This study introduces an artificial neural network (ANN) model for optimizing process parameters to reduce the chances of delamination in carbon fiber-reinforced polymer (CFRP) materials during abrasive water jet (AWJ) piercing. AWJ is a proper method for cutting CFRP. The initial step in this process is AWJ piercing, which creates entry holes in the material to facilitate further cutting operations. However, AWJ piercing is particularly challenging due to the high energy applied to the material. If it is not properly controlled, this high-energy impact can cause material delamination. Avoiding CFRP delamination is a critical aspect when expensive parts are processed with AWJ, particularly in the aerospace and automotive industries. This can compromise the CFRP workpiece, and this induces extra costs for rework. The ANN model was trained using backpropagation to predict delamination. It features a feed-forward architecture that balances model complexity and performance. Validation showed that the ANN model effectively predicted optimal process parameters, eliminating delamination in machined CFRP parts. This study underscores the potential of ANNs in enhancing AWJ piercing processes and provides a robust and reliable method of improving the quality of CFRP parts.

This paper introduces an Acoustic Emission (AE)-based monitoring method designed for supervising the Abrasive Waterjet Cutting (AWJC) process, with a specific focus on the precision cutting of Carbon Fiber-Reinforced Polymer (CFRP). In industries dealing with complex CFRP components, like the aerospace, automotive, or medical sectors, preventing cutting system malfunctions is very important. This proposed monitoring method addresses issues such as reductions or interruptions in the abrasive flow rate, the clogging of the cutting head with abrasive particles, the wear of cutting system components, and drops in the water pressure. Mathematical regression models were developed to predict the root mean square of the AE signal. The signal characteristics are determined, considering key cutting parameters like the water pressure, abrasive mass flow rate, feed rate, and material thickness. Monitoring is conducted at both the cutting head and on the CFRP workpiece. The efficacy of the proposed monitoring method was validated through experimental tests, confirming its utility in maintaining precision and operational integrity in AWJC processes applied to CFRP materials. Integrating the proposed monitoring technique within the framework of digitalization and Industry 4.0/5.0 establishes the basis for advanced technologies such as Sensor Integration, Data Analytics and AI, Digital Twin Technology, Cloud and Edge Computing, MES and ERP Integration, and Human-Machine Interface. This integration enhances operational efficiency, quality control, and predictive maintenance in the AWJC process.

This paper presents a solution aimed at enhancing the accuracy of abrasive waterjet cutting (AWJC) for the processing of carbon-fiber-reinforced polymers (CFRP). Processing CFRP with high accuracy and good surface quality in a short processing time is a difficult task. One crucial problem is the occurrence of shape errors, overcuts, at the cut-in and cut-out point during the cutting process. Shape errors have the potential to create mechanical stress concentrators, which can result in structural failures and compromise the integrity and reliability of components. The primary objective of this study was to gain a comprehensive understanding of the formation mechanism underlying the shape error. The observed shape error is closely associated with both the lead-in/lead-out strategies employed and the process parameters selected. The experimental investigation focused on two commonly used strategies for CFRP cutting: lead-in/lead-out in arc and lead-in/lead-out in line. In order to minimize shape errors, this study proposed a correction method that offers a set of recommendations for selecting the appropriate lead-in/out strategy and a suitable combination of process parameters. Additionally, a mathematical model has been developed to determine the depth of the shape error. The conclusions drawn from this study have been successfully validated through industrial applications.

Manual assembly of multi-pin cable harnesses remains vulnerable to miswiring when conductors are visually indistinguishable. This paper presents an industrial case study of a quick-connect harness composed of two connectors (receptacle-type and pin-type) linked by 16 black conductors (2.5 mm²; 200 mm length), where the dominant failure mode is a two-wire swap that breaks correct pin-to-pin mapping and may cause downstream equipment damage. In the baseline state, end-of-line verification relied on visual inspection only (1 min/unit), resulting in an internal nonconformity rate of 4% (repairable). To achieve the operational goal of zero defects (zero escapes), we propose and integrate an electronic pin-to-pin continuity and mapping fixture as a deterministic End-of-Line (EOL) quality gate implementing poka-yoke logic (“no PASS—no shipment”) and enabling structured traceability records. Using a before–after workload model that includes mandatory retest after rework, the fixture reduces test time to 0.33 min/unit. For a monthly volume of 1500 units, total quality workload (test + rework + retest) decreases from 31 h/month to 13.58 h/month, releasing 17.42 h/month. Global quality productivity increases from 48.39 units/h to 110.46 units/h (+128%). The proposed architecture couples deterministic electrical verification with data logging aligned to digital thread and data-driven quality management concepts to sustain continuous improvement and prevent customer escapes.

Manual assembly of multi-pin cable harnesses remains vulnerable to miswiring issues when conductors are visually indistinguishable. This paper presents an industrial case study of a quick-connect harness composed of two connectors (receptacle-type and pin-type) linked by 16 black conductors (2.5 mm² and 200 mm length), where the dominant failure mode is a two-wire swap that breaks correct pin-to-pin mapping and may cause downstream equipment damage. In the baseline state, end-of-line verification relies on visual inspection only (1 min/unit), resulting in an internal nonconformity rate of 4% (repairable). To achieve the operational goal of zero defects (zero escapes), we proposed and integrated an electronic pin-to-pin continuity and mapping fixture as a deterministic End-of-Line (EOL) quality-gate implementing poka-yoke logic (“no PASS—no shipment”) and enabling structured traceability records. Using a before–after workload model that includes a mandatory retest after rework, the fixture reduces test time to 0.33 min/unit. For a monthly volume of 1500 units, total quality workload (test + rework + retest) decreases from 31 h/month to 13.58 h/month, releasing 17.42 h/month. Global quality productivity increases from 48.39 units/h to 110.46 units/h (+128%). The proposed architecture couples deterministic electrical verification with data logging aligned to digital-thread and data-driven quality-management concepts to sustain continuous improvement and prevent customer escapes.