Digital Manufacturing Book Pdf

[Lise Henton]

Digitalmanufacturing is an integrated approach to manufacturing that is centered around a computer system.[1][citation needed] The transition to digital manufacturing has become more popular with the rise in the quantity and quality of computer systems in manufacturing plants. As more automated tools have become used in manufacturing plants it has become necessary to model, simulate, and analyze all of the machines, tooling, and input materials in order to optimize the manufacturing process.[2] Overall, digital manufacturing can be seen sharing the same goals as computer-integrated manufacturing (CIM), flexible manufacturing, lean manufacturing, and design for manufacturability (DFM). The main difference is that digital manufacturing was evolved for use in the computerized world.

As part of Manufacturing USA, Congress and the U.S. Department of Defense established MxD (Manufacturing x Digital), the nation's digital manufacturing institute, to speed adoption of these digital tools.

Manufacturing engineers use 3D modeling software to design the tools and machinery necessary for their intended applications. The software allows them to design the factory floor layout and the production flow. This technique lets engineers analyze the current manufacturing processes and allows them to search for ways to increase efficiency in production before production even begins.

Simulation can be used to model and test a system's behavior. Simulation also provides engineers with a tool for inexpensive, fast, and secure analysis to test how changes in a system can affect the performance of that system.[3]

Digital manufacturing systems often incorporate optimization capabilities to reduce time, cost, and improve the efficiency of most processes. These systems improve optimization of floor schedules, production planning, and decision making. The system analyzes feedback from production, such as deviations or problems in the manufacturing system, and generates solutions for handling them.[4]

Debate continues on the impact of such systems on the manufacturing workforce. Econometric models have found that each newly installed robot displaces 1.6 manufacturing workers on average. Those models also have forecasted that by 2030 as many as 20 million additional manufacturing jobs worldwide could be displaced due to robotization.[6]

There are many different tooling processes that digital manufacturing utilizes. However, every digital manufacturing process involves the use of computerized numerical controlled machines (CNC). This technology is crucial in digital manufacturing as it not only enables mass production and flexibility, but it also provides a link between a CAD model and production.[9] The two primary categories of CNC tooling are additive and subtractive. Major strides in additive manufacturing have come about recently and are at the forefront of digital manufacturing. These processes allow machines to address every element of a part no matter the complexity of its shape.[4]

Cloud-Based Design (CBD) refers to a model that incorporates social network sites, cloud computing, and other web technologies to aid in cloud design services. This type of system must be cloud computing-based, be accessible from mobile devices, and must be able to manage complex information. Autodesk Fusion 360 is an example CBD.[16]

Cloud-Based Manufacturing (CBM) refers to a model that utilizes the access to open information from various resources to develop reconfigurable production lines to improve efficiency, reduce costs, and improve response to customer needs.[16] A number of online manufacturing platforms[17] enables users to upload their 3D files for DFM analysis and Manufacture.

By modelling and simulating processes it is possible to improve the quality of manufacturing decision making, while improving the processes to create cost savings, reduce time to market, and create a joined up manufacturing process that unites digital tools with the physical execution of manufacturing.

By using a process that is centred around a computer, manufacturers can create a digital thread through the manufacturing process to analyse data across the product lifecycle and create actionable processes. Digital manufacturing systems also allow for customer data to be sent to product managers in order to anticipate demand and any ongoing maintenance requirements to deliver products via manufacturing that is centred on customer needs.

Each of these relates to a different aspect of manufacturing execution, from design and product innovation to the enhancement of production lines and the optimisation of resources for better products and customer satisfaction.

The product life cycle begins with engineering design before moving on to encompass sourcing, production and service life. Each step uses digital data to allow for revisions to design specifications during the manufacturing process.

The smart factory involves the use of smart machines, sensors and tooling to provide real time feedback about the processes and manufacturing technology. By uniting operations technology and information technology, this digital transformation allows for greater visibility of factory processes, control, and optimisation to improve performance.

With a quicker turnaround across all levels of the value chain, digital manufacturing offers reduced costs, while allowing for design changes to be implemented in real time and also lowering maintenance costs.

Furthermore, it allows an entire manufacturing process to be created virtually so that designers can test the process before investing time and money into the physical implementation.

Alongside the optimisation of processes, digital manufacture delivers a number of advantages for design too. These design advantages begin with the use of 3D modelling software to design tools and machinery as well as factory floor layouts and production flows.

Digital manufacturing has spread rapidly through industries such as aerospace and defence. This allows for the integration of supply networks through cloud computing to allows suppliers to collaborate effectively.

Digital manufacturing technology is also perfectly aligned for incorporation into automated processes such as additive manufacturing, laminated object manufacturing, and CNC cutting, milling, and lathing.

With systems that are able to interact with each other, the growth of Industry 4.0 looks set to continue the trend for joined-up production in order to increase competition and improve and streamline processes.

Digital manufacturing integrates simulation, 3D visualization, analytics and collaboration tools to create simultaneous product and manufacturing process definitions, enabling industries to design entire manufacturing processes digitally, fostering collaboration between engineers and designers.

Digital manufacturing is the use of an integrated, computer-based system comprised of simulation, 3D visualization, analytics and collaboration tools to create product and manufacturing process definitions simultaneously. Digital manufacturing evolved from manufacturing initiatives such as design for manufacturability (DFM), computer-integrated manufacturing (CIM), flexible manufacturing and lean manufacturing that highlight the need for collaborative product and process design.

Many of the long-term benefits of product lifecycle management (PLM) cannot be achieved without a comprehensive digital manufacturing strategy. Digital manufacturing is a key point of integration between PLM and shop floor applications and equipment, enabling the exchange of product-related information between design and manufacturing groups. This alignment allows manufacturing companies to achieve time-to-market and volume goals, as well as realize cost savings by reducing expensive downstream changes.

Digital manufacturing is utilized across industries. An automotive original equipment manufacturer (OEM) can design the entire manufacturing process digitally (tooling, machining, assembly sequencing, and factory layout) at the same time that designers are designing the next vehicle program. This enables manufacturing engineers to provide immediate feedback to designers if there are constraints in the part manufacturability. This collaboration between manufacturing engineers and designers creates a holistic view of product and process design.

A high-tech supplier can use a digital manufacturing system to create a 3D simulation of a complete production line and analyze the different production variants and concepts as part of the request for quote (RFQ) process. This transparency and precision in planning and proposal preparation help the company gain greater customer confidence and ultimately win the contract.

Current initiatives in the development of digital manufacturing tools involve improving user experience, so information is presented in the context of tasks performed, allowing users to make better decisions faster. Steps are being taken to provide direct connectivity with shop floor hardware, such as programmable logic controllers (PLCs), machine controllers and computer numerically controlled (CNC) machines. Unified platforms have also been developed to manage both PLM and manufacturing execution system (MES) information.

Our partners depend on fresh thinking and bold doing. In a world where innovation is a ubiquitous ambition, MxD stands apart. We are grounded by a deep understanding of what digital manufacturing transformation requires, and we hold ourselves accountable to the high stakes.

Making every single part better than the last requires production lines to be embedded with software and sensors, and hooked up to the cloud. Only with this ability to send and receive data can the equipment improve itself and learn from every part produced in real time.

Our 22,000-square-foot research factory is used to test and demonstrate these new digital manufacturing technologies, train the workforce on how to use them, and demonstrate the need for manufacturing cybersecurity to protect the entire process.

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