Journal of Manufacturing Processes最新文献

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Tool wear, mechanistic force modeling, and surface finish in CFRP milling
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-19 DOI: 10.1016/j.jmapro.2025.03.068
Junbeom Son , Chinmay Mungale , Sweta Baruah , Uday Vaidya , Tony Schmitz
{"title":"Tool wear, mechanistic force modeling, and surface finish in CFRP milling","authors":"Junbeom Son ,&nbsp;Chinmay Mungale ,&nbsp;Sweta Baruah ,&nbsp;Uday Vaidya ,&nbsp;Tony Schmitz","doi":"10.1016/j.jmapro.2025.03.068","DOIUrl":"10.1016/j.jmapro.2025.03.068","url":null,"abstract":"<div><div>This paper describes wear testing for two tool coatings, AlTiCrN and diamond, while milling a Toray 3900 prepreg system with plain weave carbon fiber architecture, T-830H-6 K fiber type, and 40 weight percentage epoxy resin. The testing objective is to establish the relationship between tool wear and: 1) the growth in cutting force coefficients for a mechanistic milling force model; and 2) degradation of areal roughness for machined CFRP surfaces. Flank wear width is used to quantify tool wear. It is observed that the diamond coating outperforms the AlTiCrN coating. Abrasive wear on the flank face is seen to be the dominant wear mechanism for the AlTiCrN coating with linear increases in flank wear width, areal roughness, and cutting force coefficients as volume is removed.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1397-1415"},"PeriodicalIF":6.1,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143644937","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 novel analytical model for predicting the thin-walled workpiece deformation considering the effect of residual stress accumulation and redistribution in layer by layer milling
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-19 DOI: 10.1016/j.jmapro.2025.03.018
Junjin Ma , Yutong Liu , Yong Zhao , Feng Jiao , Guofu Gao , Daohui Xiang , Dinghua Zhang , Bo Zhao , Xiaoyan Pang
{"title":"A novel analytical model for predicting the thin-walled workpiece deformation considering the effect of residual stress accumulation and redistribution in layer by layer milling","authors":"Junjin Ma ,&nbsp;Yutong Liu ,&nbsp;Yong Zhao ,&nbsp;Feng Jiao ,&nbsp;Guofu Gao ,&nbsp;Daohui Xiang ,&nbsp;Dinghua Zhang ,&nbsp;Bo Zhao ,&nbsp;Xiaoyan Pang","doi":"10.1016/j.jmapro.2025.03.018","DOIUrl":"10.1016/j.jmapro.2025.03.018","url":null,"abstract":"<div><div>In aviation industry, aluminum alloy is widely applied in the thin-walled workpieces owing to its high specific strength, low density and good machinability. For thin-walled workpiece, machining deformation is a very serious challenge, and with material removal in milling, the initial and milling residual stresses inside the workpiece are continuously released and redistributed, which cause the thin-walled workpiece deformation and deteriorates workpiece dimensional accuracy and milling quality. To reveal the influence of residual stress on workpiece deformation, a novel analytical model for predicting the thin-walled workpiece deformation considering the impact of residual stress accumulation and redistribution in layer by layer milling is proposed in the paper. In this process, the distribution mechanism of thin-walled workpiece initial residual stress is explored furtherly by analyzing the force state of workpiece, and the forces and the moment are obtained on the to be machined layer and the machined layer under the layer by layer conditions. Then, the residual stress generation mechanism induced by thermal stress and mechanical stress are researched, and the residual stress distributed model is founded. Subsequently, the coupled accumulation mechanism of initial and milling residual stress are determined, which directly affects the workpiece deformation. Next, an overall thin-walled workpiece deformation prediction model induced by residual stress in layer by layer milling is proposed. Finally, several experimental tests are carried out to validated the effectiveness and feasibility of the proposed model, and the experimental results manifest that the calculated workpiece deformation proximately align with that measured, the minimum and maximum errors are 1.3 % and 13 %, respectively, and the whole average error is 9.76 %.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1444-1462"},"PeriodicalIF":6.1,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143644941","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
Compensation strategy to minimize over-cut effects in robotic belt grinding with passive-compliant tools
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-19 DOI: 10.1016/j.jmapro.2025.03.044
R. Torres-Izu , X. Iriarte , S. Mata , J. Aginaga , D. Barrenetxea
{"title":"Compensation strategy to minimize over-cut effects in robotic belt grinding with passive-compliant tools","authors":"R. Torres-Izu ,&nbsp;X. Iriarte ,&nbsp;S. Mata ,&nbsp;J. Aginaga ,&nbsp;D. Barrenetxea","doi":"10.1016/j.jmapro.2025.03.044","DOIUrl":"10.1016/j.jmapro.2025.03.044","url":null,"abstract":"<div><div>At the beginning of the robotic belt grinding path, passive-compliant tools can generate an over-cut effect. The transient state from the first contact point between tool and workpiece to the grinding steady state can generate an excess of material removal at the workpiece border. If successive grinding passes are made, this effect will accumulate, increasing the shape deviation at the workpiece border. Therefore, the purpose of this research is to analyze this phenomenon and develop an easy-to-implement compensation strategy to avoid removing an excess of material at the beginning of grinding paths. Specifically, a geometric model of the contact has been developed that, together with the material removal model, allows to reproduce the cut-in effect for a robot-operated passive-compliant tool case. In turn, the compensation strategy that has been designed, avoids removing an excessive amount of material by means of a cut-in path that adjusts the feed velocity to the instantaneous contact force. This path is based on the tool geometry and grinding process parameters. In order to validate the proposed strategy, several experiments have been performed for different process conditions. Results show how the proposed solution significantly reduces the over-cut effect providing a homogeneous material removal since the beginning of the grinding.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1433-1443"},"PeriodicalIF":6.1,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143644939","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
Strengthening mechanical performance with machine learning-assisted toolpath planning for additive manufacturing of continuous fiber reinforced polymer composites
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-19 DOI: 10.1016/j.jmapro.2025.03.061
Xinmeng Zha, Huilin Ren, Ziwen Chen, Hubocheng Tang, Donghua Zhao, Yi Xiong
{"title":"Strengthening mechanical performance with machine learning-assisted toolpath planning for additive manufacturing of continuous fiber reinforced polymer composites","authors":"Xinmeng Zha,&nbsp;Huilin Ren,&nbsp;Ziwen Chen,&nbsp;Hubocheng Tang,&nbsp;Donghua Zhao,&nbsp;Yi Xiong","doi":"10.1016/j.jmapro.2025.03.061","DOIUrl":"10.1016/j.jmapro.2025.03.061","url":null,"abstract":"<div><div>Additive manufacturing of continuous fiber composites enables the realization of complex yet optimal design, fully leveraging the transversely anisotropic mechanical properties of fibers by aligning the fiber direction with the principal stress direction. This offers a new design and manufacturing pipeline to enhance the structural efficiency of composites under specific working conditions. However, the computational efficiency of existing methods based on finite element analysis for calculating principal stress fields is low and unsuitable for low-volume and high-mix type production of additive manufacturing. Herein, this study proposes a machine learning-assisted toolpath planning method to reliably and efficiently generate the continuous fiber toolpath that strengthens the mechanical performance of composite structures. The method constructs a convolutional neural network enhanced with a self-attention mechanism to accurately predict regular principal stress direction field for complex geometries with given working conditions. Subsequently, toolpaths are extracted from a scalar field whose gradient is locally orthogonal to the stress direction, followed by redundant point removal, regrouping, and continuity operations to ensure the toolpaths satisfy the manufacturing constraints. Additionally, criteria for assessing both the mechanical performance and manufacturability of the toolpath are developed. By comparing the average computation time for 100 samples, it is demonstrated that the proposed method improves computational efficiency by 87.3 % compared to existing methods. Furthermore, when applied to various structures, the direction prediction error remains within 10°, and the differences in stiffness of the toolpath-integrated structures and manufacturability of the toolpaths are both within 10 %, demonstrating the reliability of the method for complex and varying geometries.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1416-1432"},"PeriodicalIF":6.1,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143644938","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
Bimaterial topology optimization for Ti-6Al-4V lattice bushing design in PA6 injection molded structures
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-18 DOI: 10.1016/j.jmapro.2025.03.012
Evgenii Kurkin , Evgenii Kishov , Vladislava Chertykovtseva , Vyacheslav Alekseev
{"title":"Bimaterial topology optimization for Ti-6Al-4V lattice bushing design in PA6 injection molded structures","authors":"Evgenii Kurkin ,&nbsp;Evgenii Kishov ,&nbsp;Vladislava Chertykovtseva ,&nbsp;Vyacheslav Alekseev","doi":"10.1016/j.jmapro.2025.03.012","DOIUrl":"10.1016/j.jmapro.2025.03.012","url":null,"abstract":"<div><div>A technology for designing and manufacturing embedded elements is proposed that doubles the strength of the lugs in polymer pin joints. Bushing design based on bimaterial topological optimization using the convex linearization method implemented in the APDL code. The obtained topological density distribution was transformed into a three-dimensional geometric model of the lattice embedded element and its manufacturing from Ti-6Al-4 V using selective laser melting. This study considers gyroid and lattice octahedral structures with volume fractions from 21 to 88.6 % of metal filled with titanium alloy BT-6 surrounded by polyamide-6 reinforced with 30 % short carbon fibers. The results describe the coefficients of the power law function that minimize the quadratic deviation between the elastic modulus curves of the lattice and representative homogeneous volumes. Six types of embedded elements were designed and manufactured by selective laser melting: two types of lugs with three lattice cell sizes. Over 12 moldings containing M and S types of lugs and ISO 527-2 1BA witness samples were performed on an HDRIVE 140 injection molding machine. It was experimentally confirmed that the use of embedded elements designed according to the developed methodology increases the load-bearing capacity of lugs made of short-reinforced polyamide-6 by more than twice.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1368-1384"},"PeriodicalIF":6.1,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143643676","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
Fast and accurate laser powder bed fusion metamodels predicting melt pool dimensions, effective laser absorptivity and lack of fusion defects
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-18 DOI: 10.1016/j.jmapro.2025.03.006
Lucas Schlenger , Milad Hamidi Nasab , Giulio Masinelli , Eric Boillat , Jamasp Jhabvala , Toni Ivas , Claire Navarre , Reza Esmaeilzadeh , Jian Yang , Christian Leinenbach , Patrik Hoffmann , Kilian Wasmer , Roland E. Logé
{"title":"Fast and accurate laser powder bed fusion metamodels predicting melt pool dimensions, effective laser absorptivity and lack of fusion defects","authors":"Lucas Schlenger ,&nbsp;Milad Hamidi Nasab ,&nbsp;Giulio Masinelli ,&nbsp;Eric Boillat ,&nbsp;Jamasp Jhabvala ,&nbsp;Toni Ivas ,&nbsp;Claire Navarre ,&nbsp;Reza Esmaeilzadeh ,&nbsp;Jian Yang ,&nbsp;Christian Leinenbach ,&nbsp;Patrik Hoffmann ,&nbsp;Kilian Wasmer ,&nbsp;Roland E. Logé","doi":"10.1016/j.jmapro.2025.03.006","DOIUrl":"10.1016/j.jmapro.2025.03.006","url":null,"abstract":"<div><div>The significant computational expenses associated with simulating the Laser Powder Bed Fusion (LPBF) process often restrict the insights gained from modeling endeavors to specific combinations of process parameters, hindering broader conclusions. In this study, we employ a classical Design of Experiments approach on results obtained by multiphase Finite Element simulations. Utilizing this framework, we derive quadratic metamodels for the dimensions of the melt pool, enabling predictions of melt pool width, depth, and length across a wide spectrum of processing conditions. Notably, our findings indicate that as few as 25 simulations can suffice to predict melt pool dimensions in conduction mode LPBF across varying laser power, velocity, initial temperature, and spot size parameters. Among other insights, the metamodels uncover and quantify the substantial influence of initial temperature (the local temperature of the volume preceding the laser interaction). Additionally, rare insights regarding the melt pool sensitivity towards the laser spot size are provided. Furthermore, our investigation delves into laser interactions with different phases (powder, liquid, solid) across diverse processing conditions to establish a net global absorption coefficient. These analyses underscore that, under conventional process conditions, most of the incident laser intensity falls onto the liquid phase during conduction mode LPBF simulations of 316L stainless steel and Ti-6Al-4V. However, the laser spot size significantly affects the laser intensity interacting with the liquid phase, warranting consideration of laser spot size dependent absorptivity values in part-scale models. Lastly, employing straightforward geometric simulations, we derive a full processing map predicting the occurrence of Lack of Fusion defects, based on calculated melt pool dimensions and the associated scanning strategy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1337-1353"},"PeriodicalIF":6.1,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143643672","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
Partly random surface micro textures acquired by continuously varying stepover cutting to suppress the diffraction effect
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-18 DOI: 10.1016/j.jmapro.2025.03.054
Yangqin Yu, Zhiyue Wang, Shaozhi Zhang, Xinquan Zhang, Mingjun Ren, Limin Zhu
{"title":"Partly random surface micro textures acquired by continuously varying stepover cutting to suppress the diffraction effect","authors":"Yangqin Yu,&nbsp;Zhiyue Wang,&nbsp;Shaozhi Zhang,&nbsp;Xinquan Zhang,&nbsp;Mingjun Ren,&nbsp;Limin Zhu","doi":"10.1016/j.jmapro.2025.03.054","DOIUrl":"10.1016/j.jmapro.2025.03.054","url":null,"abstract":"<div><div>Diffraction effect has been troubling optical elements fabricated by ultra-precision machining for decades, which results in energy loss and imaging quality degradation. Recently, such an effect is attributed to the periodic micro textures on machined surfaces which are similar to diffraction gratings. And such textures result from the constant stepover of current turning processes. To address the issue, this study proposed a continuously varying stepover cutting (CVSC) method to disrupt the periodic surface textures during tool servo turning. Continuously varying stepover was realized by integrating harmonic variations into the conventional Archimedean driving spiral along the feed direction. The linear chirp signal, which possesses both smoothness and varying frequency, was adopted as the variation signal. A theoretical surface topography model and a diffraction model were established to predict the three-dimensional surface textures and resultant diffraction effect respectively. An X-axis tracking trial was conducted to identify the potential negative effect on following accuracy. Experimental investigations including cutting experiments, surface topography analysis and diffraction tests were conducted to validate the proposed CVSC. Disrupted surface textures and dispersed spatial frequency were observed and coincided well with simulation results. And the effect of CVSC in suppressing the diffraction of machined surfaces was verified by diffraction tests. It is indicated that moderately varying stepover is conducive to suppressing the diffraction effect of ultra-precision machined optical elements while maintaining acceptable surface finish.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1354-1367"},"PeriodicalIF":6.1,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143643673","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 quantitative study on removal mechanism for single atomic layer removal in Cu chemical mechanical polishing based on ReaxFF MD simulations
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-18 DOI: 10.1016/j.jmapro.2025.03.059
Ming Wang, HongAo Yang, ZhiHao Zheng, YouLiang Su, Bo Zhang, Song Mu
{"title":"A quantitative study on removal mechanism for single atomic layer removal in Cu chemical mechanical polishing based on ReaxFF MD simulations","authors":"Ming Wang,&nbsp;HongAo Yang,&nbsp;ZhiHao Zheng,&nbsp;YouLiang Su,&nbsp;Bo Zhang,&nbsp;Song Mu","doi":"10.1016/j.jmapro.2025.03.059","DOIUrl":"10.1016/j.jmapro.2025.03.059","url":null,"abstract":"<div><div>Atomic-scale controllable removal is very vital for achieving atomic accuracy non-destructive surface in the whole frequency domain, especially in the manufacturing process of advanced chips in the post-Moore era. The prerequisites for achieving the purpose are to ascertain atomic-scale removal mechanisms and their contributions to single atomic layer removal. In this work, we quantitatively investigate the atomic-scale removal mechanism in different polishing slurries (including H<sub>2</sub>O, H<sub>2</sub>O<sub>2</sub>, or glycine) during Cu CMP via ReaxFF molecular dynamics simulation. It shows that Cu atom can be removed via: OH adsorption, bond chain stretching, pure shearing, H<sub>2</sub>O adsorption, and interfacial bond stretching in pure H<sub>2</sub>O, OH adsorption and bond chain stretching in pure H<sub>2</sub>O<sub>2</sub>, as well as glycine adsorption, bond chain stretching, interfacial bond stretching, and pure shearing in pure glycine. Their contributions to material removal decrease in turn under each simulation condition. In aqueous glycine with/without H<sub>2</sub>O<sub>2</sub> and aqueous H<sub>2</sub>O<sub>2</sub> with/without glycine, glycine and/or OH adsorption dominate Cu atomic removal, H<sub>2</sub>O adsorption, bond chain stretching, pure shearing, and interfacial bond stretching play indispensable roles in material removal, and the occurrence of these Cu atomic removal behaviors and their contributions to material removal as well as Cu removal rate are closely dependent on the composition of polishing slurry. This work provides not only chemical and tribochemical insight into Cu atomic removal mechanism in CMP, but also a theoretical guidance for designing Cu CMP slurry.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1385-1396"},"PeriodicalIF":6.1,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143644936","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
Enhancing the mechanical integrity of Polylactic acid components via ultrasound-assisted rotary friction welding for sustainable medical device fabrication
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-18 DOI: 10.1016/j.jmapro.2025.03.052
Chil-Chyuan Kuo , Hong-Wei Chen , Armaan Farooqui , Song-Hua Huang , Shih-Feng Tseng
{"title":"Enhancing the mechanical integrity of Polylactic acid components via ultrasound-assisted rotary friction welding for sustainable medical device fabrication","authors":"Chil-Chyuan Kuo ,&nbsp;Hong-Wei Chen ,&nbsp;Armaan Farooqui ,&nbsp;Song-Hua Huang ,&nbsp;Shih-Feng Tseng","doi":"10.1016/j.jmapro.2025.03.052","DOIUrl":"10.1016/j.jmapro.2025.03.052","url":null,"abstract":"<div><div>Polylactic acid is extensively utilized in the fabrication of medical devices due to its biocompatibility and degradability. However, the dimensional limitations of additive manufacturing platforms necessitate segmenting large medical devices into multiple components for printing, followed by post-fabrication assembly. Currently, mechanical fasteners such as nuts and bolts are commonly used in laboratory settings to join these printed segments. However, this approach faces critical challenges, including loosening or detachment of fasteners due to repetitive movements in large medical devices, leading to compromised structural integrity and reliability. To address these challenges, this study focuses on developing an advanced joining method for PLA polymer rods using ultrasound-assisted rotary friction welding (UARFW). The proposed technique significantly enhances joint strength while aligning with sustainable development goals through its high energy efficiency and reduced environmental impact. The ultrasonic waves applied during UARFW promote the flow of molten material within the weld zone, which is crucial for achieving superior mechanical properties. This research demonstrates that the positioning of the ultrasonic oscillator along the <em>Z</em>-axis of the CNC lathe critically affects the weld quality. Optimal joint performance is achieved at a 5 mm displacement, resulting in a 97 % increase in bending strength due to enhanced molten material flow. Fracture analysis indicates that failures predominantly occur within the base material rather than at the weld interface, confirming that the weld interface exhibits superior strength. Moreover, the surface hardness of the weld interface increases by up to 25.7 % compared to conventional rotary friction welding without ultrasonic-assisted micro-vibrations. Numerical simulations are employed to model the temperature distribution within the weld bead, and the results show excellent agreement with experimental data, with a deviation of only 0.6 %. These findings validate the reliability of the proposed numerical approach and highlight the potential of UARFW as a robust and sustainable joining method for the assembly of larger medical devices.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1324-1336"},"PeriodicalIF":6.1,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143643671","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-situ” x-ray imaging technology for material and manufacturing science: A review
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-18 DOI: 10.1016/j.jmapro.2025.03.049
Van Anh Nguyen , Duy Han Le , Dilen Damian , The Bach Tran , Quang Hung Le , Nhu Tung Nguyen
{"title":"“In-situ” x-ray imaging technology for material and manufacturing science: A review","authors":"Van Anh Nguyen ,&nbsp;Duy Han Le ,&nbsp;Dilen Damian ,&nbsp;The Bach Tran ,&nbsp;Quang Hung Le ,&nbsp;Nhu Tung Nguyen","doi":"10.1016/j.jmapro.2025.03.049","DOIUrl":"10.1016/j.jmapro.2025.03.049","url":null,"abstract":"<div><div>“In-situ” X-ray imaging has become a powerful tool in materials and manufacturing science, enabling real-time observation of critical processes. However, access to X-ray facilities remains highly competitive due to limited availability, high operational costs, and technical complexity, restricting its use to a few research groups worldwide. This review addresses this challenge by providing a comprehensive analysis of X-ray imaging technologies, their historical development, and recent advancements in “in-situ” X-ray imaging. It explores applications across various materials and manufacturing processes, including welding, additive manufacturing (AM), casting, high-temperature furnaces, and novel materials. Key topics such as heat transfer, melt pool dynamics, solidification, microstructure evolution, and defect formation in manufacturing processes are systematically examined. Additionally, the review highlights the potential of “in-situ” X-ray imaging for discovering novel materials and advancing manufacturing technologies. It discusses current limitations, particularly the constraints of existing X-ray facilities, and outlines future directions for enhancing this technology. Expanding access to high-resolution X-ray imaging is crucial for accelerating advancements in materials and manufacturing. Integrating artificial intelligence and simulation models will further enhance its capabilities. Achieving these improvements requires upgrading existing X-ray facilities and developing new systems capable of capturing high-resolution, real-time imaging of complex material processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1245-1295"},"PeriodicalIF":6.1,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143644875","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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