Adaptive machining with internally cooled smart cutting tools is a smart solution for industrial applications, which have stringent manufacturing requirements such as contamination free machining (CFM), high material removal rate, low tool wear and better surface integrity. The absence of cutting fluid in CFM causes the cutting tool and the workpiece subject to great thermal loads owing to higher friction and adhesion, and as a result may increase the levels of tool wear drastically. The increase in cutting temperature may influence the chip morphology which in return producing metal chips in unfavourable ribbon or snarl forms. CFM is difficult to be realized as contaminants can be in various forms in the machining operation and to avoid them totally requires a very tight controlled condition. However, the ecological, economical and technological demands compel the manufacturing practitioners to implement environmentally clean machining process (ECMP). Machining with innovative cooling techniques such as heat pipe, single-phase microduct, cryogenic or minimum quantity lubrication (MQL) has been intensely researched in recent years in order to reduce the cutting temperature in ECMP, thus enabling the part quality, the tool life and the material removal rate achieved in ECMP at least equate or surpass those obtained in conventional machining. On the other hand, the reduction of cutting temperature by using these techniques is often superfluous and is adverse to the produced surface roughness as the work material tends to inherent brittle and hard property at low temperature. Open cooling system means the machining requires a constant cooling supply and it does not provide a solution for process condition feedback as well.This Ph.D. project aims to investigate the design and analysis of internally cooled cutting tools and their implementation and application perspectives for smart adaptive machining in particular. Circulating the water based cooling fluid in a closed loop circuit contributes to sustainable manufacturing. The advantage of reducing cutting temperature from localized heat at the tool tip of an internally cooled cutting tool is enhanced with the smart features of the tool, which is trained by real experimental data, to cognitively vary the coolant flow rate, cutting feed rate or/and cutting speed to control the critical machining temperature as well as optimum machining conditions. Environmental friendly internal micro-cooling can avoid contamination of generated swarf which can also reduce the cutting temperature and thus reduce tool wear, increase machining accuracy and optimize machining economics. Design of the smart cutting tool with internal micro-cooling not only takes into account of the environmental aspects but also justifies with its ability to reduce the machining cost. Reduction of production cost can be achieved with the lower consumption of cooling fluid and improved machining resources/ energy efficiency. The models of structural, heat transfer, computational fluid dynamics (CFD) and tool life provide useful insight of the performance of the internally cooled smart cutting tool. Experimental validation using the smart cutting tool to machine titanium, steel and aluminium, indicates that the application of internally cooled smart cutting tools in adaptive machining can improve machining performance such as cutting temperature, cutting forces and surface quality generated. The useful tool life span is also extended significantly with internally cooled smart cutting tools in comparison to the tool life in conventional machining. The internally cooled smart cutting tool has important implications in the application to ECMP particularly by overcoming the stigma of high uncontrollable cutting temperature with the absence of cooling fluid.

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In this new digital age, efficiency, quality and competition are all increasing rapidly as companies leverage the Industrial Internet of Things (IIoT). However, while industrial innovation moves at a faster and faster pace, educational institutions have lagged in the development of the curriculum and environment needed to support further development of the IIoT. To fully realize the potential of the IIoT in the manufacturing sector educational institutions must support the technological training and education rigor demanded to instill the skills and thought leadership to move the industry forward. The purpose of this research is to provide an IIoT core system in an educational factory environment. This system will assist in teaching basic principles of IIoT in the factory while simultaneously allowing for students to envision the manufacturing journey of any facility by implementing principles of IIoT. This will be accomplished by providing all the following capabilities together in a single data system: unified connectivity, role-based data display, real-time issue identification, data analytics, and augmented reality.

Artificial Intelligence arises in the manufacturing field very rapidly. Implementing Artificial Intelligence (AI) solutions and algorithms in the manufacturing environment is a well-known research field in academia. On the other hand, Manufacturing-Execution-System (MES) providers do not have a theoretical and pragmatic framework regarding the evaluation of MES functions in respect to their suitability for Artificial Intelligence. In order to be able to pre-evaluate whether a MES function shall be AI supported an intense literature research has been conducted. Academia shows few investigations regarding this field of research. Recent studies have been concerning about possible applications for MES functions in combination with AI. However, there is a lack of research in terms of pre-evaluating a MES function before embedding the function with AI support, since the development of AI solutions for MES functions without pre-evaluating those bears a waste of valuable resources. Therefore, the thesis work introduces an assessment framework consisting of decisive criteria and related indicators which describe qualitatively the suitability of AI for MES functions based on three criteria with related indicators. In addition, the researcher displays furthermore how the developed assessment framework can be used in order to assess the MES functions regarding their AI “readiness”. In order to cope the findings through the thesis work an inductive research approach has been applied. Existing literature in the fields of intelligent manufacturing, Manufacturing-Execution-Systems, machine learning, deep learning, intelligent manufacturing, digital twin, and assessment methodologies have been extensively studied in order to base the theoretical developed framework on grounded theory. A major issue was to focus the development of the assessment framework in harmony with academia and industry. The requirements for academia were met by providing profoundly investigation through the research fields. A case study was carried out in order to test the validity and reliability of the developed assessment framework for industry. The outcome of this thesis work was an assessment framework consisting of decisive criteria and related indicators when evaluating a MES function in respect to its AI suitability. Furthermore, an assessment checklist has been provided for the industry in order to be able to assess a MES function regards AI support in a quick and pragmatic manner. To generate a more generalizable assessment framework criteria and indicators have to be adapted, likewise testing the outcome of analogue and digital assessment methodologies will provide material for future studies. / <p>Successfully defended</p>

Em sistemas modernos de manutenção inteligente a qualidade de uma máquina ou equipamento depende do suporte que é fornecido junto com esse produto, com a confiabilidade e segurança na utilização do mesmo. Estas exigências, por vezes, não são cumpridas e podem estar indisponíveis em algumas máquinas. Este trabalho descreve uma abordagem utilizando sinais de vibração coletados em tempo real com falhas como estudo preliminar para uma abordagem mais profunda como estudo dametodologia de testes de vida acelerado para auxiliar durante a fase de vida operacional permitindo ao fabricante a determinação dos ciclos de vida do produto. A abordagem proposta construída em cima de experiências anteriores em desenvolvimento no projeto Integração de Sistemas Inteligentes de Manutenção e Cadeia de Fornecimento de Peças Sobressalentes. O objetivo deste trabalho é apresentar resultados preliminares analisando a variabilidade das assinaturas de falhas das engrenagens danificadas de maneira a permitir a identificação dos ciclos de vida do produto para partes específicas de um atuador elétrico. / In modern systems of intelligent maintenance the quality of a machine or equipment depends on the support that comes with this product, with the reliability and safety in the use of it. These requirements are sometimes not met and may be unavailable on some machines. This paper describes an approach using vibration signals collected in real-time with faults as a preliminary study for a deeper approach with the study of the methodology of accelerated life tests to assist during the operational life stage allowing the manufacturer the determination of the life cycles of product. The proposed approach built on previous experiences under development in the project Integration of Intelligent Systems of Maintenance and Chain of Supply of Spares. The objective of this work is to present preliminary results analyzing the variability of failure signatures of the damaged gears in order to allow the identification of product life cycles for specific parts of an electric actuator.

Em sistemas modernos de manutenção inteligente a qualidade de uma máquina ou equipamento depende do suporte que é fornecido junto com esse produto, com a confiabilidade e segurança na utilização do mesmo. Estas exigências, por vezes, não são cumpridas e podem estar indisponíveis em algumas máquinas. Este trabalho descreve uma abordagem utilizando sinais de vibração coletados em tempo real com falhas como estudo preliminar para uma abordagem mais profunda como estudo dametodologia de testes de vida acelerado para auxiliar durante a fase de vida operacional permitindo ao fabricante a determinação dos ciclos de vida do produto. A abordagem proposta construída em cima de experiências anteriores em desenvolvimento no projeto Integração de Sistemas Inteligentes de Manutenção e Cadeia de Fornecimento de Peças Sobressalentes. O objetivo deste trabalho é apresentar resultados preliminares analisando a variabilidade das assinaturas de falhas das engrenagens danificadas de maneira a permitir a identificação dos ciclos de vida do produto para partes específicas de um atuador elétrico. / In modern systems of intelligent maintenance the quality of a machine or equipment depends on the support that comes with this product, with the reliability and safety in the use of it. These requirements are sometimes not met and may be unavailable on some machines. This paper describes an approach using vibration signals collected in real-time with faults as a preliminary study for a deeper approach with the study of the methodology of accelerated life tests to assist during the operational life stage allowing the manufacturer the determination of the life cycles of product. The proposed approach built on previous experiences under development in the project Integration of Intelligent Systems of Maintenance and Chain of Supply of Spares. The objective of this work is to present preliminary results analyzing the variability of failure signatures of the damaged gears in order to allow the identification of product life cycles for specific parts of an electric actuator.

Em sistemas modernos de manutenção inteligente a qualidade de uma máquina ou equipamento depende do suporte que é fornecido junto com esse produto, com a confiabilidade e segurança na utilização do mesmo. Estas exigências, por vezes, não são cumpridas e podem estar indisponíveis em algumas máquinas. Este trabalho descreve uma abordagem utilizando sinais de vibração coletados em tempo real com falhas como estudo preliminar para uma abordagem mais profunda como estudo dametodologia de testes de vida acelerado para auxiliar durante a fase de vida operacional permitindo ao fabricante a determinação dos ciclos de vida do produto. A abordagem proposta construída em cima de experiências anteriores em desenvolvimento no projeto Integração de Sistemas Inteligentes de Manutenção e Cadeia de Fornecimento de Peças Sobressalentes. O objetivo deste trabalho é apresentar resultados preliminares analisando a variabilidade das assinaturas de falhas das engrenagens danificadas de maneira a permitir a identificação dos ciclos de vida do produto para partes específicas de um atuador elétrico. / In modern systems of intelligent maintenance the quality of a machine or equipment depends on the support that comes with this product, with the reliability and safety in the use of it. These requirements are sometimes not met and may be unavailable on some machines. This paper describes an approach using vibration signals collected in real-time with faults as a preliminary study for a deeper approach with the study of the methodology of accelerated life tests to assist during the operational life stage allowing the manufacturer the determination of the life cycles of product. The proposed approach built on previous experiences under development in the project Integration of Intelligent Systems of Maintenance and Chain of Supply of Spares. The objective of this work is to present preliminary results analyzing the variability of failure signatures of the damaged gears in order to allow the identification of product life cycles for specific parts of an electric actuator.

No / A conceptual design approach is an important stage for the development of a hybrid Knowledge-Based System (KBS) for Low Volume Automotive Manufacturing (LVAM). The development of a hybrid KBS, which is a blend of KBS and Gauging Absences of Pre-requisites (GAP), is proposed for LVAM research. The hybrid KB/GAP system identifies all potential elements of LVAM issues throughout the development of this system. The KBS used in the system design stage of the LVAM system analyses the gap between the existing and the benchmark organisations for an effective implementation through the GAP analysis technique. The proposed KBLVAM model at the design stage explores three major components, namely LVAM car body parts manufacturing perspective, LVAM competitive priorities perspective and LVAM lean environment perspective. Initial results reveal that the KBLVAM system has identified, for each perspective modules and sub-modules, the Problem Categories (PC) in a prioritised manner. / The financial support by the Malaysian Government, Universiti Malaysia Pahang and University of Bradford for this research is grateful acknowledged.