Journal of Manufacturing Processes最新文献

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Interface optimization design and bonding mechanism of friction rolling additive manufactured aluminum/steel dissimilar metal
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-12-02 DOI: 10.1016/j.jmapro.2024.11.040
Haibin Liu , Chenghao Wu , Ruishan Xie , Rui Pan , Xiaoguang Chen , Jhe-yu Lin , Shujun Chen
{"title":"Interface optimization design and bonding mechanism of friction rolling additive manufactured aluminum/steel dissimilar metal","authors":"Haibin Liu ,&nbsp;Chenghao Wu ,&nbsp;Ruishan Xie ,&nbsp;Rui Pan ,&nbsp;Xiaoguang Chen ,&nbsp;Jhe-yu Lin ,&nbsp;Shujun Chen","doi":"10.1016/j.jmapro.2024.11.040","DOIUrl":"10.1016/j.jmapro.2024.11.040","url":null,"abstract":"<div><div>The aluminum/steel dissimilar structure is a cornerstone for lightweight components and equipment. Yet, traditional fusion welding methods' high heat input frequently gives rise to detrimental defects such as porosity, cracks, and excessively thick intermetallic compound layers (IMCLs) at the interface. To overcome these challenges, this paper innovatively combines low heat input solid-state friction rolling additive manufacturing (FRAM) and strategic interface design to achieve reliable bonding between these dissimilar metals. Our investigation found that conventional FRAM (C-FRAM), hindered by inadequate heat input, struggled to facilitate continuous atomic migration, leading to incomplete joint formation. However, the introduction of arc-assisted FRAM (Aa-FRAM) significantly increased aluminum/steel mixing, fostering interdiffusion of interface atoms under high temperature and pressure conditions. This resulted in the formation of uniform 2.3 μm IMCLs composed of Fe<sub>7</sub>Al<sub>11</sub>, Fe<sub>4</sub>Al<sub>13</sub>, and FeAl<sub>6</sub>, and the nanoscale amorphous layer was found between IMCLs and steel. The metallurgical bonding was successfully established at the Aa-FRAM interface. Moreover, by using arc/micro-hole assisted FRAM (AHa-FRAM), which machined an array of micro-holes on the steel surface, we further optimized the aluminum-steel interface bonding quality. The plasticized aluminum alloy (Al alloy) seamlessly flowed into these micro-holes, creating a robust “self-riveting” structure that bolstered mechanical interlocking at the interface. Consequently, we achieved a high-strength joint with an exceptional ultimate tensile strength (UTS) of 167.2 MPa. In addition, the crystallographic analysis showed that the grain size was significantly refined by using the two auxiliary methods, which played a fine grain strengthening role on the interface. This paper innovatively improves the interface bonding between Al alloy and steel through the combination of solid-state FRAM and interface design, thereby opening up a new pathway for the manufacture of aluminum-steel dissimilar structural components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 1041-1052"},"PeriodicalIF":6.1,"publicationDate":"2024-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142758806","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}
引用次数: 0
A review on physics-informed machine learning for process-structure-property modeling in additive manufacturing
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-30 DOI: 10.1016/j.jmapro.2024.11.066
Meysam Faegh , Suyog Ghungrad , João Pedro Oliveira , Prahalada Rao , Azadeh Haghighi
{"title":"A review on physics-informed machine learning for process-structure-property modeling in additive manufacturing","authors":"Meysam Faegh ,&nbsp;Suyog Ghungrad ,&nbsp;João Pedro Oliveira ,&nbsp;Prahalada Rao ,&nbsp;Azadeh Haghighi","doi":"10.1016/j.jmapro.2024.11.066","DOIUrl":"10.1016/j.jmapro.2024.11.066","url":null,"abstract":"<div><div>This article presents a state-of-the-art review of the emerging field of physics-informed machine learning (PIML) models in additive manufacturing for process-structure-property modeling. Additive manufacturing processes hold immense potential for fabricating intricate and complex geometries across diverse applications and material classes. From a quality assurance standpoint, appropriate modeling of process-structure-property relationships of additive manufacturing processes using either physics-based or machine learning (ML)-based approaches has been a topic of intensive research. As an example, ML of data acquired from in-situ sensors is related to flaw formation, e.g., porosity, cracking, or deformation. In recent years, the computational burden of pure physics-based models, the large data set requirement, and their black-box nature, i.e., the lack of interpretability of ML models, have prompted researchers to turn to PIML models. In PIML models, physical insights of the additive manufacturing process gained from various means are integrated with ML models, resulting in a more robust and interpretable framework for both process and microstructure evolution. A key delineator is the source of physical knowledge to be fused into PIML models, which can be obtained either from governing physical equations, data-centric feature extraction without implementing any physical equations, or a hybrid of the two foregoing. Within this review, we stratify PIML models based on the method used for the fusion of physical knowledge to ML models, into three categories, namely: (i) physics-based feature engineering, (ii) physics-based architecture shaping of ML models, and (iii) physics-based modification of the loss function of the ML models. For each of these categories, we further delineate the source of physical knowledge, ML models, integration approach, and data-set requirement, among others. A comparative analysis of the reviewed studies is presented and critically discussed, while the potential research gaps, along with future research directions on developing PIML models for different AM technologies are outlined.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 524-555"},"PeriodicalIF":6.1,"publicationDate":"2024-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142748682","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}
引用次数: 0
Silicon-via (Si-via) hole metrology and inspection by grayfield edge diffractometry
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-30 DOI: 10.1016/j.jmapro.2024.11.086
Kuan Lu , Byunggi Kim , Masahiro Nomura , Jiyong Park , ChaBum Lee
{"title":"Silicon-via (Si-via) hole metrology and inspection by grayfield edge diffractometry","authors":"Kuan Lu ,&nbsp;Byunggi Kim ,&nbsp;Masahiro Nomura ,&nbsp;Jiyong Park ,&nbsp;ChaBum Lee","doi":"10.1016/j.jmapro.2024.11.086","DOIUrl":"10.1016/j.jmapro.2024.11.086","url":null,"abstract":"<div><div>This paper introduces a novel silicon-via (Si-via) hole metrology and inspection method based on grayfield edge diffractometry, enabling simultaneous measurement of Si-via hole geometry and roughness. The edge diffraction interferogram occurs when incident light interacts with the via edge. A grayfield imaging system consists of a pair of axicon lenses, two objective lenses and imaging system was developed to capture the fringes. Here, a pair of axicon lenses shape the collimated beam into a donut-shaped beam profile. The shaped beam has an adjustable focus point, allowing scanning along the Si-via hole depth axis. The cross-correlation approach to comprehensive analysis of the fringes was performed to extract via roundness and via-edge roughness (VER). The relationship between cross-correlation output and VER was characterized, assuming the line-edge roughness (LER) represents VER. The proposed method was cross-verified with the conventional microscopy approach. In addition, the through-focus scanning optical microscopy method was also used to intuitively characterize the fringe feature in three-dimension. In conclusion, the proposed method can characterize Si-via hole's roundness and estimate VER, showcasing potential adaptability for automated Si-via hole inspections in wafer-level hybrid bonding applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 503-509"},"PeriodicalIF":6.1,"publicationDate":"2024-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142748680","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}
引用次数: 0
X-ray tomography of polarization effects on deep laser-machined microgrooves
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-30 DOI: 10.1016/j.jmapro.2024.11.056
Ce Xiao , Jean-Yves Buffiere , Arnaud Weck
{"title":"X-ray tomography of polarization effects on deep laser-machined microgrooves","authors":"Ce Xiao ,&nbsp;Jean-Yves Buffiere ,&nbsp;Arnaud Weck","doi":"10.1016/j.jmapro.2024.11.056","DOIUrl":"10.1016/j.jmapro.2024.11.056","url":null,"abstract":"<div><div>Ultrafast laser machining has been researched extensively over the last few decades to create features such as holes in a variety of materials. The effects of laser parameters including power and polarization on the dynamics of hole formation and resulting hole geometry have been studied. Grooves formation, especially deep ones, on the other hand, has not attracted as much attention, even though grooves are essential to most laser cutting operations. One aspect limiting the study of deep machined features such as grooves is the difficulty in imaging not only the geometry but also the associated collateral damage produced in the material during machining. Here, we employed x-ray tomography for three-dimensional imaging of deep ultrafast laser-machined grooves in various metals. The 3D images of the deep grooves were quantitatively analyzed, revealing the significant effect of laser polarization on groove morphology. Under rotating polarization (also called “scrambled polarization” or “polarization trepanning”), the deep grooves are smooth and uniform, while under linear polarization, extensive branching is observed along the groove, and becomes more pronounced with increasing laser energy and groove entrance length. A mechanistic picture based on laser light reflection off the groove walls is proposed to qualitatively explain the polarization-dependent groove branching observed experimentally. These findings provide new insights into high-precision deep groove laser machining, highlighting the effectiveness of x-ray tomography as a powerful tool for in-depth three-dimensional studies of laser machining processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 479-490"},"PeriodicalIF":6.1,"publicationDate":"2024-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142748779","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}
引用次数: 0
In-depth analysis of sintering, exposure time, and layer height (um) in LRS 3D printed devices with DLP
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-30 DOI: 10.1016/j.jmapro.2024.11.060
Shenggui Chen , Sadaf Bashir Khan , Nan Li , Chuang Xiao
{"title":"In-depth analysis of sintering, exposure time, and layer height (um) in LRS 3D printed devices with DLP","authors":"Shenggui Chen ,&nbsp;Sadaf Bashir Khan ,&nbsp;Nan Li ,&nbsp;Chuang Xiao","doi":"10.1016/j.jmapro.2024.11.060","DOIUrl":"10.1016/j.jmapro.2024.11.060","url":null,"abstract":"<div><div>The technology of 3D printing, referred to as additive manufacturing, is widely acknowledged as a transformative innovation that has the potential to supplant traditional processing methods in numerous domains. The present study showcases a quantitative assessment of the mechanical properties of moon dust, also known as Lunar Regolith Simulants (LRS), printed through vat polymerization. In this study, we conduct a thorough investigation and explore the effects of layer height [L<sub>H</sub>] (L<sub>H</sub> = 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm]), exposure time [E<sub>T</sub>] (E<sub>T</sub> = 3000 ms, 5000 ms, 7000 ms, 11,000 ms), and sintering impact [1075 °C, 1082 °C, 1083 °C, 1085 °C, 1086 °C, 1087 °C, 1090 °C] on the mechanical properties of printed structures. Herein, we utilize a 55 % volume suspension of LRS to print rod and block configurations via digital light printing [DLP] that are subsequently consolidated through sintering in ambient air. This 55 % LRS via vat polymerization approach has not been previously reported. The morphology of the simulant powders exhibited irregular and angular features. Our experimental results show that a 30 um (L<sub>H</sub>) with (E<sub>T</sub>) 11,000 ms exhibits maximum compressive and flexural strength of 330 MPa and 100 MPa at 1085 °C. The sintering atmosphere greatly affects the microstructure, macroscopic features, and mechanical strength of 3D-printed LRS, which reveals diverse chemical compositions and underlying reaction mechanisms. This sintering process improves particle bonding, resulting in densification and reduced voids within the 3D-printed structure. It is essential to optimize the annealing parameters to achieve the desired strength while avoiding excessive sintering that may cause dimensional distortions or structural defects. This innovative approach opens new possibilities for future space exploration and extraterrestrial construction.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 576-591"},"PeriodicalIF":6.1,"publicationDate":"2024-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142748701","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}
引用次数: 0
Aluminum/steel dissimilar material with high interfacial strength manufactured by additive friction stir deposition
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-30 DOI: 10.1016/j.jmapro.2024.11.080
Yidi Li , Biaobiao Yang , Miao Song , Ruilin Lai , Bin Liu , Yong Liu , Zhongchang Wang , Yunping Li
{"title":"Aluminum/steel dissimilar material with high interfacial strength manufactured by additive friction stir deposition","authors":"Yidi Li ,&nbsp;Biaobiao Yang ,&nbsp;Miao Song ,&nbsp;Ruilin Lai ,&nbsp;Bin Liu ,&nbsp;Yong Liu ,&nbsp;Zhongchang Wang ,&nbsp;Yunping Li","doi":"10.1016/j.jmapro.2024.11.080","DOIUrl":"10.1016/j.jmapro.2024.11.080","url":null,"abstract":"<div><div>Dissimilar metallic materials find broad applications owing to the possibility of integrating multiple functions. However, the joining interface is a vulnerable site for failure in service. The design of high-strength bonding of dissimilar materials has been urgently needed. This study showed that a combination of additive friction stir deposition coupled with post-processing annealing enables the formation of a continuous Mg/O-enriched amorphous layer dotted with nano-rivet structures at the aluminum (Al)/steel interface. As a result, a high bonding strength (138.1 MPa) of Al/steel was achieved. We clarify the formation of discontinuous nano-rivet intermetallic compounds thanks to the AFSD-induced severe plastic deformation and local chemical reaction upon annealing, and we demonstrate the highest bonding strength is achieved at the size of nano-rivet compounds of ~200 nm and the aspect ratio ~ 0.5. Our findings provide a simple but versatile strategy to reverse the adverse effects of intermetallic compounds on the interface strength of dissimilar materials.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 491-502"},"PeriodicalIF":6.1,"publicationDate":"2024-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142748780","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}
引用次数: 0
Metal transfer and forming behavior of bypass-coupled variable polarity plasma arc additive manufacturing
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-30 DOI: 10.1016/j.jmapro.2024.11.079
Guokai Zhang , Zhihe Xu , Fan Jiang , Cheng Li , Bin Xu , Xiaoyu Cai , Shujun Chen , Hao Liu , Bingxue Wang
{"title":"Metal transfer and forming behavior of bypass-coupled variable polarity plasma arc additive manufacturing","authors":"Guokai Zhang ,&nbsp;Zhihe Xu ,&nbsp;Fan Jiang ,&nbsp;Cheng Li ,&nbsp;Bin Xu ,&nbsp;Xiaoyu Cai ,&nbsp;Shujun Chen ,&nbsp;Hao Liu ,&nbsp;Bingxue Wang","doi":"10.1016/j.jmapro.2024.11.079","DOIUrl":"10.1016/j.jmapro.2024.11.079","url":null,"abstract":"<div><div>This study proposes a novel bypass-coupled variable-polarity plasma arc additive manufacturing process. This process enables independent control of the main current, bypass current, and their polarities, thereby achieving decoupled control of thermal input to the deposited layers and wire melting. Additionally, the variable polarity effectively removes the oxide film on the surface of aluminum alloys, improving defects in aluminum alloy additive manufacturing. The research results indicate that the bypass-coupled variable-polarity plasma arc additive manufacturing presents different metal transfer forms compared to conventional arc additive manufacturing (MIG/TIG arc heat sources). The droplet transfer behavior manifests in various forms at different wire heights, including droplet transfer, Intermittent bridging transfer, and complete bridging transfer. Notably, the complete bridging transfer results in short metal bridge, which weakens the influence of the coupled arc magnetic field and provides a wider process window for shaping. A detailed analysis of the effects of main and bypass EN/EP currents on the formation morphology reveals that the influence of the main EN current on the width of the deposited layer is twice that of the bypass EN current. By adjusting the main EN current, the remelting depth can be effectively controlled, allowing for precise control over the morphology of the deposited layers. This study demonstrates the potential of this process to enhance deposition efficiency, reduce thermal input, and achieve effective shaping control.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 510-523"},"PeriodicalIF":6.1,"publicationDate":"2024-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142748681","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}
引用次数: 0
Investigation of microstructure and mechanical properties of 304 stainless steel under high-frequency vibratory arc conditions
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-30 DOI: 10.1016/j.jmapro.2024.11.004
Hongyan Zhao , Tao Lv , Yue Yu , Yian YAN , Jingzhang Zhang , Shujun Chen , Hongxiao Li
{"title":"Investigation of microstructure and mechanical properties of 304 stainless steel under high-frequency vibratory arc conditions","authors":"Hongyan Zhao ,&nbsp;Tao Lv ,&nbsp;Yue Yu ,&nbsp;Yian YAN ,&nbsp;Jingzhang Zhang ,&nbsp;Shujun Chen ,&nbsp;Hongxiao Li","doi":"10.1016/j.jmapro.2024.11.004","DOIUrl":"10.1016/j.jmapro.2024.11.004","url":null,"abstract":"<div><div>In traditional cross-coupled welding, the main arc swings with the polarity changes of the bypass arc, leading to uneven heat distribution and compromising the decoupling of heat and mass transfer. To address this issue, a new cross-coupled welding method based on high-frequency bypass arc was developed. When the bypass arc operates at a high frequency of over 20 kHz, the main arc does not significantly swing with the polarity shifts. Instead, it vibrates at a high frequency with a small amplitude. To verify whether this vibration behavior influences the molten pool flow and promotes grain refinement, a series of experiments were designed and conducted. The results showed that, under identical conditions, the weld width produced by cross-coupled welding with a 50 Hz bypass arc is greater than that of tungsten inert gas welding (TIG) welding. However, under high-frequency bypass arc conditions, the weld width is similar to that of TIG welding, indicating a more effective decoupling of heat and mass transfer in this method. Moreover, compared to TIG welding and low-frequency cross-coupled arc welding, the high-frequency bypass cross-coupled method refines the weld zone grains, enhances material toughness, and improves the tensile properties of the weld.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 566-575"},"PeriodicalIF":6.1,"publicationDate":"2024-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142748684","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}
引用次数: 0
Understanding the influence of free-volume generation, thermal instabilities and fracture energy on shear localization in micromachining of bulk metallic glass
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-30 DOI: 10.1016/j.jmapro.2024.11.074
Priyabrata Sahoo , Nilanjan Banerjee , Ramesh Singh
{"title":"Understanding the influence of free-volume generation, thermal instabilities and fracture energy on shear localization in micromachining of bulk metallic glass","authors":"Priyabrata Sahoo ,&nbsp;Nilanjan Banerjee ,&nbsp;Ramesh Singh","doi":"10.1016/j.jmapro.2024.11.074","DOIUrl":"10.1016/j.jmapro.2024.11.074","url":null,"abstract":"<div><div>Bulk metallic glasses (BMGs) are a new class of amorphous metallic alloys having enhanced mechanical and tribological properties. However, the chip formation behavior of BMGs is not as well established as that of the crystalline materials, which hinders its prospective applications. In this paper, an orthogonal micromachining experiment is conducted, and chip morphology, force signature, hardness, and enthalpy of the machined surface are analyzed. The chips show segmented morphology with distinct fractures. The chip exhibits primary shear zones along with several secondary shear bands emanating within a single segmentation, which evidenced shear localization. Additionally, the machined surface exhibits softening as compared to the undeformed material. The shear localization, responsible for chip segmentation in BMG machining, is assumed to be driven primarily by free volume and the shear zone temperature. Hence, a localized chip segmentation model has been formulated by incorporating the effects of temperature and free volume generation-induced instabilities. The proposed chip formation model accounts for the contributions of the fracture and the new surface creation energies, in addition to the shear and friction energies used traditionally. The contribution of fracture energy was observed to be significant in the chip formation of BMGs. To differentiate between the relative contributions of temperature-induced instabilities and free volume generation on shear localization, four distinct regimes were identified based on the critical value of free volume flow coefficient (FVFC) and heat flow coefficients (HFC). The findings demonstrate that if the FVFC is greater than the critical value, significant shear localization takes place. Conversely, the shear localization becomes less pronounced if the FVFC is smaller than the critical values. Thus, it can be deduced that temperature has an insignificant role in shear localization, and free volume acts as the main driver.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 466-478"},"PeriodicalIF":6.1,"publicationDate":"2024-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142748778","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}
引用次数: 0
A superspreading bioinspired micro-texture with the function of self-priming liquid for enhancing boiling heat transfer of cutting-fluid on tool surface
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-30 DOI: 10.1016/j.jmapro.2024.11.064
He Tong , Xu Liu , Ning Zhang , Zijian Liu , Yingbing Sun , Yunze Qi , Fenghe Wu
{"title":"A superspreading bioinspired micro-texture with the function of self-priming liquid for enhancing boiling heat transfer of cutting-fluid on tool surface","authors":"He Tong ,&nbsp;Xu Liu ,&nbsp;Ning Zhang ,&nbsp;Zijian Liu ,&nbsp;Yingbing Sun ,&nbsp;Yunze Qi ,&nbsp;Fenghe Wu","doi":"10.1016/j.jmapro.2024.11.064","DOIUrl":"10.1016/j.jmapro.2024.11.064","url":null,"abstract":"<div><div>Nickel-based superalloys are indispensable materials for hot-end components of aircraft engines and gas turbines. Nonetheless, machining nickel-based superalloys is a formidable challenge due to the high cutting heat resulting from their low thermal conductivity. Enhancing cooling and lubrication conditions is an effective approach to address the challenge. Inspired by the surface microstructure of <em>Ligia exotica</em>'s caudal legs, we develop a superspreading bioinspired micro-texture (BMT) with a “self-priming liquid” function to enhance the boiling heat transfer performance of tool surfaces, thereby improving cooling condition in the cutting zone. BMT surface is designed based on the analysis of the “self-priming liquid” function and fabricated using femtosecond laser. The results of boiling heat transfer tests show that the critical heat flux (CHF) and heat-transfer coefficient (HTC) on BMT surface increases by 52.1 % and 48.9 % compared to the original non-textured (ONT) surface. Additionally, turning tests on GH4698 superalloy show that at the cutting distance of 150 m, the flank wear of BMT tool is reduced by 87 % and 57.7 % compared to ONT and normal-grooved-textured (NGT) tools, and the maximum cutting temperature of BMT tool is reduced by 34.9 % and 22.3 % compared to ONT and NGT tools. Hence, the application of BMT tools in the precision cutting of nickel-based superalloys is feasible and promising.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 556-565"},"PeriodicalIF":6.1,"publicationDate":"2024-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142748683","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}
引用次数: 0
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