Integrated finite element method, AI, and digital twin technologies for drawing die design: A comprehensive review of advanced simulation and production efficiency optimization
			
	
 
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				1
				Department of Automated Manufacturing Engineering, Al-Khwarizmi College of Engineering, University of Baghdad, Baghdad, Iraq
				 
			 
						
				2
				Al-Naji University, Baghdad, Iraq
				 
			 
										
				
				
		
		 
			
			
		
		
		
		
		
		
	
							
					    		
    			 
    			
    				    					Corresponding author
    					    				    				
    					Wael Hekmat Shaheen   
    					Department of Automated Manufacturing Engineering, Al-Khwarizmi College of Engineering, University of Baghdad, Baghdad, Iraq
    				
 
    			
				 
    			 
    		 		
			
																	 
		
	 
		
 
 
Adv. Sci. Technol. Res. J. 2026; 20(2)
 
 
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ABSTRACT
One of the technical developments is a shift towards the use of the finite element method (FEM) simulation and artificial intelligence and digital twins to improve die-design applications. It is a huge discussion of how the traditional methodologies of the empirical designs are being complemented by the new computational methodologies, in which there is high production efficiency and quality products. By a combination of computational modeling, materials characterization, nondestructive testing validation, and machine learning algorithms, the performance will significantly increase; experiments on industrial applications show that the design period can be cut down to 4-6 weeks with a 90-95 percent productivity increase. The given article is a deep examination of the FEM modeling methods that may be applied to the process of drawing optimization, the synthesis of the non-destructive testing tools that may be used to guarantee the validity of the process, and the rising uses of machine learning and Industry 4.0. The integration of technologies presents important possibilities to enhance the production efficiency, level the environmental sustainability, and gain competitive advantages in metal forming operations. The implementation process would be done appropriately based on the computing requirements, validation, and interface with the existing production systems.