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The increasing utilization of hard-to-cut materials in high-performance sectors such as aerospace and defense has pushed manufacturing systems to be flexible in processing large workpieces with a wide range of materials while also delivering high precision. Recent studies have highlighted the potential of integrating industrial robots (IRs) with electric discharge machining (EDM) to create a non-contact, low-force manufacturing platform, particularly suited for the accurate machining of hard-to-cut materials into complex and large-scale monolithic components. In response to this potential, a novel robotic EDM system has been developed. However, the manual programming and control of such a convoluted system present a significant challenge, often leading to inefficiencies and increased error rates, creating a scenario where the EDM process becomes unfeasible. To enhance the industrial applicability of this robotic EDM technology, this study focuses on a novel methodology to develop and validate a digital twin (DT) of the physical robotic EDM system. The digital twin functions as a virtual experimental environment for tool motion, effectively addressing the challenges posed by collisions and kinematic singularities inherent in the physical system, yet with proven 20-micron EDM gap accuracy. Furthermore, it facilitates a CNC-like, user-friendly offline programming framework for robotic EDM cutting path generation.

Exotic materials such as titanium offer superior characteristics that, paradoxically, make them hard-to-cut by conventional machining. As a solution, electric discharge machining (EDM) stands out as a non-conventional process able to cut complex profiles from hard-to-cut materials, delivering dimensional accuracy and a superior surface. However, EDM is embodied in CNC machines with a reduced axis and machining envelope, which constrains design freedom in terms of size and shape. To overcome these CNC constraints, traditional machining using six-axis industrial robots have become a prominent research field, and some applications have achieved cost efficiency, an improved envelope, and high flexibility. However, due to the lack of stiffness and strength of the robot arm, accuracy, material rate removal, and surface finishing are not comparable to CNC machining. Therefore, the present study investigates the design of a novel WEDM combined with six-axis robotic machining to overcome the limitations of traditional robotic machining and enhance EDM applications. This study extends the work of a conference paper to confirm potential outcomes, quantifying and ranking undesired interactions to map technical problems and applying the TRIZ approach to trigger solutions. Finally, an effective robotic end-effector design is proposed to free EDM from CNC and deliver robotic machining as a flexible and accurate machining system for exotic materials.

Stroke is the second most common cause of death and remains a persistent health challenge globally. Due to its highly time-sensitive nature, earlier stroke treatments should be enforced for improved patient outcome. The mobile stroke unit (MSU) was conceptualized and implemented to deliver the diagnosis and treatment to a stroke patient in the ultra-early time window (<1 h) in the pre-hospital setting and has shown to be clinically effective. However, due to geographical challenges, most rural communities are still unable to receive timely stroke intervention, as access to specialized stroke facilities for optimal stroke treatment poses a challenge. Therefore, the aircraft counterpart (Air-MSU) of the conventional road MSU offers a plausible solution to this shortcoming by expanding the catchment area for regional locations in Australia. The implementation of Air-MSU is currently hindered by several technical limitations, where current commercially available CT scanners are still oversized and too heavy to be integrated into a conventional helicopter emergency medical service (HEMS). In collaboration with the Australian Stroke Alliance and Melbourne Brain Centre, this article aims to explore the possibilities and methodologies in reducing the weight and, effectively, the size of an existing CT scanner, such that it can be retrofitted into the proposed search and rescue helicopter—Agusta Westland AW189. The result will be Australia’s first-ever customized CT scanner structure designed to fit in a search-and-rescue helicopter used for Air-MSU.

Traditional computer numeric control (CNC) machines have high accuracy but are limited by workpiece size and axes. Therefore, many researchers attempted to equip six-axis industrial robots (IRs) with milling end-effectors to explore the robot’s large and flexible working envelope. However, IRs lack stiffness and have limited force, resulting in low accuracy, poor surface roughness (SR), and low material removal rate (MRR). On the contrary, electric discharge machining (EDM) is a non-conventional process capable of shaping complex profiles in any conductive material. Since the EDM process has no physical contact between the electrode and the workpiece, it can machine diverse hard-to-cut materials accurately and free of vibration. However, to this day, EDM is found in limited conditions of CNC machines only. Thus, this research investigates a synergistic combination of IR and milling EDM. Adopting advanced CAM tools and offline programming, it examines pre-designed electrodes working analogue to conventional milling to perform the desired machining by intricate cutting paths. The results deliver a robotic machining technique able to cut hard materials using small industrial robots yet free of vibration and not pose dependent.

The concept of concurrent engineering (CE) was first developed in the 1980s. Now often referred to as transdiciplinary engineering, it is based on the idea that different phases of a product life cycle should be conducted concurrently and initiated as early as possible within the Product Creation Process (PCP). The main goal of CE is to increase the efficiency and effectiveness of the PCP and reduce errors in later phases, as well as incorporating considerations - including environmental implications - for the full lifecycle of the product. It has become a substantive methodology in many industries, and has also been adopted in the development of new services and service support. This book presents the proceedings of the 25th ISPE Inc. International Conference on Transdisciplinary Engineering, held in Modena, Italy, in July 2018. This international conference attracts researchers, industry experts, students, and government representatives interested in recent transdisciplinary engineering research, advancements and applications. The book contains 120 peer-reviewed papers, selected from 259 submissions from all continents of the world, ranging from the theoretical and conceptual to papers addressing industrial best practice, and is divided into 11 sections reflecting the themes addressed in the conference program and addressing topics as diverse as industry 4.0 and smart manufacturing; human-centered design; modeling, simulation and virtual design; and knowledge and data management among others. With an overview of the latest research results, product creation processes and related methodologies, this book will be of interest to researchers, design practitioners and educators alike.

For decades, researchers have struggled to solve 6-axis robotic vibration while machining hard-to-cut materials. On the other hand, wire electric discharge machining (WEDM) stands out as a non-conventional machining process able to cut large and complex profiles of any conductive hard-to-cut material with minor non-contact forces. Thus, WEDM is a promising process to be combined into a robot to overcome vibration and low accuracy. However, the robot characteristics of a high degree of freedom combined with payload limitation oblige to separate the heavy wire winding system from the robot end-effector, demanding an equally high degree of freedom and unconventional solutions to feed and control the wire electrode. This study designs and reports experimental findings of the first robotic WEDM apparatus based on a high-speed winding system with 600 m of wire length, capable of controlling the wire speed from 1 to 10 m/s and wire tension from 0.1 to 10 N. The system adopts flexible outer cases to travel and reciprocate the wire into a 7-axis robotic system composed of a 6-axis robot and an external rotating axis. The proposed design is a highly dynamic process whose wire tension and speed are achieved by a hybrid controller to cope with the non-linear relation of speed and tension provided by the magnetic clutch. It combines a regression open-loop control for optimality and wire breakage avoidance with a closed-loop control to guarantee admissibility while coping with wire friction disturbances. The findings review a novel wire winding system capable of controlling usual wire disturbance and stepped surface of reciprocating high-speed WEDM as well as additional friction and elastic behaviour of the flexible case, delivering wire tension of ± 12% along with stable EDM process and uniform surface roughness between wire reciprocation areas with a Ra of 2.94 μm. Potential adoption of the method can finally make 6-axis robots a feasible and advantageous technique compared to computer numeric control (CNC) while shaping monolithic and complex workpieces of conductive and hard-to-cut materials.

Engineering systems such as an aircraft or frigate are highly complex and specifically designed to meet the customer's requirements.This important book provides the information necessary to acquire and support complex engineering systems expected to last for a long time.

Due to the numerous factors that affect the air passenger traffic in the air transportation market and the randomness of various factors, in addition, the relationship between it and the air passenger traffic is very complicated, so the air passenger traffic forecast in the air transportation market has always been difficult to solve problem. This research mainly discusses the prediction model of air transportation management based on the intelligent algorithm of wireless network communication. This article uses the wireless network communication intelligent algorithm, comprehensively considers the influence of the GDP growth rate, population growth rate, total import and export volume, and other factors on the air transportation market, and draws a relatively complete forecasting model of aviation business volume. In this paper, we use an equal-weight method, linear combination model method, and Bayesian combination model method when selecting the combination forecasting method (these three methods). Because of the parallelism, robustness, nonlinearity, and other characteristics of the Bayesian network method, it adapts to the complex and highly nonlinear characteristics between air passenger traffic and its influencing factors. In the comprehensive prediction of the single model, the different information contained in the single model is used to achieve different combined prediction effects. The economic information and forecasting angle of the system can reduce systematic forecasting errors and optimize the prognostic results, which can make us more intuitively understand the difference of forecasting results brought by different combination forecasting methods. The Theil inequality coefficient of the ARIMA model is 0.004874, and the average absolute percentage error is 0.005914. This research will play a certain guiding role in the development of China’s civil aviation industry.