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Machine Tools This book introduces the applications of Industry 4.0 in machine tools through an overview of the latest available digital technologies. It focuses on digital twining, communication between industrial controls, motion, and input/output devices, along with sustainability in SMEs. Machine Tools: An Industry 4.0 Perspective focuses on the digital twining of machine tools, which improves the life of the machines and provides a method of operating a factory during times of complete lockdown resulting from various conditions. It presents an overview of the communication between industrial controls, motion and input/output devices through standardized digital interfaces such as SERCOS and USB. The book goes on to discuss industrial cybersecurity systems applicable to discrete manufacturing, which include cyberattacks and human errors and address the security aspects related to software, hardware and data. The book also explores the application of big data for different stages of production and illustrates the uses such as predictive maintenance, product quality, product life cycle management (PLM) and more. This book is an ideal reference for undergraduate, graduate, and postgraduate students of industrial, mechanical and mechatronics engineering, along with professionals and general readers. Computers in Engineering Design and Manufacturing Series Editor: Wasim Ahmed Khan GIK Institute of Engineering Sciences and Technology, Topi, Pakistan Functional Reverse Engineering of Machine Tools Edited by Wasim Ahmed Khan, Ghulam Abbas, Khalid Rahman, Ghulam Hussain, Cedric Aimal Edwin Functional Reverse Engineering of Strategic and Non-Strategic Machine Tools Edited by Wasim Ahmed Khan, Khalid Rahman, Ghulam Hussain, and Ghulam Abbas Machine Tools An Industry 4.0 Perspective Edited by Wasim Ahmed Khan, Khalid Rahman, Ghulam Hussain, Ghulam Abbas, and Wang Xiaoping For more information on this series, please visit: www.routledge.com/Computers- in-Engineering-Design-and-Manufacturing/book-series/CRCCOMENGDES Machine Tools An Industry 4.0 Perspective Edited by Wasim Ahmed Khan, Khalid Rahman, Ghulam Hussain, Ghulam Abbas and Wang Xiaoping Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business MATLAB® is a trademark of The MathWorks, Inc. and is used with permission. The MathWorks does not warrant the accuracy of the text or exercises in this book. This book’s use or discussion of MATLAB® software or related products does not constitute endorsement or sponsorship by The MathWorks of a particular pedagogical approach or particular use of the MATLAB® software. First edition published 2023 by CRC Press 6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487–2742 and by CRC Press 4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN CRC Press is an imprint of Taylor & Francis Group, LLC © 2023 selection and editorial matter, Wasim Ahmed Khan, Khalid Rahman, Ghulam Hussain, Ghulam Abbas, and Wang Xiaoping; individual chapters, the contributors Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microflming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, access www.copyright.com or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978–750–8400. For works that are not available on CCC please contact [email protected] Trademark notice: Product or corporate names may be trademarks or registered trademarks and are used only for identifcation and explanation without intent to infringe. Library of Congress Cataloging-in-Publication Data Names: International Workshop on Functional Reverse Engineering of Machine Tools (3rd : 2022 : Ghulam Ishaq Khan Institute of Engineering Sciences and Technology (Pakistan)) | Khan, Wasim A., editor. | Ghulam Ishaq Khan Institute of Engineering Sciences and Technology (Pakistan), host institution. Title: Machine tools : an industry 4.0 perspective / edited by Wasim A. Khan, Khalid Rahman, Ghulam Hussain, Ghulam Abbas, Wang Xiaoping Description: First edition. | Boca Raton, FL : CRC Press, 2023. | Series: Computers in engineering design & manufacturing | “The present work is the output of the Third International Workshop on Functional Reverse Engineering of Machine Tools. The workshop, for which Professor Khan kindly asked me to be the Honorary Chair, was a successful hybrid meeting held both online and in-person at Ghulam Ishaq Khan (GIK) Institute of Engineering Sciences and Technology”—Preface. | Includes bibliographical references and index. Identifers: LCCN 2022036268 (print) | LCCN 2022036269 (ebook) | ISBN 9781032116693 (hbk) | ISBN 9781032116709 (pbk) | ISBN 9781003220985 (ebk) Subjects: LCSH: Machine-tools—Congresses. | Machining—Data processing—Congresses. | Industry 4.0—Congresses. Classifcation: LCC TJ1185 .I578 2022 (print) | LCC TJ1185 (ebook) | DDC 621.9/02—dc23/eng/20221012 LC record available at https://lccn.loc.gov/2022036268 LC ebook record available at https://lccn.loc.gov/2022036269 ISBN: 978-1-032-11669-3 (hbk) ISBN: 978-1-032-11670-9 (pbk) ISBN: 978-1-003-22098-5 (ebk) DOI: 10.1201/9781003220985 Typeset in Times by Apex CoVantage, LLC Mr. Jehangir Bashar For encouraging us, always Contents Foreword ...................................................................................................................ix Preface.......................................................................................................................xi About the Editors ................................................................................................... xiii Contributors .............................................................................................................xv Chapter 1 Promoting Enterprises of Functional Reverse Engineering through Design Thinking: Engineers’ and Marketers’ Perspective ...........1 Cedric Aimal Edwin Chapter 2 Everything You Need to Know about Intelligent Manufacturing: Industry 4.0 .............................................................. 19 Ali Akbar Shah, B. S. Chowdhry, Tanweer Hussain, Kashif Nisar, Muhammad Zakir Shaikh and Saifullah Samo Chapter 3 Security at the Internet of Things ...................................................... 31 Yousaf Ali, Syed Waqar Shah and Wasim A. Khan Chapter 4 Internet of Things Advancements and Challenges in Manufacturing Industries ................................................................... 49 S. S. Farooq, Muhammad F. Shah, Muhammad S. Sahar, Ghias M. Khan, Zareena Kausar and Muhammad U. Farooq Chapter 5 Internet of Things-Enabled 3D Printer .............................................. 57 G. Hussain, Abid Imran, Salman Amin, Wasim A. Khan, K. Rehman, G. Abbas, Ali Alvi, Ahmed Murtaza, Daniyal Akram and Roshan Rehman Chapter 6 Collaborative Robot with Collision Avoidance System .....................65 Ijlal Ullah Khan, Muhammad Umair Shafq, Abid Imran, Arsalan Arif and Wasim Ahmed Khan Chapter 7 Design, Manufacturing and Sustainability Analysis of Textile Spinning Machine .................................................................. 81 G. Hussain, Wasim A. Khan, K. Rehman, G. Abbas, Muhammad S. Khan, Muhammad S. Qaiser, Muhammad U. Kaimkhani, Sayed Qaisar Hussain, Syed Essa Rasan and Ulfat Hussain vii viii Contents Chapter 8 An Introduction to Additive Manufacturing (AM) of Metals and Its Trends in Wire-Arc Additive Manufacturing (WAAM) Simulations....................................................................................... 103 Rameez Israr and Johannes Buhl Chapter 9 Additive Manufacturing Based Rapid Tooling ................................ 115 Syed Waqar Ahmed, Khurram Altaf, G. Hussain, Junaid Qayyum and Adeel Tariq Chapter 10 Process Design for Hot Forging via Finite Element Analysis Considering Reverse Engineering.....................................137 Omar Youssef, Cuneyt Boz and Volkan Esat Chapter 11 Milling Path Planning of Glasses Lens Edge Based on Dynamic Gaussian Smoothing......................................................... 163 Hao Liu, Shuhao Xu and Zhengyin Chen Chapter 12 MATLAB® Simulation of Various Sliding Mode Control Techniques for Practical Applications.............................................. 179 Ali Nasir Index......................................................................................................................203 Foreword This book is the third in a series edited by Professor Wasim A. Khan and his col- leagues focusing on functional reverse engineering of machine tools. I have known the lead editor Professor Khan for over ten years, mainly through correspondence. He is no stranger to machine tools and advanced manufacturing, having authored many publications on these subjects, including a popular monograph on virtual manufacturing for my Springer Series in Advanced Manufacturing. The present work is the output of the Third International Workshop on Functional Reverse Engineering of Machine Tools. The workshop, for which Professor Khan kindly asked me to be the honorary chair, was a successful hybrid meeting held both online and in-person at Ghulam Ishaq Khan (GIK) Institute of Engineering Sciences and Technology. The range of topics covered was broader than the title of the event implies and included the internet of things, robotics, artifcial intelli- gence, augmented reality and additive manufacturing, all key enabling Industry 4.0 technologies. I understand that the initial motivation for functional reverse engineering of CNC machine tools might be to help the so-called N11 countries—the next emerg- ing eleven economies—to learn how to design and build advanced manufacturing equipment. However, in isolation, ‘reverse engineering’ which is a euphemism for ‘copying’ would at best just allow technological catching up. It is through innovation afforded by the creative and appropriate use of advanced tools such as those associ- ated with Industry 4.0 that leapfrogging could happen. This book should thus be of particular interest to readers from the N11 countries wishing to study some of the latest developments in the feld that might enable their companies to leapfrog and compete against those in the industrialized nations. D. T. Pham, OBE FREng FLSW FSME PhD DEng CEng FIET FIMechE Chance Professor of Engineering University of Birmingham England ix