Shivakumar Raman

Md Manjurul Ahsan, Yingtao Liu, Shivakumar Raman et al.

Digital Twins (DTs) are becoming popular in Additive Manufacturing (AM) due to their ability to create virtual replicas of physical components of AM machines, which helps in real-time production monitoring. Advanced techniques such as Machine Learning (ML), Augmented Reality (AR), and simulation-based models play key roles in developing intelligent and adaptable DTs in manufacturing processes. However, questions remain regarding scalability, the integration of high-quality data, and the computational power required for real-time applications in developing DTs. Understanding the current state of DTs in AM is essential to address these challenges and fully utilize their potential in advancing AM processes. Considering this opportunity, this work aims to provide a comprehensive overview of DTs in AM by addressing the following four research questions: (1) What are the key types of DTs used in AM and their specific applications? (2) What are the recent developments and implementations of DTs? (3) How are DTs employed in process improvement and hybrid manufacturing? (4) How are DTs integrated with Industry 4.0 technologies? By discussing current applications and techniques, we aim to offer a better understanding and potential future research directions for researchers and practitioners in AM and DTs.

Md Manjurul Ahsan, Shivakumar Raman, Yingtao Liu et al.

Diffusion Models are probabilistic models that create realistic samples by simulating the diffusion process, gradually adding and removing noise from data. These models have gained popularity in domains such as image processing, speech synthesis, and natural language processing due to their ability to produce high-quality samples. As Diffusion Models are being adopted in various domains, existing literature reviews that often focus on specific areas like computer vision or medical imaging may not serve a broader audience across multiple fields. Therefore, this review presents a comprehensive overview of Diffusion Models, covering their theoretical foundations and algorithmic innovations. We highlight their applications in diverse areas such as media quality, authenticity, synthesis, image transformation, healthcare, and more. By consolidating current knowledge and identifying emerging trends, this review aims to facilitate a deeper understanding and broader adoption of Diffusion Models and provide guidelines for future researchers and practitioners across diverse disciplines.

Abdullah al Nomaan Nafi, Md. Alamgir Hossain, Rakib Hossain Rifat et al.

Data scarcity in medical imaging poses significant challenges due to privacy concerns. Diffusion models, a recent generative modeling technique, offer a potential solution by generating synthetic and realistic data. However, questions remain about the performance of convolutional neural network (CNN) models on original and synthetic datasets. If diffusion-generated samples can help CNN models perform comparably to those trained on original datasets, reliance on patient-specific data for training CNNs might be reduced. In this study, we investigated the effectiveness of diffusion models for generating synthetic medical images to train CNNs in three domains: Brain Tumor MRI, Acute Lymphoblastic Leukemia (ALL), and SARS-CoV-2 CT scans. A diffusion model was trained to generate synthetic datasets for each domain. Pre-trained CNN architectures were then trained on these synthetic datasets and evaluated on unseen real data. All three datasets achieved promising classification performance using CNNs trained on synthetic data. Local Interpretable Model-Agnostic Explanations (LIME) analysis revealed that the models focused on relevant image features for classification. This study demonstrates the potential of diffusion models to generate synthetic medical images for training CNNs in medical image analysis.

Tasfiq E. Alam, Md Manjurul Ahsan, Shivakumar Raman

Bearings play an integral role in ensuring the reliability and efficiency of rotating machinery - reducing friction and handling critical loads. Bearing failures that constitute up to 90% of mechanical faults highlight the imperative need for reliable condition monitoring and fault detection. This study proposes a multimodal bearing fault classification approach that relies on vibration and motor phase current signals within a one-dimensional convolutional neural network (1D CNN) framework. The method fuses features from multiple signals to enhance the accuracy of fault detection. Under the baseline condition (1,500 rpm, 0.7 Nm load torque, and 1,000 N radial force), the model reaches an accuracy of 96% with addition of L2 regularization. This represents a notable improvement of 2% compared to the non-regularized model. In addition, the model demonstrates robust performance across three distinct operating conditions by employing transfer learning (TL) strategies. Among the tested TL variants, the approach that preserves parameters up to the first max-pool layer and then adjusts subsequent layers achieves the highest performance. While this approach attains excellent accuracy across varied conditions, it requires more computational time due to its greater number of trainable parameters. To address resource constraints, less computationally intensive models offer feasible trade-offs, albeit at a slight accuracy cost. Overall, this multimodal 1D CNN framework with late fusion and TL strategies lays a foundation for more accurate, adaptable, and efficient bearing fault classification in industrial environments with variable operating conditions.

Tasfiq E. Alam, Md Manjurul Ahsan, Shivakumar Raman

Accurate and interpretable bearing fault classification is critical for ensuring the reliability of rotating machinery, particularly under variable operating conditions where domain shifts can significantly degrade model performance. This study proposes a physics-informed multimodal convolutional neural network (CNN) with a late fusion architecture, integrating vibration and motor current signals alongside a dedicated physics-based feature extraction branch. The model incorporates a novel physics-informed loss function that penalizes physically implausible predictions based on characteristic bearing fault frequencies - Ball Pass Frequency Outer (BPFO) and Ball Pass Frequency Inner (BPFI) - derived from bearing geometry and shaft speed. Comprehensive experiments on the Paderborn University dataset demonstrate that the proposed physics-informed approach consistently outperforms a non-physics-informed baseline, achieving higher accuracy, reduced false classifications, and improved robustness across multiple data splits. To address performance degradation under unseen operating conditions, three transfer learning (TL) strategies - Target-Specific Fine-Tuning (TSFT), Layer-Wise Adaptation Strategy (LAS), and Hybrid Feature Reuse (HFR) - are evaluated. Results show that LAS yields the best generalization, with additional performance gains when combined with physics-informed modeling. Validation on the KAIST bearing dataset confirms the framework's cross-dataset applicability, achieving up to 98 percent accuracy. Statistical hypothesis testing further verifies significant improvements (p < 0.01) in classification performance. The proposed framework demonstrates the potential of integrating domain knowledge with data-driven learning to achieve robust, interpretable, and generalizable fault diagnosis for real-world industrial applications.

Hamidreza Samadi, Md Manjurul Ahsan, Shivakumar Raman

This study addresses the challenge of accurately forecasting geometric deviations in manufactured components using advanced 3D surface analysis. Despite progress in modern manufacturing, maintaining dimensional precision remains difficult, particularly for complex geometries. We present a methodology that employs a high-resolution 3D scanner to acquire multi-angle surface data from 237 components produced across different batches. The data were processed through precise alignment, noise reduction, and merging techniques to generate accurate 3D representations. A hybrid machine learning framework was developed, combining convolutional neural networks for feature extraction with gradient-boosted decision trees for predictive modeling. The proposed system achieved a prediction accuracy of 0.012 mm at a 95% confidence level, representing a 73% improvement over conventional statistical process control methods. In addition to improved accuracy, the model revealed hidden correlations between manufacturing parameters and geometric deviations. This approach offers significant potential for automated quality control, predictive maintenance, and design optimization in precision manufacturing, and the resulting dataset provides a strong foundation for future predictive modeling research.