Journal of Manufacturing Processes最新文献

Thermal behavior, residual stress, and deformation of thin-walled parts in double electrode arc-directed energy deposition 双电极电弧定向能沉积中薄壁零件的热行为、残余应力和变形

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-19 DOI: 10.1016/j.jmapro.2025.05.013

Xiaowen Fan , Zhiwei Zhao , Hui Chen , Guangjun Zhang , Jun Xiong

{"title":"Thermal behavior, residual stress, and deformation of thin-walled parts in double electrode arc-directed energy deposition","authors":"Xiaowen Fan , Zhiwei Zhao , Hui Chen , Guangjun Zhang , Jun Xiong","doi":"10.1016/j.jmapro.2025.05.013","DOIUrl":"10.1016/j.jmapro.2025.05.013","url":null,"abstract":"<div><div>Arc-directed energy deposition (DED) can produce large-scale metal components with high deposition rates. However, large residual stress (RS) and deformation are formed in as-built parts since serious heat accumulation is generated due to considerable heat input, damaging the mechanical properties of deposited parts. This study aims at controlling stress and deformation of as-built thin walls by applying a double electrode arc-DED technique with lower heat input. By introducing an additional branch electrode to divert some current from the main wire, the heat input to deposited layers is reduced. Double electrode arc-DED has the potential to achieve higher deposition rates and lower heat input to deposited layers without compromising the forming quality. The novelty is that how the branch current affects the temperature, RS, and deformation of walls in double electrode arc-DED is revealed by using finite element simulation. A composite heat source model is developed to characterize the thermal effect of the double electrode arc. Experimental tests check the finite element model's effectiveness. The simulation results are in good agreement with the experimental results. Compared to conventional gas metal arc-DED, the high-temperature zone on as-built layers shrinks, and the melt pool's peak temperature and length decrease in double electrode arc-DED. As the branch current increase from 0 to 105 A, the maximum longitudinal RS on as-built layers decreases from 292 to 265 MPa, and the maximum deformation on the substrate reduces by 1.5 mm, indicating that introducing a branch arc can effectively reduce the heat input, RS, and deformation in arc-DED. This study provides valuable guidelines on regulating RS and deformation in arc-DED from the perspective of decreasing heat input to as-built layers.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"148 ","pages":"Pages 11-23"},"PeriodicalIF":6.1,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144083645","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

Performance assessment of hybrid lubricating conditions on machining-induced surface/subsurface characteristics during a novel heat assisted machining Hastelloy C4 新型热辅助加工哈氏合金C4过程中混合润滑条件对加工诱导表面/次表面特性的影响

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-19 DOI: 10.1016/j.jmapro.2025.05.019

Mayur Makhesana , Amit Arora , Kaushik Patel , Navneet Khanna

{"title":"Performance assessment of hybrid lubricating conditions on machining-induced surface/subsurface characteristics during a novel heat assisted machining Hastelloy C4","authors":"Mayur Makhesana , Amit Arora , Kaushik Patel , Navneet Khanna","doi":"10.1016/j.jmapro.2025.05.019","DOIUrl":"10.1016/j.jmapro.2025.05.019","url":null,"abstract":"<div><div>Nickel-based superalloys are widely used in important applications in various industries, including aerospace, defence, chemical processing, and marine. However, the difficulties encountered in machining these alloys pose specific challenges regarding the efficiency and quality of the parts. Thus, adopting economical and environmentally friendly cutting strategies during machining is essential for the environment and performance. For this purpose, silicon dioxide (SiO<sub>2</sub>) and aluminium oxide (Al<sub>2</sub>O<sub>3</sub>) nanoparticles were added to a base-cutting fluid to develop a novel hybrid nanofluid MQL (HNFMQL) cutting fluid, which is then applied during turning experiments. The thermo-physical characteristics, namely pH, thermal conductivity, and coefficient of friction of different fluid mixtures, are studied. The machining experiments are performed on Hastelloy C4 under conventional (dry, MQL, HNFMQL) and heat-assisted (HA) machining (HA dry, HA MQL, HA HNFMQL), and the cooling-lubrication ability is analyzed by measuring machining responses. Compared to HNFMQL and dry conditions, heat-assisted machining with HNFMQL reduced surface roughness by 20 % and 55.56 % and decreased tool wear by 14 % and 41.47 %. The SEM and EDX analysis of worn cutting tools revealed the efficacy of HNFMQL and HA HNFMQL with lower abrasive wear. Whereas, abrasion, adhesion, and chipping are observed under dry machining. The study of the material's microstructural behaviour using Electron Backscatter Diffraction (EBSD) revealed important details about its behaviour under various machining conditions. The EBSD investigation revealed a well-aligned microstructure, proving that heat impacts a limited region in heat-assisted machining.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"148 ","pages":"Pages 45-60"},"PeriodicalIF":6.1,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144083647","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

Dry sliding wear behaviour of 3D printed Polyetheretherketone with varying layer thickness 不同层厚的3D打印聚醚醚酮干滑动磨损行为

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-19 DOI: 10.1016/j.jmapro.2025.05.022

Sunil Kumar Prajapati, R. Gnanamoorthy

{"title":"Dry sliding wear behaviour of 3D printed Polyetheretherketone with varying layer thickness","authors":"Sunil Kumar Prajapati, R. Gnanamoorthy","doi":"10.1016/j.jmapro.2025.05.022","DOIUrl":"10.1016/j.jmapro.2025.05.022","url":null,"abstract":"<div><div>The additive manufacturing process fabricates parts with various parameters and surface features, significantly impacting the structure and mechanical properties of the part. Polymers like Polyetheretherketone (PEEK) demonstrate excellent wear resistance, and it is feasible to be processed with high-temperature polymer additive manufacturing with different surface features for applications such as bearings. The variation in layer thickness of the 3D printed part will result in different surface features and influencing their contact characteristics and wear response. In applications requiring lubrication, like bush bearing, the 3D-printed samples with layered structures can be advantageous by providing space between layers for lubricant storage. The layer thickness affects crystallinity, indentation hardness, tensile strength, surface roughness and energy. Surface roughness impacts the contact mechanism, and surface energy affects the adhesion of 3D-printed cuboid samples with a bearing steel counter body during a dry sliding test using a pin-on-disc configuration for an hour. PEEK's friction coefficient and wear rate increase with layer thickness, and the maximum wear rate of 8.3 × 10<sup>−5</sup> mm<sup>3</sup>/Nm and friction coefficient of 0.62 by the sample with 0.3 mm layer thickness. The space/grooves between layers were observed to accommodate wear debris and influence the wear process during the test. The transfer layer formation on the steel surface affects the wear rate and mechanism, which is influenced by the trapped debris between the grooves formed by stacked layers of the sample surface.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"148 ","pages":"Pages 1-10"},"PeriodicalIF":6.1,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144083644","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

Heterogeneous plastic deformation of stainless steel‑copper composites during multi-step micro deep drawing: experiment and modeling 不锈钢-铜复合材料在多步微拉深过程中的非均匀塑性变形：实验与建模

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-19 DOI: 10.1016/j.jmapro.2025.05.010

Yanyang Qi , Xiaoguang Ma , Zhengyi Jiang , Jingwei Zhao

{"title":"Heterogeneous plastic deformation of stainless steel‑copper composites during multi-step micro deep drawing: experiment and modeling","authors":"Yanyang Qi , Xiaoguang Ma , Zhengyi Jiang , Jingwei Zhao","doi":"10.1016/j.jmapro.2025.05.010","DOIUrl":"10.1016/j.jmapro.2025.05.010","url":null,"abstract":"<div><div>In the present study, laminated 316 L stainless steel - T2 copper composites (50 μm) were initially annealed at 800, 900 and 1000 °C for 5 min, respectively, to achieve diverse microstructural characteristics. Then the formability of stainless steel‑copper composites was investigated through numerical simulation and multi-step micro deep drawing (MMDD) tests, and the deformation law and forming mechanism during MMDD was analyzed. The finite element model, which incorporates material inhomogeneity and surface morphology, exhibits excellent consistency with the experiment results obtained from MMDD tests. The stainless steel‑copper composites annealed at 900 °C exhibit the best plasticity owing to the homogeneous and refined microstructure and texture structure in both stainless steel and copper matrixes, and the micro composite cup with specimen annealed at 900 °C exhibits a uniformly distributed and symmetrical height profile, uniform wall thickness as well as high drawing ratio and superior surface quality with the fewest wrinkles. Additionally, the formability of stainless steel‑copper composites during MMDD is significantly influenced by size effects, and the barrel-shaped micro composite cups manufactured by the second step of MMDD exhibit a considerably deteriorated forming quality compared with bowl-shaped products obtained by the first step of MMDD. The stainless steel exhibits uniform wall thickness distribution comparing to copper during MMDD, and the maximum thickening and the maximum thinning occur at the cup mouth region where the compressive stress is the highest and nose radius region where the tensile stress is the highest, respectively.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 151-176"},"PeriodicalIF":6.1,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144084152","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 bridging characteristics and button-hole suppression mechanisms in pulse waveform-integrated oscillation laser beam welding (OLBW) of Ti6Al4V sheets under an air gap condition: A hydrodynamic perspective 气隙条件下脉冲波形集成振荡激光束焊接Ti6Al4V薄板的金属桥接特性及扣孔抑制机理

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-19 DOI: 10.1016/j.jmapro.2025.05.006

Jicheng Chen , Xiong Fen , Qianyun Zhang , Zheming Qi , Zipeng Ouyang , Xiaohong Zhan

{"title":"Metal bridging characteristics and button-hole suppression mechanisms in pulse waveform-integrated oscillation laser beam welding (OLBW) of Ti6Al4V sheets under an air gap condition: A hydrodynamic perspective","authors":"Jicheng Chen , Xiong Fen , Qianyun Zhang , Zheming Qi , Zipeng Ouyang , Xiaohong Zhan","doi":"10.1016/j.jmapro.2025.05.006","DOIUrl":"10.1016/j.jmapro.2025.05.006","url":null,"abstract":"<div><div>In the aerospace manufacturing industry, conventional laser welding often fails due to assembly errors, resulting in discontinuous long-straight welds in titanium cabin skin structures. This study introduced a novel oscillation laser beam welding (OLBW) approach, combined with a low-frequency, medium-duty cycle pulse waveform. We applied this method to fabricate tailor-welded blanks (TWBs) of Ti6Al4V alloy under reserved air gap conditions. Experiments involved various combinations of beam trajectory and pulse waveform parameters. Keyhole and weld pool dynamics were numerically simulated by developing a validated multi-phase thermo-fluid coupling model. Key findings include: At an oscillation frequency of 100 Hz, the process enhances metal bridge formation between workpieces, with the keyhole maintaining a normal shape and an opening area of 0.196 mm<sup>2</sup>—smaller than the focused beam spot—enabling continuous weld beads. At 200 Hz, however, the average metal bridge area drops by 23.2 % indicating a weakened gap bridging capacity, and the keyhole opening expands to over 0.8 mm<sup>2</sup> after several cycles, creating a button-hole geometry. This is primarily due to insufficient hydrostatic pressure response on the keyhole's posterior wall under the rapid anterior wall's movement, along with a surface tension coefficient increasing from 1.1 N/m to 1.2 N/m. Introducing a 50 Hz square pulse waveform addresses this by promoting periodic keyhole collapse and weld pool cooling, keeping the keyhole in a semi- or full-penetration state and therefore suppressing the button-hole effect. Additionally, increasing beam oscillation frequency or incorporating pulse reduced α′-martensite grain size, primarily driven by an average cooling rate over 2.6 × 10<sup>5</sup> K/s or cyclic remelting in overlap regions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"148 ","pages":"Pages 24-44"},"PeriodicalIF":6.1,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144083646","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

Tensile properties of flanged NiTi pin fabricated by laser rod end melting and immediate flange processing 激光棒端熔和直接法兰加工的带法兰镍钛销的拉伸性能

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-19 DOI: 10.1016/j.jmapro.2025.05.014

Yang Lu , Hannes Fröck , Benjamin Milkereit , Tim Radel

{"title":"Tensile properties of flanged NiTi pin fabricated by laser rod end melting and immediate flange processing","authors":"Yang Lu , Hannes Fröck , Benjamin Milkereit , Tim Radel","doi":"10.1016/j.jmapro.2025.05.014","DOIUrl":"10.1016/j.jmapro.2025.05.014","url":null,"abstract":"<div><div>To achieve a joining of Nickel-Titanium alloys to components that are resistant to heat, stress and corrosion, a process chain called laser rod end melting with immediate flange processing has been proved as a promising alternative to conventional joining and laser welding. A laser beam melts the end of a NiTi wire to a melt droplet, immediately reshaped to a flange, connected to the rest wire as a flanged pin. Considering that tensile properties of laser-welded NiTi alloys can be improved by appropriate process parameters and post-weld heat treatment, this approach has potential to be applied on the flanged pins, which was systematically investigated in this study. Despite the earlier fracture of the flanged pin than the base material, the laser process had a negligible influence on the tensile behavior of the pin under the different parameter combinations. However, the relative position of the pin in the flange had to be carefully concerned during the fabrication. Except the laser power, laser-scan speed and delay time, the flange height led to an apparent change of the tensile strength. Besides the laser process, the post heat treatment improved the tensile strength of the flanged pin. It modified not only the hardness distribution in the flanged pin but also the tensile behavior under loading. This study revealed the mechanism determining the tensile behavior of the flanged pin for superelastic application.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 191-207"},"PeriodicalIF":6.1,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144084003","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

Relationship between associated acoustic emission and crack position during directed energy deposition of a metal matrix composite 金属基复合材料定向能沉积过程中伴生声发射与裂纹位置的关系

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-19 DOI: 10.1016/j.jmapro.2025.05.015

Md Jonaet Ansari , Anthony Roccisano , Elias J.G. Arcondoulis , Christiane Schulz , Thomas Schläfer , Colin Hall

{"title":"Relationship between associated acoustic emission and crack position during directed energy deposition of a metal matrix composite","authors":"Md Jonaet Ansari , Anthony Roccisano , Elias J.G. Arcondoulis , Christiane Schulz , Thomas Schläfer , Colin Hall","doi":"10.1016/j.jmapro.2025.05.015","DOIUrl":"10.1016/j.jmapro.2025.05.015","url":null,"abstract":"<div><div>Laser-based directed energy deposition (DED) is a versatile additive manufacturing (AM) technique capable of depositing high-quality coatings, repairing components, and fabricating complex metal matrix composite structures. The DED process, however, is prone to defects, particularly cracking, due to dynamic thermal gradients and residual stresses inherent in the process. Conventional monitoring methods, such as optical and thermal imaging, primarily focus on surface defects and often fail to detect subsurface cracks, that can significantly affect the structural integrity of fabricated structures. This study presents a novel acoustic emission (AE)-based monitoring method capable of detecting and quantifying both surface and subsurface cracks during the DED process. By exploiting the exponential decay of the unique acoustic emissions due to DED, the second-order derivative of the acoustic signal is invariant, thereby filtering extraneous noise sources and hence yielding a robust methodology for relating DED-based cracking initiation times and their associated positions. The results reveal that crack formation timing and location vary significantly with energy density. The novel techniques were used to show that higher energy density leads to slower cooling and solidification rates, resulting in delayed crack formation and detection further behind the laser beam's position.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 177-190"},"PeriodicalIF":6.1,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144084002","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

Depth prediction of plastic vortex toward vortex flow-based friction stir additive manufacturing 基于涡流搅拌摩擦增材制造的塑料涡流深度预测

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-17 DOI: 10.1016/j.jmapro.2025.05.012

Tao Ye , Xianjun Pei , Xiaochao Liu , Wentao Li , Xincheng Wang , Yongzhe Li , Zhonghua Ni , Lei Shi , Chuansong Wu

{"title":"Depth prediction of plastic vortex toward vortex flow-based friction stir additive manufacturing","authors":"Tao Ye , Xianjun Pei , Xiaochao Liu , Wentao Li , Xincheng Wang , Yongzhe Li , Zhonghua Ni , Lei Shi , Chuansong Wu","doi":"10.1016/j.jmapro.2025.05.012","DOIUrl":"10.1016/j.jmapro.2025.05.012","url":null,"abstract":"<div><div>Vortex flow-based friction stir additive manufacturing (VFSAM) advances conventional FSAM by replacing the stir tool with a plastic vortex, eliminating tool wear in high-melting-point metals. However, the precise control of the vortex depth (which directly affects the deposition layer thickness and bonding quality) still faces the challenge of selecting process parameters. This study used the Order of Magnitude Scaling (OMS) method to establish a one-dimensional (1D) vortex depth analytical model, which enables rapid parameter selection for desired layer thickness. The core of the OMS method is to ignore the influence of secondary physical quantities and only retain the magnitude relationship of dominant factors, thereby achieving efficient parameter screening within the allowable error range. The 1D analytical model was applied to Ti-6Al-4V titanium alloy, with an objective function <em>f</em> (<em>N</em>, <em>R</em>) = <em>NR</em> identifying optimal parameters for maximum vortex depth. For Ti-6Al-4V, the optimal solution is <em>f</em> (<em>N</em>, <em>R</em>) = 6000, providing ideal parameters for achieving maximum depth. This streamlines the process optimization, enhancing VFSAM efficiency for high-performance applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 127-132"},"PeriodicalIF":6.1,"publicationDate":"2025-05-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144071299","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

Microscale mechanism of material removal process on burr defect formation in grinding superalloy honeycomb composites 磨削高温合金蜂窝复合材料毛刺缺陷形成的微尺度机理

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-17 DOI: 10.1016/j.jmapro.2025.04.065

Haihang Wang , Chenguang Wang , Jiaqiang Dang , Guoqiang Guo , Qinglong An , Weiwei Ming , Ming Chen

{"title":"Microscale mechanism of material removal process on burr defect formation in grinding superalloy honeycomb composites","authors":"Haihang Wang , Chenguang Wang , Jiaqiang Dang , Guoqiang Guo , Qinglong An , Weiwei Ming , Ming Chen","doi":"10.1016/j.jmapro.2025.04.065","DOIUrl":"10.1016/j.jmapro.2025.04.065","url":null,"abstract":"<div><div>Nickel-based superalloy honeycomb composite (NBSHC) is indispensable in the extreme fields such as missile, hypersonic vehicles and aeroengine due to the high temperature resistance and light weight. However, the NBSHC is difficult to be machined, and microscale mechanism of material removal process on burr of NBSHC is not clarified, resulting in burrs that are particularly to be formed during conventional processing and clamping methods. To solve these problems, the NBSHC was ground with ice fixation. The simulation models of grinding depth, speed and cutting angle (process parameters) were established considering the grinding path and ice freezing condition for the first time. Based on the simulations, the microscale material removal and process parameters action mechanisms of NBSHC grinding were comprehensively revealed by coupling stress, plastic strain and temperature fields. To verify the mechanisms and obtain the machined quality of NBSHC, the NBSHC grinding experiments were designed by the novel cutting angle analytical model and ice clamp. The results showed the material removal volume and plastic strain increased with the increment of grinding depth, leading to a subsequent increase in burrs. The increasing volume of material removal per time, decreasing force and fracture strength, and thermal softening effects induced by temperature factors dominated in sequence with the increment of grinding speed, resulting that the burr increased initially, decreased subsequently and ultimately increased as the grinding speed incrementally adjusted. Cutting angle affected burr size by influencing the fracture difficulty of burr and thermal softening effects, and the optimal cutting angle intervals were [0°, 30°] and [150°, 180°].</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 133-150"},"PeriodicalIF":6.1,"publicationDate":"2025-05-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144071215","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 interfacial bonding behavior in multilayer injection molding of optical products 光学制品多层注射成型界面结合行为的研究

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-05-16 DOI: 10.1016/j.jmapro.2025.05.004

Ruoxiang Gao , Chengqian Zhang , Jianguo Zheng , Hongwei Zhou , Jianzhong Fu , Peng Zhao

{"title":"Investigation of interfacial bonding behavior in multilayer injection molding of optical products","authors":"Ruoxiang Gao , Chengqian Zhang , Jianguo Zheng , Hongwei Zhou , Jianzhong Fu , Peng Zhao","doi":"10.1016/j.jmapro.2025.05.004","DOIUrl":"10.1016/j.jmapro.2025.05.004","url":null,"abstract":"<div><div>Multilayer injection molded transparent polymers are widely used in a variety of commercial and industrial applications, as key optical component. In multilayer injection molding, as the most typical feature of the process, the fusion interfaces and bonding behaviors between layers is a critical factor influencing the performance of the final product, while the characteristics has not been fully revealed in existing studies. Here, through theoretical and experimental perspectives, we thoroughly investigated the fusion interface characteristics of transparent polymers produced by multilayer injection molding. The fusion interface strength is used as the evaluation index of interface performance, and a theoretical strength model considering the characteristics of the multilayer injection molding process was established based on the molecular diffusion theory. Experimental studies on the fusion interface were conducted using a specially designed multilayer injection mold. Mechanical and microscopic characterizations show that increasing process temperatures, such as insert, melt, and mold temperatures, can significantly improve interface bonding strength. The proposed bonding strength theory can accurately predict experimental results, with the RMS error does not exceed 4 %. Moreover, the correlation between fusion interface properties and optical performance such as transmittance and haze were verified. Based on the above research, ultra-thick-walled optical products with a thickness of up to 30 mm were molded, achieving transmittance and haze values of 82.77 % and 0.05, respectively. The results reveal the properties of multilayer injection molding fusion interfaces of transparent polymers and will aid in the improvement of quality of thick-walled polymer optical products.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 112-126"},"PeriodicalIF":6.1,"publicationDate":"2025-05-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144071298","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