International Journal of Machine Tools & Manufacture最新文献

{"title":"Alternate deposition and remelting microdroplets via single laser for printing low-defect and high-performance metal micropillars","authors":"Guohu Luo,&nbsp;Di Wu,&nbsp;Yu Zhou,&nbsp;Yongxiang Hu,&nbsp;Siyuan Chen,&nbsp;Zhenqiang Yao","doi":"10.1016/j.ijmachtools.2024.104136","DOIUrl":"10.1016/j.ijmachtools.2024.104136","url":null,"abstract":"<div><p>Laser-induced forward transfer (LIFT) has emerged as a versatile technique for printing high-resolution metal microstructures. However, a common drawback of this method is the inadequate coalescence of the deposited metal microdroplets, which results in inferior electrical and mechanical properties. This paper proposes a novel approach for fabricating high-performance metal micropillars using a single-pulsed laser to alternately deposit and remelt metal microdroplets. Specifically, an ultraviolet nanosecond laser was used to induce the deposition of copper microdroplets, forming a patterned powder bed with high resolution. Subsequently, a laser pulse train was applied to fuse the patterned powder bed. The results showed that voids and microdroplet delamination were eliminated in the printed copper micropillars, whose yield strength and elastic modulus increased threefold, approaching 63% of those of the bulk metal. The remelting behavior of the deposited microdroplets was elucidated by modelling and analysing the thermal accumulation effects of a laser pulse train. A remelting map was proposed, including the non-melting, remelting, and vaporizing regimes. According to the depth of melt pool, the evolutions of morphology and microstructure in the depositing and remelting process were elucidated. Hence, this study advances the LIFT process for fabricating high-performance metal microstructures.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"197 ","pages":"Article 104136"},"PeriodicalIF":14.0,"publicationDate":"2024-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140020282","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Insights into the high-speed electrochemical discharge drilling for film cooling hole: Machining phenomena, morphological evolution, and visualize simulation","authors":"Tianyu Geng,&nbsp;Zhengyang Xu,&nbsp;Jiangwei Lu,&nbsp;Jin Ning,&nbsp;Zongju Yang","doi":"10.1016/j.ijmachtools.2024.104126","DOIUrl":"10.1016/j.ijmachtools.2024.104126","url":null,"abstract":"<div><p>High-speed electrochemical discharge drilling (ECDD) offers substantial benefits for efficient, high-quality fabrication of film cooling holes. One shortfall of this technique is the lack of a visual model for simulations. The determination of optimal machining parameters predominantly depends on trial-and-error methodologies. In order to develop a visual model for simulations, an in-depth analysis of the machining mechanism is necessary. This entails direct observation of the machining phenomena and a thorough understanding of the surface topography evolution processes. The study focuses on machining Ni-based single-crystal materials that are used in turbine blades, employing experiments to investigate the material removal mechanism. Based on the relevant conclusions, a visualized simulation model is developed for the first time. The results show that discharge and electrochemical dissolution occur alternately at the microscopic level. Besides, the discharge in low conductivity solutions is similar to pure electrical discharge drilling (EDD) rather than a gas film discharge. Discrepancies in the elemental distribution of the matrix and recast layer cause changes in the electrochemical dissolution behavior. The current efficiency of the recast layer is significantly lower than that of the matrix. Based on the mechanistic exploration, this study integrates discrete discharge with continuous electrochemical dissolution to construct a visual model of high-speed ECDD, by leveraging a dead grid method and explicit differential. This model can precisely anticipate the distribution of the recast layer and the diameter of the hole, thereby contributing valuable insights towards achieving zero recast layer machining and enhancing the use of ECDD in the aerospace industry.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"196 ","pages":"Article 104126"},"PeriodicalIF":14.0,"publicationDate":"2024-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139661094","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Portable robotised machines tools (RoboMach), for in-situ inspection and (re)manufacture: Research challenges and opportunities","authors":"D. Axinte","doi":"10.1016/j.ijmachtools.2024.104115","DOIUrl":"10.1016/j.ijmachtools.2024.104115","url":null,"abstract":"<div><p>Machine tool have traditionally been developed for the manufacture of new parts and to be operated in workshop environments. With a remit of addressing clearly defined tasks, the concepts/configurations of these are nowadays, somehow, standard. This perspective intends to flag up to the community the relatively unexplored topic of portable Robotised Machine (RoboMach) tools that address the need for in-situ maintenance and repair of industrial installations. By the immense variety of tasks that RoboMach are designed to fulfil, there is an open ground for exploring, at the confluence with other complementary research disciplines, novel machine tool configurations that could open fresh academic challenges.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"195 ","pages":"Article 104115"},"PeriodicalIF":14.0,"publicationDate":"2024-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S0890695524000014/pdfft?md5=dd9256c576123937ff50a3e9ad33c13a&pid=1-s2.0-S0890695524000014-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139081995","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"In-situ synthesis of spatial heterostructure Ti composites by laser powder bed fusion to overcome the strength and plasticity trade-off","authors":"Yunmian Xiao,&nbsp;Yongqiang Yang,&nbsp;Di Wang,&nbsp;Hanxiang Zhou,&nbsp;Zibin Liu,&nbsp;Linqing Liu,&nbsp;Shibiao Wu,&nbsp;Changhui Song","doi":"10.1016/j.ijmachtools.2024.104117","DOIUrl":"10.1016/j.ijmachtools.2024.104117","url":null,"abstract":"<div><p><span><span><span>Recent research has focused on laser in-situ additive manufacturing of </span>metal matrix composites<span> with spatially controllable microstructures (phases). This study, inspired by the process of inserting mesh fibers into reinforced concrete, synthesizes TiN in situ using laser </span></span>powder bed fusion and N</span>₂<span> gas. The laser-melted track, embedded with TiN particles, formed a spatially heterostructured Ti composite (SHTC) with a three-dimensional, artificially controlled architecture in a pure Ti matrix. The influences of process parameters on the mechanical properties of the spatially heterostructured Ti composite and the microstructural evolution of TiN/Ti were investigated emphatically. The results showed that the growth direction of the microstructure was changed by laser powder bed fusion additive manufacturing with alternating N</span>₂–Ar gas under suitable N₂<span> concentration and melting track spacing. Among all spatially heterostructured Ti composites, the TiN–Ti heterolayer net-like structure achieved a high ultimate tensile strength<span><span> of ∼1.0 GPa and elongation of 27 %, demonstrating a superior strength-ductility combination than intrinsic pure Ti and uniform TiN composites, as well as traditional layered structure Ti-based composites. During the tensile test, the </span>deformation behavior<span><span> was monitored in situ using digital image correlation<span>, and the fracture mechanism was investigated. Hetero-deformation induced strengthening and toughening potentially explains the mechanism behind the strength enhancement of spatially heterostructured Ti composites. Furthermore, this work may stimulate research and development in additive manufacturing of spatial </span></span>heterostructures with configurable structures, targeting synergistic regulation of strength and ductility in the integration of structure-material-function.</span></span></span></p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"196 ","pages":"Article 104117"},"PeriodicalIF":14.0,"publicationDate":"2024-01-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139573951","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Atomic-scale smoothing of semiconducting oxides via plasma-enabled atomic-scale reconstruction","authors":"Yongjie Zhang ,&nbsp;Jin Tang ,&nbsp;Shaoxiang Liang ,&nbsp;Junlei Zhao ,&nbsp;Mengyuan Hua ,&nbsp;Chun Zhang ,&nbsp;Hui Deng","doi":"10.1016/j.ijmachtools.2024.104119","DOIUrl":"10.1016/j.ijmachtools.2024.104119","url":null,"abstract":"<div><p><em>β</em>-Ga₂O₃, known as a next-generation wide-bandgap transparent semiconducting oxide (TSO), has considerable application potential in ultra-high-power and high-temperature devices. However, fabricating a smooth <em>β</em>-Ga₂O₃ substrate is challenging owing to its strong mechanical strength and chemical stability. In this study, an atomic-scale smoothing method named plasma-enabled atomic-scale reconstruction (PEAR) is proposed. We find that three reconstruction modes, namely, 2D-island, step-flow, and step-bunching, can be identified with the increase in the input power; only the step-flow mode can result in the formation of an atomically smooth <em>β</em>-Ga₂O₃ surface (<em>S</em>a = 0.098 nm). Various surface and subsurface characterizations indicate that the smooth <em>β</em>-Ga₂O₃<span> surface shows excellent surface integrity, high crystalline quality<span>, and remarkable photoelectric properties. The atomic-scale density functional theory-based calculations show that the diffusion energy barrier of a Ga atom is only 0.46 eV, thereby supporting the atomic mass migration induced by high-energy plasma irradiation in the experiment. Nanoscale molecular dynamics simulations reveal that O atoms firstly migrate to crystallization sites, followed by Ga atoms with a lower migration rate; reconstruction mainly proceeds along the &lt;010&gt; direction and then expands along the &lt;100&gt; and &lt;001&gt; directions. The millimeter-scale numerical simulations based on the finite element method demonstrate that the coupling of the thermal and flow fields of plasma is the impetus for PEAR of </span></span><em>β</em>-Ga₂O₃. Furthermore, the smoothing generality of PEAR is demonstrated by extending it to other common TSOs (<em>α</em>-Al₂O₃, ZnO, and MgO). As a typical plasma-based atomic-scale smoothing method, PEAR is expected to enrich the theoretical and technological knowledge on atomic-scale manufacturing.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"196 ","pages":"Article 104119"},"PeriodicalIF":14.0,"publicationDate":"2024-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139112253","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A review of parallel kinematic machine tools: Design, modeling, and applications","authors":"Matteo Russo ,&nbsp;Dan Zhang ,&nbsp;Xin-Jun Liu ,&nbsp;Zenghui Xie","doi":"10.1016/j.ijmachtools.2024.104118","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2024.104118","url":null,"abstract":"<div><p>Parallel manipulators are generally associated with high speed, stiffness, and repeatability. Nonetheless, after decades of development, their industrial uptake is still limited when compared to serial architectures. In this paper, we investigate the reasons behind this gap between parallel machine tool potential and real-case applications with a critical analysis of the state of the art. This paper aims to provide machine tool users with the understanding of the functional and technological characteristics of parallel manipulators, as well as to help roboticists approach machining applications with an in-depth perspective and a curated collection of references. We outline fundamental modeling tools for parallel mechanisms and then explain how they can be applied to the development, optimization, and performance evaluation of machine tools, with a focus on kinematic and dynamic metrics, error analysis, and calibration. We then discuss the evolution of parallel machine tools in industry, highlighting successful designs and commercial applications. Finally, we provide our perspective of the field, summarizing the main characteristics, advantages, and disadvantages of parallel machine tools, highlighting the barriers preventing a more widespread implementation of these systems, outlining current research trends, and identifying potential future developments.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"196 ","pages":"Article 104118"},"PeriodicalIF":14.0,"publicationDate":"2024-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S089069552400004X/pdfft?md5=c270b839557f557976e253916f5b43a8&pid=1-s2.0-S089069552400004X-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139406383","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Editorial – Special issue “Manufacturing technologies for metamaterials”","authors":"A.T. Clare,&nbsp;K. Zhou","doi":"10.1016/j.ijmachtools.2024.104116","DOIUrl":"10.1016/j.ijmachtools.2024.104116","url":null,"abstract":"","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"195 ","pages":"Article 104116"},"PeriodicalIF":14.0,"publicationDate":"2024-01-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S0890695524000026/pdfft?md5=1fe0184effadd31f0da12e92d6bbd444&pid=1-s2.0-S0890695524000026-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139091723","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Dual-droplet transition control for improving forming quality and composition homogenizing in dual-wire additive manufacturing of Ti2AlNb alloy","authors":"Zixiang Li ,&nbsp;Baohua Chang ,&nbsp;jiachen Wang ,&nbsp;Haoyu Zhang ,&nbsp;Zhiyue Liang ,&nbsp;Zhenyu Liao ,&nbsp;Li Wang ,&nbsp;Changmeng Liu ,&nbsp;Dong Du","doi":"10.1016/j.ijmachtools.2023.104114","DOIUrl":"10.1016/j.ijmachtools.2023.104114","url":null,"abstract":"<div><p><span><span>Dual-wire additive manufacturing (AM) couples traditional wire-based AM for part fabrication and the molten pool metallurgy for material-preparation with high deposition efficiency and material utilization. However, compared with traditional single-wire </span>AM technology, it has a more complex and sensitive dual-droplet transition distance (TD), which not only affects the forming quality but also the metallurgical quality. Therefore, it is necessary and urgent to monitor and control its TD value online. In this study, we systematically investigated the sensing, controlling, and influential mechanism of the TD value in dual-wire AM technology, and Ti</span>₂<span>AlNb was taken as the target alloy owing to its great application prospects in the aerospace field. Specifically, a deposition experiment with different initial TD value was conducted to study the effect on the morphology and composition distribution of the as-printed part. Based on the optimal distance, the related image extraction algorithms and closed-loop control methods are developed. The closed-loop controlled verification experiment on the slope and step substrate, as well as the multi-layer deposition test, were carried out and analyzed. The results indicate that the developed system can control the TD to the desired value with good robustness. In addition, the controlled deposited multi-layer part exhibited good morphology and composition homogenizing in the post-characterization experiment. This study is of great significance for the intelligent and industrial development of dual-wire AM technology.</span></p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"195 ","pages":"Article 104114"},"PeriodicalIF":14.0,"publicationDate":"2023-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139060708","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Gradient process parameter optimization in additive friction stir deposition of aluminum alloys","authors":"Yuqi Jin ,&nbsp;Tianhao Wang ,&nbsp;Tingkun Liu ,&nbsp;Teng Yang ,&nbsp;Shelden Dowden ,&nbsp;Arup Neogi ,&nbsp;Narendra B. Dahotre","doi":"10.1016/j.ijmachtools.2023.104113","DOIUrl":"10.1016/j.ijmachtools.2023.104113","url":null,"abstract":"<div><p><span>As one of the most novel additive manufacturing<span> methods, currently selection and optimization of processing parameters in additive friction stir deposition (AFSD) have mainly relied on experiments and subsequent characterization of microstructural and mechanical properties. Such approaches are both time- and resource-consuming. Therefore, an ultrasound elastography enhanced gradient process parameter optimization method was applied in the present work to obtain a window of optimized processing parameters for AFSD processing of aluminum alloy by varying both rotational and linear deposition speeds. The quality of AFSD processed layer was investigated for physical nature of surface, dynamic </span></span>elastic modulus<span>, and microstructural aspects in cross-sections of the deposited layer. The efficiency in exploring process parameters was significantly enhanced by implementing a high-throughput screening experimental design based on application of gradient process parameters and continuous ultrasound elastographs. In addition, the applied ultrasonic elastography technique assisted in evaluating the homogeneity in microstructure and mechanical properties of AFSD sample over the entire gradients of the process parameters. The techniques adopted in current work can be further extended to identify suitable parameters for AFSD fabrication of components with desired mechanical properties such as hardness, fatigue, etc.</span></p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"195 ","pages":"Article 104113"},"PeriodicalIF":14.0,"publicationDate":"2023-12-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139059642","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Breaking through the bending limit of Al-alloy tubes by cryogenic effect controlled mechanical properties and friction behaviours","authors":"Hong Sun ,&nbsp;Heng Li ,&nbsp;Heng Yang ,&nbsp;Jun Ma ,&nbsp;Xuancheng Hao ,&nbsp;M.W. Fu","doi":"10.1016/j.ijmachtools.2023.104111","DOIUrl":"10.1016/j.ijmachtools.2023.104111","url":null,"abstract":"<div><p><span><span><span>Aluminium alloy (Al-alloy) tubes, especially large-diameter thin-walled tubes with a tough </span>bending radius, have been widely utilised in different industrial clusters owing to their high strength-to-weight ratio and </span>good corrosion resistance<span><span>. However, achieving such extreme specifications is challenging because severe and nonuniform bending deformation may cause tension and compression instabilities, such as overthinning, cracking, and wrinkling. Considering possible improvements in mechanical properties and friction behaviours of Al-alloy at </span>cryogenic temperature (CT), the cryogenic bending potential of the 6061-O tubes with an extreme ratio of </span></span><em>D</em>/<em>t</em><span> of 89 (diameter/wall thickness) was explored at different deformation temperatures<span><span><span>, including room temperature (RT) 20 °C, −60 °C, −120 °C, and −180 °C. First, the cryogenic mechanical properties and friction behaviour of the tubes were characterised. It was found that the overall mechanical properties of the Al-alloy tube were improved because of sub-grain formation and a more uniform distribution of dislocations at CT. The coefficient of friction between the tube and tooling exhibited a varying degree of reduction owing to the sensitivity of the tubes and the lubricant to CT. Subsequently, an innovative experimental platform for cryogenic bending was designed, and a </span>finite element model of cryogenic bending was established. Third, cryogenic tube </span>bendability and mechanism were explored. It was found that 6061-O tube formability can be effectively improved by cryogenic bending; however, there is no monotonic relationship between the bendability improvement and temperature decrease. The temperature to obtain the best bendability is −60 °C, at which the average wrinkle height is decreased by 81.4 %, and the average wall thickness reduction rate is reduced by 23.8 %. The bending limit represented by the bending radius is reduced from a 3.0</span></span><em>D</em> bending radius at RT to 1.0<em>D</em><span> at −60 °C, which is realised by the different or even opposite effects of the mechanical properties of tubes and the friction coefficient between the multiple contact interfaces on wall thinning and wrinkling.</span></p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"195 ","pages":"Article 104111"},"PeriodicalIF":14.0,"publicationDate":"2023-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139041620","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}