Implementation of Industry 4.0 Technological Methods in the Production of Cast Ice Components, an Algorithm for Their Comprehensive Application
Year: 2025
Type: article
Abstract: The study presents the results of research on the implementation of Industry 4.0 technological approaches in the manufacturing of cast internal combustion engine (ICE) components, which continues the discourse on transforming strategies for using Product Lifecycle Management (PLM) systems in the context of achieving sustainable development goals. Given that the foundry industry is a key supplier of metal components for the automotive and energy sectors, particular attention is paid to the integrated application of computer modeling, additive technologies, and microstructure control of alloys, which are considered essential for ensuring sustainability in this field. It is noted that the implementation of the proposed approach enables the minimization of waste, improvement of mechanical properties of components, enhancement of energy efficiency in manufacturing processes, and reduction of the product development life cycle for new designs. Research in this area opens up new prospects for realizing circular economy principles and creating more environmentally responsible production in engine manufacturing. Technological casting processes for producing the cylinder of a two-stroke engine were modeled to analyze crystallization characteristics and phase transformations during the cooling of the casting. As a result of numerical simulations, data were obtained regarding mold filling, temperature field distribution, cooling and solidification sequences, and the kinetics of phase transitions, with an assessment of the areas prone to shrinkage-related defects. Control over these processes made it possible to prevent crystal growth irregularities in the transition zones of the casting, thus mitigating their negative impact on the mechanical properties of the component during operation. Conclusions were drawn on the application of simulation within PLM systems for automating the improvement of casting technologies. The integration of additive manufacturing into technological stages of shape formation in ICE casting production was also examined. It was determined that the implementation of these technologies in engine manufacturing allows for the creation of components with optimized designs that meet the requirements of sustainable development. As a model tooling case, a printed cast cylinder part was developed, and the key parameters of the 3D printing process were presented. Directions for future research on the use of additive technologies were outlined. The study also highlights the enhancement of microstructure control using machine learning and artificial intelligence as a promising area for future research in sustainable manufacturing. The paper proposes fundamental steps for a methodology for the comprehensive application of Industry 4.0 technologies in the sustainable production of cast ICE components. An interaction algorithm between major production stages was developed, placing the concept of the digital twin at the center as the core management unit. It is concluded that the proposed approach enables systematic improvements of technological processes, ensuring production adaptability to sustainable development challenges through the comprehensive integration of Industry 4.0 technologies and laying the foundation for the transition to Industry 5.0.
Source: Internal combustion Engines
Authors: V.I. Alokhin, A.P. Marchenko, S.S. Kravchenko, A.G. Lal
Language: English
Subfield: Industrial and Manufacturing Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: diamond
OpenAlex ID: W7083197866