Journal of Manufacturing Processes最新文献

{"title":"Surface evolution mechanism for atomic-scale smoothing of Si via atmospheric pressure plasma etching","authors":"","doi":"10.1016/j.jmapro.2024.10.080","DOIUrl":"10.1016/j.jmapro.2024.10.080","url":null,"abstract":"<div><div>Atmospheric plasma etching-based machining methods generally suffer from surface roughness deterioration. To achieve an atomic-scale smooth surface of Si via purely plasma etching, clarifying the etching evolution and mechanism is essential. In this study, we study surface evolution and smoothening mechanisms from the perspective of plasma etching modes comprehensively. The morphology and roughness evolutions of isotropic, orientation-selective, and atom-selective etching are investigated, respectively. The semi-finishing effect is realized through the growing and merging of hemispherical pits during isotropic etching, with the surface roughness being reduced from 103 nm to 0.79 nm. Orientation-selective etching is a roughening process, transforming square-opening pits into pyramid structures. Under the atom-selective mode, an atomically smooth surface with <em>S</em>a 0.17 nm can be obtained. The top-down smoothing process of atom-selective is much more efficient than isotropic etching. Atom-selective etching with a maximum removal rate of 22 μm/min enables the rapid thinning of Si substrate thickness from 715 μm to 90.4 μm within 45 min. Additionally, atom-selective etching is a universal polishing approach regardless of pre-processed methods and is a damage-less process. This paper provides a promising strategy for atomic and close-to-atomic scale manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142593908","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":"Developing the optimized control scheme for digital light processing 3D printing by combining numerical simulation and machine learning-guided temperature prediction","authors":"","doi":"10.1016/j.jmapro.2024.10.049","DOIUrl":"10.1016/j.jmapro.2024.10.049","url":null,"abstract":"<div><div>Digital light processing (DLP) 3D printing has attracted significant attention for its rapid printing speed, high accuracy, and diverse applications. However, the continuous DLP printing process releases substantial heat, resulting in a swift temperature rise in the curing area, which may lead to printing failures. Due to the lack of effective means to measure real-time temperature changes of the curing surface during continuous DLP 3D printing, the prevailing approach is to predict temperature variations during printing via numerical simulation. Nevertheless, temperature prediction methods relying solely on numerical simulation tend to be slow and overlook heat exchange dynamics during printing, potentially resulting in prediction inaccuracies, particularly for complex models. To address these issues, this paper proposes a method to combine numerical simulation and a machine learning approach for temperature prediction in the DLP 3D printing process, along with a printing control scheme generation method. Firstly, the <span><math><msup><mrow><mfenced><mrow><mtext>m</mtext><mo>+</mo><mtext>n</mtext></mrow></mfenced></mrow><mrow><mi>t</mi><mi>h</mi></mrow></msup></math></span> order autocatalytic kinetic model considering the light intensity and the Beer–Lambert law are employed to formulate the heat calculation equation for the photopolymer resin curing reaction. Subsequently, a heat exchange calculation equation is established based on Fourier heat conduction law and Newton’s cooling equation. A numerical simulation model for temperature changes during the printing process is then developed by integrating the heat calculation equation, heat exchange calculation equation, and measurement data from Photo-DSC. Furthermore, a temperature measurement device for the printing process is designed to validate the accuracy of the numerical simulation. Following this, an improved Long Short-term Memory (LSTM) network is proposed, using temperature change data generated by the numerical simulation model to train the network for rapid (<span><math><mrow><mn>2</mn><mo>×</mo><msup><mrow><mn>10</mn></mrow><mrow><mo>−</mo><mn>4</mn></mrow></msup></mrow></math></span> <span><math><mrow><mtext>s</mtext><mo>/</mo><mtext>layer</mtext></mrow></math></span>) prediction of temperature changes during printing. Finally, aiming for the shortest printing time, an optimized control scheme planning algorithm and a target function are designed based on the model’s temperature change data and the monomer’s flash point to ensure the temperature remains below this threshold. This algorithm can automatically generate the optimal printing control scheme for any model. Experimental results demonstrate that the proposed temperature prediction method can predict temperature variation accurately. Based on this, the generated printing control scheme can guarantee efficient and high-quality manufacturing for anymodel.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142593965","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 insights into the material removal mechanism of cerium oxide polished fused silica based on ReaxFF-MD","authors":"","doi":"10.1016/j.jmapro.2024.10.068","DOIUrl":"10.1016/j.jmapro.2024.10.068","url":null,"abstract":"<div><div>Reactive force field molecular dynamics simulation (ReaxFF-MD) was utilized to investigate the atomic-level material removal mechanism of fused silica polished by cerium oxide (111) abrasives during the computer-controlled optical surface (CCOS) process. The study reveals that interactions between the cerium oxide abrasives and fused silica surface in the presence of water molecules result in the formation of structures such as Ce/Si-OH. During polishing, Ce-O-Si bridge bonds are formed, which transmit mechanical forces to the surface of the fused silica glass, leading to atomic removal through stretching. The CCOS process is characterized by a synergistic interaction of both mechanical and chemical mechanisms. The study also explored the chemical and mechanical effects on the surfaces of cerium oxide abrasives and fused silica under varying pH, pressure, and slip velocity conditions. Experimental validation demonstrated that at pH 11, the surface roughness reached 0.126 nm, and the material removal rate (MRR) peaked at 593.56 nm/min under a high polishing speed of 375 RPM. Additionally, higher polishing pressure (0.2 MPa) further enhanced removal efficiency, with an MRR of 214.63 nm/min. These findings provide valuable insights for optimizing process parameters in practical applications and offer crucial theoretical guidance for achieving picometer-level ultra-smooth surface processing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142585996","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":"Study on the nano-cutting mechanism of monocrystalline silicon material with an amorphous layer by molecular dynamics simulations","authors":"","doi":"10.1016/j.jmapro.2024.10.078","DOIUrl":"10.1016/j.jmapro.2024.10.078","url":null,"abstract":"<div><div>Monocrystalline silicon is prone to brittle fracture during the nano-cutting process. Surface modification through ion implantation to create an amorphous layer on monocrystalline silicon significantly enhances its processability. This paper conducted molecular dynamics simulations to deeply reveal the nanometric cutting mechanism for monocrystalline silicon with an amorphous layer. The influence of the amorphous layer on material removal, subsurface damage, cutting forces, stress distribution, and temperature profiles was analyzed and thoroughly discussed. The calculating results reveal that primary material removal mode transitions from shearing to extrusion under the influence of the amorphous layer. The presence of an amorphous layer can efficiently reduce stress concentration and defects in the nanometric machining process. When the thickness of the amorphous layer equals the cutting depth of the tool, subsurface damage is reduced to approximately 2 nm, indicating that an optimal surface quality is achieved. When the thickness of the amorphous layer reaches more than cutting depth, the hydrostatic stress of the monocrystalline silicon part is significantly lower than the phase transition threshold of 12 GPa, which greatly reduces the occurrence of phase transition. Furthermore, the formation and evolution of shear bands are the primary reasons for the fluctuations in cutting force. The cutting temperature is closely related to structural transformations. The heat generated by shear slip in monocrystalline silicon material is higher than the heat generated by plastic deformation of material in the amorphous layer. Moreover, the heat energy produced by plastic deformation of amorphous layer atoms exceeds that generated by structural transformation of monocrystalline silicon atoms. This work reveals the nanometric cutting behavior of the monocrystalline silicon material with amorphous layer surfaces based on phase transformation. It can provide effective references for the preparation of amorphous layer thickness and selection of cutting parameters in nanometric cutting process of the monocrystalline silicon with amorphous layer surfaces.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142586371","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":"Machining of Cf/SiC composite with indigenously developed nano green cutting fluid: Machined surface fibre morphology","authors":"","doi":"10.1016/j.jmapro.2024.10.084","DOIUrl":"10.1016/j.jmapro.2024.10.084","url":null,"abstract":"<div><div>The Carbon fibre reinforced Silicon Carbide (Cf/Sic) composites are widely used in different industries such as automotive, aerospace, etc. The Cf/SiC is indigenous developed and detail of the fabrication procedure is presented. The nano fluid, namely Graphene Oxide Organo Boron (GOOB) is developed indigenously for using as the cutting fluid. This nano fluid is mixed in green cutting fluid (GCF) in different proportions and the concentration is optimized. The nano fluid is characterized by advanced techniques for the confirmation. To reduce the surface roughness on the fabricated Cf/SiC, end milling operation is carried out with different machining environments such as dry, flood cooling with cutting fluid and nano fluid and minimum quantity cutting fluid with nano fluid. The machining operations are carried out by varying different input parameters, namely, cutting speed, feed rate, and depth of cut. The results indicated that the minimum surface roughness of 1.845 μm is obtained when 0.5 % GOOB with GCF is used. This work would benefit the researchers exploring the preparation and interaction mechanism of the indigenously developed nano green cutting fluid for machining Cf/SiC-based ceramic matrix composites.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142586378","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":"Microstructure analysis and interfacial wave formation mechanism research of Mg/Al dissimilar metal laser impact welding in a vacuum environment","authors":"","doi":"10.1016/j.jmapro.2024.11.001","DOIUrl":"10.1016/j.jmapro.2024.11.001","url":null,"abstract":"<div><div>Laser impact welding (LIW) joints for the center exists springback region, resulting in a small effective welding area seriously affects the LIW joints performance problems. This paper for the first time put forward the vacuum environment LIW process, to carry out the vacuum environment of the two dissimilar lightweight metal magnesium/aluminum (Mg/Al) LIW. Results of the research showed that no springback occurred in the welded area. In order to reveal the vacuum environment LIW mechanism, the surface and cross-section morphological characteristics, weld interface microstructure, interface waveform element content and mechanical properties of laser impact welded Mg/Al dissimilar metals were investigated by optical microscope (OM), scanning electron microscope (SEM), electron backscattering diffraction (EBSD), energy spectrometry (EDS), and the universal testing machine. Studies have shown that the experimental success rate in the vacuum environment is much higher than that in the atmospheric environment, and the vacuum environment eliminates the springback cracking defect phenomenon generated in the center of the welded joints, which greatly increases the effective welding area of the weld. The number of Mg grain refinement in the interface region of the vacuum environment welding is more, and the bonding force of the two-plate welding is increased. Significant orientation differences, severe plastic deformation and high strain at the weld interface are one of the reasons for the successful LIW. Mg/Al welding samples produced elemental diffusion phenomenon, no obvious melting phenomenon, which is conducive to improving the welding quality. Tensile strength of the welded samples in the vacuum environment was higher than that in the atmospheric environment. Using the SPH-Lagrange coupling method, numerical simulations were carried out to study the trends shear stress, pressure, velocity, temperature and equivalent plastic strain distribution at the weld interface under vacuum environment, which revealed the interface wave formation mechanism in the center of laser impact welded joints with no springback cracking phenomenon. Vacuum laser impact welding opens up a new technology pathway for LIW of Mg/Al welded joints without springback in the center, which plays an important role in improving Mg/Al welding performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142586243","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 on the grinding of SiC-based ceramic matrix composites reinforced by continuous fibre: Damage mechanisms and evaluations","authors":"","doi":"10.1016/j.jmapro.2024.10.067","DOIUrl":"10.1016/j.jmapro.2024.10.067","url":null,"abstract":"<div><div>SiC-based ceramic matrix composites reinforced by continuous fibre (SiC-based FRCMCs) are distinguished by their superior mechanical properties and high-temperature resistance, positioning them as candidates for demanding high-temperature applications. However, their brittleness, hardness, and heterogeneity present machining challenges, e.g., large machining force, unsynchronised material removal, and complex crack propagation, frequently resulting in severe damage even with advanced grinding methods. This paper critically reviews recent studies addressing these grinding difficulties, initially employing a combination of fibre-related angles to clarify the basic scratching behaviours, and then systematically elucidating the damage mechanisms from scratching to grinding. Distinctive aspects of damage mechanics have been also discussed, including fibre-induced differences in up grinding versus down grinding, and the influence from fibre architecture relative to grinding conditions. Moreover, the corresponding damage evaluations for both surface and subsurface have been summarised to understand how to effectively and efficiently acquire the data, bridging the gap between scientific exploration and industrial application. Lastly, this paper attempts to provide an outlook on future developments in this domain.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142586231","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":"Tool trajectory planning method for CFRP curved component milling: Considering variable inclination to adapt to different directions of fiber layers","authors":"","doi":"10.1016/j.jmapro.2024.10.081","DOIUrl":"10.1016/j.jmapro.2024.10.081","url":null,"abstract":"<div><div>Improper tool trajectory selection during CFRP curved component milling can lead to sudden changes in instantaneous cutting parameters, such as fiber cutting angle, resulting in significant machining damage and profile deviation. In this paper, a novel tool trajectory planning method for CFRP curved component milling is proposed. The key innovation of this method lies in considering the effect of tool variable inclination on fiber removal behavior. Employing the developed method, the influence of trajectories under different tool inclination angles on the milling quality of CFRP surfaces is thoroughly investigated. The results indicate that, to minimize machining damage, an inclination angle within 10° is recommended when the fiber cutting direction is in the range of 0°-60° and 150°-180°. For fiber cutting directions falling within 60°-150°, it is recommended to select an inclination angle above 25°. Additionally, the novel tool trajectory planning method decreases CFRP surface profile errors by over 20 %.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142578193","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":"Single start end tool path generation for arbitrary porous surfaces","authors":"","doi":"10.1016/j.jmapro.2024.10.050","DOIUrl":"10.1016/j.jmapro.2024.10.050","url":null,"abstract":"<div><div>The CNC machining of non-zero genus surfaces in B-rep models has become a prevalent challenge in modern manufacturing. The computational complexity inherent in generating tool paths for such geometries remains a significant hurdle. In this study, an efficient path planning algorithm tailored for porous structures of this nature is presented. Initially, we create a parametric grid using the adaptive iso-scallop height method and subsequently utilize a marching cells algorithm to construct a cell grid capable of preserving arbitrary boundaries. Based on the graph structure naturally induced by marching cells, we employ a designated weighting method to establish a minimum spanning tree, upon which a path with a singular start and end point is generated. We conduct various experiments on examples from industrial scenarios as well as synthetic examples. The results show the superior performance and effectiveness of our method concerning scallop height limits, sharp turns, and structural stability.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142578194","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":"Analysis and prediction of axial force and exit damage in drilling of composites with delamination damage","authors":"","doi":"10.1016/j.jmapro.2024.10.051","DOIUrl":"10.1016/j.jmapro.2024.10.051","url":null,"abstract":"<div><div>In aircraft maintenance, the delaminated composites are commonly repaired by riveting to inhibit delamination propagation and restore load-bearing performance. Making connecting holes in damaged areas is inevitable and may cause damage aggravation. This paper focused on the axial force and exit delamination damage in the drilling of delaminated composites. The influence factors including spindle speeds, feeds, drilling positions, and delamination locations and widths were considered for the drilling test, in which the axial force was collected to analyze the interaction mechanism between the tool and workpiece. The equivalent delamination factor was used to evaluate exit damage. The quadratic nonlinear regression (QNR) and Support Vector Regression (SVR) models were built to predict the cutting force curve and exit damage, respectively. The results revealed that the cutting force curves of the delaminated laminates produced obvious concavity when the drill bit reached the position of delamination. The optimal cutting conditions were 10,000 r/min and 100 mm/min for both intact and delaminated laminates in the drilling test. It was better to make holes in the inside of the damaged area to obtain small equivalent delamination factor and the increase of delamination width would aggravate exit damage. The errors of the QNR model were controlled within 13.40 % and 11.07 % for the intact and delaminated laminates, respectively. The maximum error of SVR models was 3.79 %. The results of QNR and SVR models had been proven to be accurate.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-11-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142578186","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}