Revolutionizing sheet metal stamping through industry 5.0 digital twins: a comprehensive review

Ossama Abou Ali Modad, Jason Ryska, Abdallah Chehade and Georges Ayoub ()
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Ossama Abou Ali Modad: University of Michigan- Dearborn
Jason Ryska: University of Michigan- Dearborn
Abdallah Chehade: University of Michigan- Dearborn
Georges Ayoub: University of Michigan- Dearborn

Journal of Intelligent Manufacturing, 2025, vol. 36, issue 6, No 3, 3717-3739

Abstract: Abstract In this manuscript, we present a comprehensive overview of true digital twin applications within the manufacturing industry, specifically delving into advancements in sheet metal forming. A true digital twin is a virtual representation of a physical process or production system, enabling bidirectional data exchange between the physical and digital domains and facilitating real-time optimization of performance and decision-making through synchronized data from sensors. Hence, we will highlight the difference between Industry 4.0 and the digital twin concept, which is considered synonymous with Industry 5.0. Additionally, we will be outlining the relationship between the true digital twin and Zero Defect Manufacturing. In manufacturing processes, including sheet metal stamping, the advantages of high production speed, cost-effective tooling, and consistent component production are counterbalanced by the challenge of dimensional variability in finished parts, which is influenced by process parameters. Data collection, storage, and analysis are essential for understanding manufactured parts variability, and leveraging true digital twins ensures high-quality parts production and processes optimization.

Keywords: True digital twins; Industry 4.0; Industry 5.0; Manufacturing digitalization; Sheet metal stamping; Process optimization (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1007/s10845-024-02453-9

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