Following the rapid development of lightweight and flexible smart electronic products, providing energy for these electronics has become a hot research topic. The human body produces considerable mechanical and thermal energy during daily activities, which could be used to power most wearable electronics. In this context, fiber-based energy conversion devices (FBECD) are proposed as candidates for effective conversion of human-body energy into electricity for powering wearable electronics. Herein, functional materials, fiber fabrication techniques, and device design strategies for different classes of FBECD based on piezoelectricity, triboelectricity, electrostaticity, and thermoelectricity are comprehensively reviewed. An overview of fiber-based self-powered systems and sensors according to their superior flexibility and cost-effectiveness is also presented. Finally, the challenges and opportunities in the field of fiber-based energy conversion are discussed.

Fiber-Based Energy Conversion Devices for Human-Body Energy Harvesting

Models and modelling for process limits in metal forming

The intensifying of the manufacturing process and increasing the efficiency of production planning of precise and non-rigid parts, mainly crankshafts, are the first-priority task in modern manufacturing. The use of various methods for controlling the cutting force under cylindrical infeed grinding and studying its impact on crankpin machining quality and accuracy can improve machining efficiency. The paper deals with developing a comprehensive scientific and methodological approach for determining the experimental dependence parameters’ quantitative values for cutting-force calculation in cylindrical infeed grinding. The main stages of creating a method for conducting a virtual experiment to determine the cutting force depending on the array of defining parameters obtained from experimental studies are outlined. It will make it possible to get recommendations for the formation of a valid route for crankpin machining. The research’s scientific novelty lies in the developed scientific and methodological approach for determining the cutting force, based on the integrated application of an artificial neural network (ANN) and multi-parametric quasi-linear regression analysis. In particular, on production conditions, the proposed method allows the rapid and accurate assessment of the technological parameters’ influence on the power characteristics for the cutting process. A numerical experiment was conducted to study the cutting force and evaluate its value’s primary indicators based on the proposed method. The study’s practical value lies in studying how to improve the grinding performance of the main bearing and connecting rod journals by intensifying cutting modes and optimizing the structure of machining cycles.

https://www.mdpi.com/1996-1944/13/23/5357/pdf

Parameter Identification of Cutting Forces in Crankshaft Grinding Using Artificial Neural Networks.

Machine tools play a pivotal role in the manufacturing world since their performance significantly affects the product quality and production efficiency. In the era of Industry 4.0, machine tools a...

Digitalisation and servitisation of machine tools in the era of Industry 4.0: a review

Lightweight materials, such as titanium alloys, magnesium alloys, and aluminium alloys, are characterised by unusual combinations of high strength, corrosion resistance, and low weight. However, some of the grades of these alloys exhibit poor formability at room temperature, which limits their application in sheet metal-forming processes. Lightweight materials are used extensively in the automobile and aerospace industries, leading to increasing demands for advanced forming technologies. This article presents a brief overview of state-of-the-art methods of incremental sheet forming (ISF) for lightweight materials with a special emphasis on the research published in 2015–2021. First, a review of the incremental forming method is provided. Next, the effect of the process conditions (i.e., forming tool, forming path, forming parameters) on the surface finish of drawpieces, geometric accuracy, and process formability of the sheet metals in conventional ISF and thermally-assisted ISF variants are considered. Special attention is given to a review of the effects of contact conditions between the tool and sheet metal on material deformation. The previous publications related to emerging incremental forming technologies, i.e., laser-assisted ISF, water jet ISF, electrically-assisted ISF and ultrasonic-assisted ISF, are also reviewed. The paper seeks to guide and inspire researchers by identifying the current development trends of the valuable contributions made in the field of SPIF of lightweight metallic materials.

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Incremental sheet metal forming on the example of car exterior skin parts

A multi-sensor approach for failure identification during production enabled by parallel data monitoring

Adaptive Grinding Process—Prevention of Thermal Damage Using OPC-UA Technique and In Situ Metrology

The development approach for energy storage systems focuses on optimally sized capacitor modules to reduce peak power and to avoid energy recovery of production machines. Using servo presses as an example, the application of two different energy storage systems in the DC link is practically examined. A simulation model in Matlab/Simulink and a test stand of a servo press are proposed for representing the power flows between the mains supply, the electric drives and the storage systems. The description of forming machines and the behaviour of the electric components are used to control the amount of stored energy in a storage system and to influence the process regarding a reduction of peak power.

Energy storage in drive systems of servo presses for reduction of peak power and energy recovery

The direct integration of piezo elements into micro-structured aluminum sheets is a new approach for adaptronics and lightweight constructions. With the integration of the active piezoceramic elements the aluminum sheets gain sensor and actuator functionalities. The mechanical interconnections and the preload of the piezoceramic elements are an important issue for the sensor and actuator capability of the later smart material. Post-process inspection methods to characterize the mechanical interconnection of the joining partners and the performance of the transducer after the joining operation are state of the art. Scope of the paper is the development of a novel in-process monitoring method that utilizes the piezoceramic transducer as inherent sensor for failure mode detection and preload evaluation during the joining by forming operation. Within this study, results of forming experiments with array batches of interconnected piezoceramic elements are presented. The piezoceramic batches are electrically contacted inside the joining tool and utilized as material inherent sensor during joining by forming experiments. Test samples are characterized by impedance spectroscopy during the joining operation. Based on the experimental results, a novel in-process-monitoring method utilizing the piezoceramic joining partners as inherent sensor is outlined. It is shown, that with this method a sufficient preload can be adjust on the basis of the intensity of the resonance peak without an overload. Furthermore, error effects to the transducer can be detected at an early stage.

Alexander Pierer

Papers

Incremental sheet metal forming on the example of car exterior skin parts

A multi-sensor approach for failure identification during production enabled by parallel data monitoring

Adaptive Grinding Process—Prevention of Thermal Damage Using OPC-UA Technique and In Situ Metrology

Energy storage in drive systems of servo presses for reduction of peak power and energy recovery

In-Process Monitoring of Joining Operations for Piezoceramic Elements