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Analysis of challenges of wire-arc additive manufacturing process in the context of Industry 4.0 using graph theory approach

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Abstract

The fourth industrial revolution, also known as Industry 4.0 (I4.0), is promoting the integration of advanced information technologies and smart production systems. Additive manufacturing is recognized as an essential element in driving I4.0 in automotive industries. Among additive manufacturing processes, wire-arc additive manufacturing (WAAM) has a wide range of applications in automotive industries. Moreover, in comparison to other fusion processes, WAAM provides a higher deposition rate and substantial cost savings. However, it possesses several challenges in integration with I4.0 that need to be addressed for its smooth adoption in industries. Thus, in this study, an analysis of WAAM and I4.0 challenges has been done using the graph theory (GT) approach. Potential 54 challenges of WAAM and I4.0 integration grouped in seven categories were recognized using literature review and expert opinion. GT approach helps in establishing the logical and systematic diagrammatic representation of entire integration systems in the form of interrelationships among various integration challenges. Based on the permanent values, it has been observed that the “technology (C7)” category performs a significant role in intensifying the WAAM-I4.0 integration adoption in the case of an organization, whereas the challenges category “pre-processing C3” requires less but significant attention while implementing WAAM in I4.0. The study also measured the overall intensity of the challenges in the form of a comprehensive intensity index (CII) which was found to be “59.0495,” which denotes the intensity of the WAAM and I4.0 integration challenges require careful attention for its smooth adoption in the case organization. Industry practitioners can utilize the findings of the study to innovate existing additive manufacturing systems with the advanced capability of I4.0.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Pandit Deendayal Energy University, Gandhinagar, Gujarat, India

    Vishal Ashok Wankhede

  2. Department of Production Engineering, National Institute of Technology, Tiruchirappalli, Tamil Nadu, 620015, India

    Sekar Vinodh

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  1. Vishal Ashok Wankhede
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  2. Sekar Vinodh
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Vishal Ashok Wankhede: methodology, analysis, writing – original draft; Sekar Vinodh: conceptualization, validation, writing – review and editing.

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Correspondence to Sekar Vinodh.

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Wankhede, V.A., Vinodh, S. Analysis of challenges of wire-arc additive manufacturing process in the context of Industry 4.0 using graph theory approach. Int J Adv Manuf Technol 123, 1059–1078 (2022). https://doi.org/10.1007/s00170-022-10233-z

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