Journal of Manufacturing Processes最新文献

Physics-informed inhomogeneous wear identification of end mills by online monitoring data 通过在线监测数据识别立铣刀非均质磨损的物理信息

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-17 DOI: 10.1016/j.jmapro.2024.11.020

Guochao Li , Shixian Xu , Ru Jiang , Yinfei Liu , Leyi Zhang , Hao Zheng , Li Sun , Yujing Sun

{"title":"Physics-informed inhomogeneous wear identification of end mills by online monitoring data","authors":"Guochao Li , Shixian Xu , Ru Jiang , Yinfei Liu , Leyi Zhang , Hao Zheng , Li Sun , Yujing Sun","doi":"10.1016/j.jmapro.2024.11.020","DOIUrl":"10.1016/j.jmapro.2024.11.020","url":null,"abstract":"<div><div>Online tool wear monitoring is an important component of intelligent milling. Integral end mill is one of the typical high-value cutting tools which has been widely used in aerospace, automobile, mold and other industries. Its cutting edge may produce inhomogeneous wear after suffering variable cutting depth experience. The existing methods are mainly focused on monitoring the maximum value of the tool wear, which cannot identify the inhomogeneous wear state and results in insufficient accuracy and practicality. Therefore, a physics-informed method is proposed to online identify inhomogeneous tool wear state. Firstly, a milling force mechanism model considering tool wear is established. The force model are expressed with matrix formulation so that the time-domain signals of the forces considering inhomogeneous wear can be easily simulated. Then, a total of 11 groups of single-factor simulation experiments are carried out to provide data support. Accordingly, 48 features for each group are extracted, including time-domain and frequency-domain features. By analyzing the Mean Absolute Percentage Error (MAPE) of the extracted features, it is found that the inhomogeneous wear has significant effect on the feature of skewness. Finally, the conclusion is verified by practical experiments through comparing the extracted features in homogeneous and inhomogeneous wear state. The study will provide theoretical and experimental supplement to the engineering application and improve the online wear monitoring accuracy of end mill.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 759-771"},"PeriodicalIF":6.1,"publicationDate":"2024-11-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657323","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

Role of metal surface amorphization on enhancing interfacial bonding in TC4-UHMWPE hybrid structure 金属表面非晶化对增强 TC4-UHMWPE 混合结构中界面结合的作用

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-17 DOI: 10.1016/j.jmapro.2024.11.010

Xin Zou , Ke Chen , Wei Zhou , Cong Chen , Zhenkun Cheng , Feifei Xie , Yafei Pei , Lingti Kong , Min Wang

{"title":"Role of metal surface amorphization on enhancing interfacial bonding in TC4-UHMWPE hybrid structure","authors":"Xin Zou , Ke Chen , Wei Zhou , Cong Chen , Zhenkun Cheng , Feifei Xie , Yafei Pei , Lingti Kong , Min Wang","doi":"10.1016/j.jmapro.2024.11.010","DOIUrl":"10.1016/j.jmapro.2024.11.010","url":null,"abstract":"<div><div>Securing high-performance bonding between metals and non-polar polymers presents a significant challenge. Existing research mainly focused on the metal surface treatments to modify the morphology and chemical components, or introducing polar groups on the non-polar polymer via complicated modifications. This study introduced a novel interface engineering strategy involving metal surface amorphization, aimed at producing a high-performance hybrid structure of Ti6Al4V titanium alloy (TC4) and ultra-high molecular weight polyethylene (UHMWPE) for applications in artificial joint prostheses. The amorphous oxide layer grown on the TC4 surface significantly enhanced its chemical reactivity, facilitating interfacial chemical bonding between TC4 and in-situ functionalized UHMWPE during thermal-direct bonding. High-performance TC4-UHMWPE hybrid structures with lap-shear strength reaching 17.77 MPa (lap-shear force of 3732.4 N) were obtained using friction spot joining, underscoring the effectiveness of chemical bonding as the primary interfacial bonding mechanism. Meanwhile, both the chemical bonding type and the reaction mechanism were revealed with solid experimental evidence and density functional theory calculations for the first time. More importantly, the differences in bonding characteristics between amorphous and crystalline titanium oxides were revealed. This research not only deepens the understanding of interfacial bonding mechanisms and behaviors between different titanium oxides and polar groups but also provides a pioneering insight into manufacturing high-performance metal-polymer hybrid structures.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 772-788"},"PeriodicalIF":6.1,"publicationDate":"2024-11-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657324","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

Die design parameters effect on dimensional conformity of PEM fuel cell bipolar plates in rotary forming of SS316L thin sheets 在 SS316L 薄板旋转成型过程中，模具设计参数对 PEM 燃料电池双极板尺寸一致性的影响

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-16 DOI: 10.1016/j.jmapro.2024.11.035

A. Asgari , M. Zeestraten , C.L. Walters

引用次数: 0

Enhancing controllability in ultra-precision grinding of anisotropic rounded diamond tools through an in situ feature identification approach 通过现场特征识别方法提高各向异性圆形金刚石工具超精密磨削的可控性

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.018

Ruitao Zhang , Zhanfeng Wang , Zengqiang Li , Rongkai Tan , Junjie Zhang , Tao Sun

{"title":"Enhancing controllability in ultra-precision grinding of anisotropic rounded diamond tools through an in situ feature identification approach","authors":"Ruitao Zhang , Zhanfeng Wang , Zengqiang Li , Rongkai Tan , Junjie Zhang , Tao Sun","doi":"10.1016/j.jmapro.2024.11.018","DOIUrl":"10.1016/j.jmapro.2024.11.018","url":null,"abstract":"<div><div>The conventional mechanical grinding approach for diamond tools, which is characterised by constant pressure and influenced by the pronounced anisotropy of single-crystal diamonds, faces challenges in precisely controlling the material removal rate on the tool’ flank face. This leads to uncertainties in both the processing quality and efficiency. To achieve ultra-precision manufacturing of rounded diamond cutting tools, this study meticulously explored the anisotropic characteristics of the material removal rate. An innovative in situ feature identification method is proposed to determine the process parameters for ultra-precision grinding processes with controlled removal rates. Experimental investigations scrutinized the intricate relationship between the model and the output current signal of the feed guide. Significantly, through the dynamic adjustment of the output current of the guide, the controllable grinding process achieved the successful production of ultra-precision tools, showing a remarkable profile error of <50 nm. These findings provide invaluable insights into ultra-precision machining, particularly in addressing the challenges posed by anisotropic diamond materials.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 721-734"},"PeriodicalIF":6.1,"publicationDate":"2024-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657128","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

Surface modification of brittle polycrystalline materials by laser-assisted rolling 通过激光辅助轧制对脆性多晶材料进行表面改性

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.019

Kaiyuan You , Wei Wang , Bei Peng , Min Lai , Hai Jiang

引用次数: 0

Additive manufacturing of AISI M2 tool steel by binder jetting (BJ): Investigation of microstructural and mechanical properties 通过粘结剂喷射 (BJ) 对 AISI M2 工具钢进行增材制造：微观结构和机械性能研究

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.008

Amit Choudhari , James Elder , Manoj Mugale , Sanoj Karki , Venkata Bhuvaneswari Vukkum , Rajeev Kumar Gupta , Tushar Borkar

{"title":"Additive manufacturing of AISI M2 tool steel by binder jetting (BJ): Investigation of microstructural and mechanical properties","authors":"Amit Choudhari , James Elder , Manoj Mugale , Sanoj Karki , Venkata Bhuvaneswari Vukkum , Rajeev Kumar Gupta , Tushar Borkar","doi":"10.1016/j.jmapro.2024.11.008","DOIUrl":"10.1016/j.jmapro.2024.11.008","url":null,"abstract":"<div><div>The presented research demonstrates for the first time the successful processing of AISI M2 tool steel by binder jetting, a promising additive manufacturing technique capable of producing complex shapes with minimal residual stresses and isotropic properties. The optimal printing parameters were explored by varying processing parameters such as the binder saturation (45 %–105 %), binder set time (0 to 10 s), targeted bed temperature (50–60 °C), oscillator (2600–2750 rpm), recoater (20–28 mm/s), and roller speeds (200–300 rpm). Microstructural characterization and evaluation of mechanical properties of binder jetted parts were performed using x-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) to study their chemical composition, powder morphology, microstructure, carbide morphologies, relative density, hardness, compressive strength, and ductility. Two powder sizes (5 and 10 <span><math><mi>μm</mi></math></span>) were used, and sintering was performed at varying temperatures (1270, 1280, and 1300 °C) and durations (60 and 120 min), followed by a furnace, air, and water cooling. An optimum hardness of ∼970 HV was obtained when parts were sintered at 1270 °C for 60 min, followed by water quenching. Impressive compressive strength of ∼ 3580 MPa was observed in the sample sintered at 1280 °C for 60 min duration, followed by air cooling. Furnace-cooled parts showed the highest density of ∼95 %, whereas the relative density of air- and water-cooled parts varied between ∼91 to 93.50 %, respectively. The microstructure of sintered samples revealed the formation of M<sub>6</sub>C stable carbide, M<sub>2</sub>C metastable carbide, MC as a secondary carbide, and α-Fe matrix, which contributed to the observed increase in mechanical properties.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 686-711"},"PeriodicalIF":6.1,"publicationDate":"2024-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657317","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

Material deformation mechanism of polycrystalline tin in nanometric cutting 纳米切割中多晶锡的材料变形机理

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.021

Zhifu Xue , Min Lai , Feifei Xu , Fengzhou Fang

引用次数: 0

A parametric evaluation model of abrasive interaction for predicting tooth rough surface in spiral bevel gear grinding 用于预测弧齿锥齿轮磨削中齿面粗糙度的磨料相互作用参数评估模型

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.012

Weihua Zhou , Jinyuan Tang , Kaibin Rong , Zhuan Li , Wen Shao

{"title":"A parametric evaluation model of abrasive interaction for predicting tooth rough surface in spiral bevel gear grinding","authors":"Weihua Zhou , Jinyuan Tang , Kaibin Rong , Zhuan Li , Wen Shao","doi":"10.1016/j.jmapro.2024.11.012","DOIUrl":"10.1016/j.jmapro.2024.11.012","url":null,"abstract":"<div><div>The grinding of complex surface parts, such as spiral bevel gears (SBGs), involves intricate machine-tool settings and localized machining conditions. These factors contribute to the nonuniformity of the macro envelope and the complex cumulative behavior of grits, thereby increasing the challenge of predicting surface roughness. This paper proposes a novel parametric model that directly relates local envelope parameters influenced by machine-tool settings to abrasive interaction features. Four inclination angles are defined to describe the irregular abrasive posture and the coupled kinematics of generating grinding. Additionally, the calculation strategy of undeformed chip thickness with discrete grinding groove overlap is introduced. Based on the parametric model and the macro wheel-tooth geometry, we further simulate the micro-tooth surface and validate the simulation through experiments. The results indicate that the roughness of the convex surface of the pinion is lower compared to the concave surface. This discrepancy arises from variations in the equivalent contact radius and the inclined abrasive posture. Increasing the speed ratio between the tool rotation and the generating effectively reduces the roughness distribution discrepancy. This work provides a valuable guidance for the manufacturing of high-performance SBGs and quantifies the micro-topography evolution for any abrasive geometry, kinematics, and posture.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 659-676"},"PeriodicalIF":6.1,"publicationDate":"2024-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657319","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

Molecular dynamics simulation for temperature assisted machining of a polycrystalline γ-TiAl alloy 多晶γ-TiAl 合金温度辅助加工的分子动力学模拟

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.016

Zehai Ren , Ruicheng Feng , Baocheng Zhou , Hui Cao , Haiyan Li , Wenle Yang , Chunli Lei

{"title":"Molecular dynamics simulation for temperature assisted machining of a polycrystalline γ-TiAl alloy","authors":"Zehai Ren , Ruicheng Feng , Baocheng Zhou , Hui Cao , Haiyan Li , Wenle Yang , Chunli Lei","doi":"10.1016/j.jmapro.2024.11.016","DOIUrl":"10.1016/j.jmapro.2024.11.016","url":null,"abstract":"<div><div>Temperature-assisted machining is an effective method for improving the machining quality of difficult-to-machine materials. A nano-cutting model was developed using molecular dynamics simulation to reveal the effect of temperature on the cutting performance of a polycrystalline γ-TiAl alloy. The effects of temperature on cutting force, tool wear, plastic deformation, microstructure evolution, subsurface damage, and surface formation process were analyzed based on the levels of thermal activation energy and dislocation theory. Results indicated that the machining quality was a combination of the softening of temperature fields and hardening of stress fields. If the assisting temperature was too high or low, the temperature fields and the stress fields, one of which dominates, the improvement in machining quality was poor. When the assisting temperature was approximately 500 K, the temperature fields and the stress fields matched, plastic deformation, tool wear, and subsurface damage were small, and the machined surface quality was relatively optimal. Recovery and recrystallization lead to microstructural evolution; higher temperatures increased the degree of migration of grain boundaries, and the removal of material from the shear mode gradually transitioned to the removal mode for the coexistence of shear and extrusion. This study can deepen our understanding of the temperature-assisted machining characteristics of the alloy and provide a theoretical basis for regulating the performance of the alloy and improving the machining quality at a macro scale.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 615-628"},"PeriodicalIF":6.1,"publicationDate":"2024-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657320","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

An on-machine tool wear area identification method based on image augmentation and advanced segmentation 基于图像增强和高级分割的机上刀具磨损区域识别方法

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.10.085

Honghuan Chen , Cong Cheng , Jiangkun Hong , Mengqin Huang , Yaguang Kong , Xiaoqing Zheng

{"title":"An on-machine tool wear area identification method based on image augmentation and advanced segmentation","authors":"Honghuan Chen , Cong Cheng , Jiangkun Hong , Mengqin Huang , Yaguang Kong , Xiaoqing Zheng","doi":"10.1016/j.jmapro.2024.10.085","DOIUrl":"10.1016/j.jmapro.2024.10.085","url":null,"abstract":"<div><div>In industrial manufacturing, tool wear monitoring (TWM) is essential for ensuring high-quality machining, operational efficiency, cost-effectiveness, and safety. However, due to the complexities of on-machine imaging and the constraints of direct measurement techniques, TWM methods face challenges such as unclear boundaries, class imbalance between wear and unworn area, and image diversity. This paper proposes a novel two-step approach for identifying tool wear areas. Firstly, DeepLabV3<span><math><msup><mrow></mrow><mrow><mo>+</mo></mrow></msup></math></span> with Focal Loss is utilized to identify the Region of Interest (ROI) of the tool. Secondly, the method employs Intuitionistic Fuzzy C-Means Clustering (IFCM) for detailed segmentation of the wear area. This integration effectively addresses challenges arising from uneven illumination that blur image boundaries and the class imbalance between images with tool wear and those without. To enhance image diversity and quality, we utilize Denoising Diffusion Probabilistic Models (DDPM) for image augmentation, significantly enriching the training dataset. The proposed approach achieves a Mean Pixel Accuracy (MPA) of 95.32% and a Mean Intersection over Union (MIoU) of 93.67%, which marks a substantial improvement over existing TWM models. This progress not only provides a more reliable and efficient tool wear monitoring solution but also sets a new standard for precision in industrial machining processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 558-569"},"PeriodicalIF":6.1,"publicationDate":"2024-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657380","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