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Virtual Manufacturing: a Review Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 NCERAME - 2015 Conference Proceedings Virtual Manufacturing: A Review Bharath V G Dr. Rajashekar Patil Research Scholar, School of Mechanical Engineering Head, School of Mechanical Engineering REVA University REVA University Bengaluru, India Bengaluru, India Abstract:- Virtual engineering is an emerging technology processes and the total manufacturing enterprise. Virtual which integrates geometric models and related engineering tools Manufacturing systems enable early optimization of cost, such as design, analysis, simulation, optimization and decision quality and time drivers, achieve integrated product, process making tools within computer-generated environment that and resource design [3]. Virtual manufacturing eliminates facilitates multidisciplinary collaborative product development. material waste and faulty design. It provides better In manufacturing, the major component of virtual engineering is Virtual Manufacturing (VM). VM use computer aided design understanding of a process without making of prototype models and simulations of manufacturing for production of models. Virtual Manufacturing greatly reduces the product manufactured products. VM provides the capability to and process development cycle. It also provides a platform to “Manufacture in the computer” and has the ability to train new operators on a particular machine without having to interchange models between their use in simulation and control waste precious machine time [4]. VM is the reflection of environments. actual manufacturing process on computer, that is adopting An innovative and effective solution to overcome recent the computer simulation and virtual reality technology, with product development lifecycle problems in manufacturing the aid of high performance computer and high-speed industries is the application of Virtual Reality (VR) and network, conducting the coordination work on the computer, Augmented Reality (AR) technologies to simulate and improve the manufacturing processes before they are carried out. This realizing the product design, technology planning, processing would ensure that activities such as design, planning, simulation, and manufacturing, performance analysis, quality inspection, machining are done right-the-first-time without subsequent and the control and management of each procedure of rework and modifications. The challenge is to design and enterprise, processes of product manufacturing in order to integrate VR and AR in Virtual Manufacturing Systems (VMS) enhance the decision-making and control ability of each that could enhance manufacturing processes and product procedure of manufacturing. VM technology is bringing a development process leading to shorter lead time, reduced cost, revolutionary change to the worldwide manufacturing more efficient and improved quality with clean and green industry [5]. Virtual Manufacturing system [6] is a computer process. The paper aims at providing a review on virtual system which can produce the similar information concerning manufacturing: definition, its origin, types, benefits, virtual manufacturing systems, applications, future and challenges to manufacturing system structure, states and behaviors as one overcome the drawbacks associated by adopting VM. can observe in real manufacturing systems. K. Iwata, M. Onosato attempt to show the possibility of a new Keywords—Virtual engineering, virtual manufacturing, virtual manufacturing style in the 21st century in its cultural aspect reality, augmented reality, virtual environment rather than its technological and economical aspects which is based on each individual person, not on a factory [7]. I. INTRODUCTION Manufacturing is an indispensable part of the economy and II. PROBLEMS IN MANUFACTURING is the central activity that encompasses product, process, A. Problems inside Manufacturing resources and plant. The competition between the industries is K. Iwata explained factory based manufacturing systems has becoming tougher and challenging at present economic certain issues in current scenario. There is a difficulty of scenario of global integration. So in order to adapt rapid acquiring advanced manufacturing technology concepts and changing market demands and win-win situation, modern skills in companies or factories [8]. R. Wise reviewed that in manufacturing enterprises must solve TQCS questions (reduce order to obtain more profits from the product users several manufacturing time, best quality, lowest cost, optimal industries try to expand their business scope from design and service). Nowadays the industrial world is undergoing manufacturing to all services of product life-cycle [9]. profound changes as products are more and more complex, L. Alting in his paper explained that to promote product processes are highly-sophisticated and use micro-technology reuse/recycle and safety of wastes, manufacturing industries and mechatronic as market demands [1]. The competitive must have more responsibilities on their products [10]. The advantage in manufacturing has shifted from the mass- long-term employment of labor in the manufacturing industry production archetype to one that is based on fast becomes more and more difficult. responsiveness and on flexibility [2]. B. Problems of manufacturing with respect to social In this complex and evaluative environment, industrialists circumstances must know about their processes before trying them in order People come to prefer a tailor-made product rather than one to get it right the first time. To achieve this goal, the use of a by mass-production. B.J. Pine explains that the user wants to virtual manufacturing environment will provide a computer- fit new product to new life style, climate, culture, and other based environment to simulate individual manufacturing products in individual possession. Artificial teeth and eye Volume 3, Issue 17 Published by, www.ijert.org 1 Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 NCERAME - 2015 Conference Proceedings glasses are old examples, and order made Personal Computer an actualized product.” Some researchers present VM with is a new example of this tendency [11]. At the beginning of respect to virtual reality (VR) [24]. On one hand, Bowyer A 20th century these are the few problems observed in markets, [25] represents VM as a virtual world for manufacturing, on consumers, logistics, natural resources, labor which are the other hand, one can consider virtual reality as a tool probably caused by the dispute between the social situation which offers visualization for VM. The most comprehensive and the manufacturing scheme of mass-production [12]. definition has been proposed by the Institute for Systems Research, University of Maryland, and discussed by Lin E III. NEW MANUFACTURING TECHNOLOGIES [22] is “an integrated, synthetic manufacturing environment The manufacturing process in earlier are carried out in a exercised to enhance all levels of decision and control.” The efficient way under controlled conditions and concentrated definition of VM given by a Bath University project team much on manufacturing resources such as labor, facilities, deserves attention. According to this definition: "Virtual materials, money, knowledge and information in closed Manufacturing is the use of a desktop virtual reality system environment of a factory. Under the advanced manufacturing for the computer aided design of components and processes technologies and economics, the current situation has the for manufacturing - for creating viewing three dimensional following emerging situations in manufacturing. engineering models to be passed to numerically controlled One can get all manufacturing knowledge and information machines for real manufacturing". This definition emphasizes from anywhere outside factories , even from home through the functions aiding the machining process [26]. the progress of the information and communication technology such as internet and multi-media [13]. The V. HISTORY OF VM progress of CAD/CAM/CAE facilitates alternative design by Virtual Manufacturing is the advanced form of Computer using product/process model data and reduces the design cost Aided Manufacturing based on Virtual reality and for product customization [14]. The possibility of economical Augmented Reality. The concept of artificial reality already production for a single part or a small batch of parts in new appeared in 1970s by Miron Krueger and with the notion of forming processes is due to rapid prototyping [15, 16]. The this virtual reality concept was introduced by Jaron Lanier in concept of virtual organizations like virtual enterprises 1989 . In 1990 the concepts of Virtual World and Virtual [17, 18] decomposes the manufacturing functions included in Environments appeared. Virtual reality is defined as a a factory into autonomous modules. The combination of computer generated interactive and immersive 3D information technology and production technology has greatly environment simulating reality [27].The term VM first came changed traditional manufacturing industries. Many activities into prominence in the early 1990s, in U.S. Department of in manufacturing systems can be carried out using computer Defense Virtual Manufacturing Initiative. Both the concept systems; the concept of virtual manufacturing (VM) has now and the term have recently gained wide international evolved [19]. acceptance and broadened in
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