores recently developed digital manufacturing technologies;
Discusses the successful fabrication of multipurpose digital manufacturing technologies, the sustainability of digital manufacturing technologies, and the future scope and challenges presented by digital manufacturing technologies.
Audience
Engineers, researchers, academics, and industry professionals invested in digital manufacturing technologies.
Table of Contents:
Preface xxv
Acknowledgement xxix
Part I: Overview 1
1 Introduction to Digital Manufacturing System 3
Sandip Kunar and Gurudas Mandal
1.1 Introduction 3
1.2 Manufacturing as Craft and Technique 5
1.3 Manufacturing Becoming a Science 5
1.4 Concepts and Research and Development Status of Digital Manufacturing 9
1.5 Definition of Digital Manufacturing 11
1.6 Features and Developments of Digital Manufacturing 16
1.7 Digital Manufacturing Science: Significance and Research Approach 19
1.8 Conclusion 22
2 Industrial Production through the Ages: A Historical Analysis and Forecast 25
Sameeha Khan, Juveiria Khan, Abdul Ahad, Zehra Fatima and Faisal Talib
2.1 Introduction 26
2.2 Industrial Production 51
2.3 Discussion 65
2.4 Conclusion 68
3 Technology Management in Digital Manufacturing Science 75
D.V.S.S.S.V. Prasad, M. Sreenivasa Reddy and A. Ramesh
3.1 Introduction 76
3.2 Technological Landscape of Digital Manufacturing 79
3.3 Strategic Management of Technology 83
3.4 Operational Management of Digital Manufacturing Technologies 87
3.5 Technology Integration and Interoperability 92
3.6 Human Capital and Skills Management 98
3.7 Case Studies and Best Practices 102
3.8 Conclusion and Future Directions 107
4 Design Methodologies and Approaches in Traditional and Additive Manufacturing Systems: A Comparative Study 111
Noor Yamshi, Fiza Siddiqui, Sabih Ahmad Khan and Faisal Talib
4.1 Introduction 112
4.2 Conventional Manufacturing Design Methodologies 115
4.3 AM Design Methodologies 119
4.4 Comparative Analysis of Design Methodologies 124
4.5 Challenges and Limitations 127
4.6 Future Trends and Opportunities 129
4.7 Conclusions 131
5 Simulation and Process Optimization in Wire Arc Additive Manufacturing: A Review 137
Ajithkumar Sitharaj, Arulmurugan B., M.D. Barath Kumar, Ganesh N., Dharani Kumar S. and Gokulkumar S.
5.1 Introduction 138
5.2 Heat Source Modeling for Numerical Simulation in WAAM 140
5.3 Thermal and Mechanical Analysis in FEA for WAAM 145
5.4 Future Scope 154
5.5 Conclusion 156
6 The Role of Polymer Materials and Their Properties in Shaping the Future of Additive Manufacturing 161
Ganesh Nataraj, Ramesh Babu S., Ramu Murugan, Senthil Kumar A.P. and Ajithkumar Sitharaj
6.1 Introduction 162
6.2 Types of Polymer Materials Used in AM 166
6.3 Material Properties and Their Influence on AM 169
6.4 Processing Techniques in Polymer AM 172
6.5 Design Considerations for Polymer AM 175
6.6 Advanced Polymer Materials for AM 176
6.7 Applications of Polymer Materials in AM 179
6.8 Challenges and Limitations 181
6.9 Future Trends in Polymer Materials for AM 182
6.10 Conclusion 183
7 Metal Additive Manufacturing 187
Nebechi Kate Obiora, Chika Oliver Ujah, Sandip Kunar, Peter Apata Olubambi and Daramy Vandi Von Kallon
7.1 Introduction 188
7.2 Basic Principles of MAM 193
7.3 MAM Processes 196
7.4 Metals Used in AM 206
7.5 Recent Advances and Future Outlook 210
7.6 Conclusion and Recommendation 215
7.7 Recommendations 216
8 Advancement in Materials for Functional Three-Dimensional Printing 223
Arhaan Nawab, Waquar Alam, Wasim Alam, Mohd. Hamza and Faisal Talib
8.1 Introduction 224
8.2 Materials and Methods 227
8.3 Applications of Materials 238
8.4 Conclusions 243
9 Cross-Country Comparative Analysis of Digital Manufacturing Systems 249
Sunita Routray, Rudra Narayan Mohapatro and Ranjita Swain
9.1 Introduction 250
9.2 Digital Technological Review for the Manufacturing Process 253
9.3 Cross-Country Comparative Analysis of DMS 255
9.4 Advances in DMS in Today’s World 261
9.5 Future Prospects in the Manufacturing Industry 264
9.6 Conclusion 273
10 A Review and Analysis from Industry 4.0 Toward Industry 5.0 279
Sandip Kunar, Jagadeesha T., Chika Oliver Ujah, Norfazillah Talib, Gurudas Mandal, K. Nagasuresh, N. Naresh, S. Rama Sree and M. Sreenivas Reddy
10.1 Introduction 280
10.2 Historical Overview 283
10.3 Basic Driving Concepts of Industry 4.0 and Industry 5.0 284
10.4 Review of Key Enablers in Practical Context of Industry 4.0 and Industry 5.0 287
10.5 Discussion 293
10.6 Are We Fear of Technology? The Role of Regulations 294
10.7 Controlling AI 295
10.8 Conclusions 296
10.9 The Future 297
11 Envisioning Industry 4.0: A Review 307
Sumanta Banerjee and Anindita Kundu
11.1 Introduction and Background 308
11.2 Changes and Transformation of Manufacturing Ecosystems: A Review 311
11.3 Smart Manufacturing Systems: Role of AI, IoT, and Big Data 315
11.4 Intelligent Factories 321
11.5 The Fourth Industrial Revolution (Industry 4.0) 324
11.6 Industry 3.0 to Industry 4.0: Mapping the Transformation 325
11.7 Impact of Industry 4.0: Technological Inference 327
11.8 Impact of Industry 4.0: Socio-Cultural Impacts 328
11.9 Impact of Industry 4.0: Business Prospects 329
11.10 Conclusions and Present/Futuristic Trends 330
12 Future Development of Digital Manufacturing Science 335
Alok Kumar and Sachin Kumar
12.1 Introduction 336
12.2 Conventional Methodology of the DMS Process 337
12.3 The Electrical Mechanical (Elec-Mech) System with DMS 339
12.4 The Externalization of DMS 345
12.5 The Environmental Protection of DMS 349
12.6 Applications of DMS 357
12.7 Conclusion 359
Part II: Computing Applications 365
13 Computing Manufacturing in Digital Manufacturing Science 367
Dasari Madhusudhan, Rupa Srivani and Keerthi Prabhavathi
13.1 Introduction 368
13.2 Theoretical Foundations of Computing in Manufacturing 372
13.3 Mathematical Methods 377
13.4 Key Computing Technologies in Manufacturing 381
13.5 Applications of Computing in Digital Manufacturing 388
13.6 Case Studies 395
13.7 Discussion and Analysis 402
13.8 Conclusion 405
13.9 Implications for Industry 406
13.10 Suggestions for Future Research 407
14 Unlocking the Potential of Intelligent Manufacturing Guide to Digital Manufacturing 413
Adnan Zafar, Imad Ur Rehman, Jamal Abdullah Haider and Faisal Talib
14.1 Introduction 414
14.2 Progression of Manufacturing Innovations 416
14.3 Case Studies 421
14.4 Challenges and Barriers 424
14.5 Conclusion 426
15 Bionic Manufacturing in Digital Manufacturing Science 429
Debjani Bhakta, Jyoti Bhattacharjee and Subhasis Roy
15.1 Introduction 430
15.2 Digital Technologies Used for Bionic Manufacturing 435
15.2.1 Artificial Intelligence (AI) and Machine Learning 435
15.3 Applications of Bionic Manufacturing 436
15.4 Applications of Bionic Manufacturing in Digital Manufacturing Science 438
15.5 Challenges and Future Directions 444
15.6 Case Studies 449
15.7 Conclusions 454
16 Direct Digital Manufacturing for Biomedical Applications: Toward Efficient Healthcare 465
Amey Dukle and M. Ravi Sankar
16.1 Introduction 466
16.2 Technological Foundations of DDM for Biomedical Applications 468
16.3 Application of DDM for Biomedical Applications 475
16.4 Challenges in Adoption of DDM for Biomedical Applications 480
16.5 Conclusion and Future Outlook 482
17 Digital Manufacturing and the Fifth Industrial Revolution 491
Alok Kumar and Ravi Shankar Rai
17.1 Digital Manufacturing 492
17.2 Development of Industrial Revolutions 498
17.3 Uses of Digital Manufacturing 502
17.4 Characterizing Industry 5.0 506
17.5 Applications of DM Sectors 513
17.6 Conclusion 515
18 Factories of the Future: Digital Manufacturing in the Manufacturing Industry 523
Rasu Karunanithi, Mohammed Abdur Rahman and Gopal Rajesh
18.1 Introduction 524
18.2 Advanced Technologies Used in Digital Manufacturing 525
18.3 Workforce Transformation: Skills Needed for Managing and Operating Digital Manufacturing Systems 539
18.4 Case Studies 541
18.5 Challenges and Barriers to Adoption 546
18.6 Cost of Technology Upgrades and Maintenance 547
18.7 Conclusion 549
19 Business Models for Additive Manufacturing: A Consulting Services Perspective 559
Yogeshwaran Kumarasamy, Prases Kumar Mohanty and Shubhajit Das
19.1 Introduction 559
19.2 Business Background 560
19.3 Importance of Business Model 562
19.4 Business Models for Consulting Services 564
19.5 Requirements for Consulting Services 566
19.6 Opportunities in Various Segments 570
19.7 Challenges in Additive Manufacturing for Consulting Service 573
19.8 Conclusion 575
20 Integration of Additive Manufacturing with Digital Technologies for Future Manufacturing 579
Ganesh Nataraj, Ramesh Babu S., Ramu Murugan, Senthil Kumar A.P. and Ajithkumar Sitharaj
20.1 Introduction 580
20.2 Understanding Additive Manufacturing 581
20.3 The Intersection of Additive Manufacturing and Digital Transformation 583
20.4 Impact of Additive Manufacturing on Supply Chains 585
20.5 Sustainability in Additive Manufacturing 587
20.6 Customization and Personalization in Digital Manufacturing 588
20.7 Challenges and Opportunities 589
20.8 Future Trends in Additive Manufacturing and Digital Transformation 590
20.9 Conclusion 593
21 Computational Approaches to Advanced Digital Manufacturing Practices 597
D.V.S.S.S.V. Prasad, Akhilesh Kumar Singh, Marxim Rahula Bharathi. B., Yarrapragada K.S.S. Rao and V.V. Kamesh
21.1 Introduction 598
21.2 Foundations of Digital Manufacturing 600
21.3 Overview of Computational Models in Manufacturing 603
21.4 Data Management and Analytics 606
21.5 Software and Tools 609
21.6 Computing Architectures and Systems 611
21.7 Challenges and Limitations 615
21.8 Future Trends and Innovations 619
21.9 Conclusion 623
References 625
Index 627
About the Author :
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.
