This paper presents a methodology for describing the relationship between forces acting on the cutting head of an abrasive waterjet machine and the structural response of its supporting structure. The study was conducted in two stages. First, experimental measurements of reaction forces during high-pressure AWJ cutting were performed to determine the influence of process parameters and define the loading conditions. Next, a finite element (FEM) model of the supporting structure was developed, in which the cutting head was idealized as a reference point to enable controlled loading in three directions. A series of simulations with unit loads was carried out to determine the compliance matrix of the structure. The model allows rapid prediction of sensor displacements for arbitrary force combinations without repeated FEM analyses. Experimental validation showed good agreement, with a relative error of approximately 8% in the direction of the lowest stiffness, demonstrating the applicability of the proposed approach for monitoring loads in AWJ processes.
The oil-filling stage in electric oil heater production is a critical operation impacting product safety, thermal performance, and long-term reliability. Thermal oil acts as both a heat transfer medium and an electrical insulator. Deviations in oil quality or filling conditions may cause latent defects appearing only during operation. Contamination, especially moisture ingress, reduces dielectric strength and accelerates oil degradation. Air entrapment during filling can cause uneven temperature distribution, localized overheating, and premature heating element failure. Variability from manual or poorly controlled filling increases the risk of underfilling or overfilling, affecting compliance with technical standards. This paper examines the main technical issues in oil filling, including risks, process control challenges, and safety concerns. From an IT perspective, the process demands precise measurement, system reliability, and integration of control software, sensors, and data acquisition platforms. Software misconfiguration, communication errors, or inadequate validation may lead to incorrect filling parameters and delayed fault detection. The paper outlines key functional and user-interface requirements for IT systems supporting and stabilizing the oil-filling process.
This study reports a combined experimental–numerical investigation of hydraulic-assisted single point incremental forming (HA-SPIF) to enhance thickness uniformity in truncated quadrilateral parts formed from AA1050 aluminum alloy sheets. A finite element model is established and validated using experiments on circular blanks of 220 mm diameter and 1.0 mm thickness, forming components with a 60° wall angle and a target height of 55 mm. Material anisotropy is characterized through uniaxial tensile tests along 0°, 45°, and 90° to the rolling direction, and direction-dependent Voce hardening laws are calibrated from true stress–strain data, with flow stresses of 69.0–82.6 MPa and anisotropy coefficients of 0.45–0.86. The validated model is first employed to assess the effect of material orientation on thickness distribution, revealing pronounced differences in thinning behavior. A subsequent parametric study examines the coupled influences of hydraulic pressure, tool feed rate, and vertical step size on thickness variation and minimum residual thickness. Hydraulic assistance is shown to effectively suppress localized thinning and significantly improve thickness homogeneity relative to conventional SPIF. The main contribution of this work is the integrated consideration of anisotropic Voce hardening and hydraulic support for a non-axisymmetric geometry, providing a reliable predictive framework and practical guidelines for thinning control in high-precision forming applications.
Additive manufacturing with powder bed fusion of metals using a laser beam (PBF-LB/M) enables the manufacturing of complex medical implant geometries, such as patient-specific dental implants that replicate the shape of natural tooth roots. Such geometries may support improved osseointegration in the jawbone. This study investigates commercially pure titanium grade 2 (TiGd2) produced by PBF-LB/M as the basis of an additive-subtractive process for medical implants. Specimens were manufactured in different build orientations (BO) to assess material and surface properties. Micro computed tomography indicated a low internal defect density. Tensile testing showed BO dependent anisotropy, whereas compression testing showed no pronounced anisotropy. Across all BO, mean values were ultimate tensile strength RM = 772 MPa, elongation at break A = 24.4 %, and compressive yield strength R_dp = 746 MPa. Surface post processing enabled adjustment of roughness, with Ra decreasing from Ra_as = 6.3 µm in the as built state to Ra_pb = 5.1 µm after particle blasting, Ra_et = 3.6 µm after acid etching, and Ra_df = 0.36 µm after disc finishing. Overall, the results confirm the potential of PBF-LB/M processed TiGd2 for additive subtractive manufacturing of medical implants.
Industry 4.0 and the rise of collaborative value chains necessitate seamless data integration across organizational and technological boundaries. Yet the fragmented standardization environment prevents interoperability across systems and within frameworks like the Digital Twin (DT). While the Asset Administration Shell (AAS) and Open Platform Communications (OPC) Unified Architecture (UA) are established as core standards for digital asset representation and communication, their independent origins and differing metamodels create semantic gaps that hinder unified machine-level understanding. This systematic mapping study examines how Knowledge Graphs (KG) can bridge semantic gaps to create unified semantic models. Current research demonstrates progress in pairwise integrations, such as transforming OPC UA models into RDF graphs or synchronizing AAS repositories with graph databases. However, these efforts often remain isolated solutions that address specific integration challenges. Consequently, large-scale industrial deployment remains limited. This paper consolidates current knowledge on integrating AAS, OPC UA and KGs, contextualizing these efforts and highlights research gaps toward achieving interoperable manufacturing ecosystems.
