Journal of Manufacturing Processes最新文献

{"title":"Improvement of geometry of multi-tooth milling cutter for surface damage suppression in milling of CFRP with theoretical method","authors":"Xiaonan Wang ,&nbsp;Guangjian Bi ,&nbsp;Qiang Zhang ,&nbsp;Fuji Wang ,&nbsp;Rao Fu","doi":"10.1016/j.jmapro.2025.03.093","DOIUrl":"10.1016/j.jmapro.2025.03.093","url":null,"abstract":"<div><div>Multi-tooth milling cutters with segmented right- and left-hand helical cutting edges have been developed to minimize surface damages in milling carbon fiber reinforced polymer (CFRP). However, current studies on the cutting performance of the cutter under various tool geometries are mainly conducted through experimental methods, and the removal mechanism of the surface fibers during milling has rarely been revealed. Therefore, an effective method to improve the geometry of the cutter is required to be proposed to suppress surface damage. In this paper, theoretical models considering multiple cutting actions of the cutter are established to calculate the deformation and fracture of surface fibers at various cutting conditions during CFRP milling. It is found that the fiber would be effectively removed with large cutting depths and axial forces directed to the inside of workpiece. Then, the cutting depths of the right- and left-hand helical cutting edges during milling are quantitatively compared, identifying the segmented left-hand helical cutting edge (SLHCE) to be more important in affecting surface damage. Subsequently, a novel arrangement of segmented cutting edges is proposed by designing overlapping part between adjacent SLHCEs in the circumferential direction, which increases the cutting depth of SLHCEs and helps to inhibit burrs. Finally, the effectiveness of the proposed milling cutter in damage suppression is validated with experiments. This research could provide theoretical bases and technology guidance for low-damage milling of CFRP.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"142 ","pages":"Pages 84-98"},"PeriodicalIF":6.1,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143725214","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Analysis of spatial distribution characteristics and ejection behavior of plasma in deep penetration laser welding process of Ti6Al4V titanium alloy","authors":"Yunfu Tian ,&nbsp;Changxing Li ,&nbsp;Hanbo Zhang ,&nbsp;Hongfei Xu ,&nbsp;Lijun Yang ,&nbsp;Yiming Huang","doi":"10.1016/j.jmapro.2025.03.092","DOIUrl":"10.1016/j.jmapro.2025.03.092","url":null,"abstract":"<div><div>The spatial distribution characteristics and ejection behavior of the plasma is vital to complete understanding of the underlying physical mechanism of deep penetration laser welding process. Existing works concerning the dynamic behavior of the plasma mostly encounters challenges in direct detection and high temporal resolution detection. In this paper, an electrical detection approach based on the passive dual-probe sprayed by high-temperature-resistant and electrically insulating coating was proposed. This method was used to study the spatial distribution characteristics and ejection behavior of the plasma during deep penetration laser welding process of Ti6Al4V titanium alloy. The results indicated that within the laser power range of 1200–1500 W, the plasma temperature and electron density with the peak probability density exhibited the trend of firstly increasing and then decreasing along the axial direction of the plasma. Additionally, the ejection velocity with the peak probability density presented a tendency of increasing with the increasing laser power. Moreover, the relationship between the ejection velocity and maximum plasma temperature detected by the lower probe was analyzed in the view of the peak probability density. By quantitative statistical analysis, it was found that when the ejection velocity (or the maximum plasma temperature) had the peak probability density, the corresponding data points of the maximum plasma temperature (or the ejection velocity) mainly fell within one standard deviation. Finally, the linear regression model between the logarithms of the ejection velocity and plasma temperature variation rate detected by the lower probe was established for the ejection behavior analysis. Based on the linear regression model, the plasma ejection behavior could be reasonably analyzed using plasma temperature variation rate.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"142 ","pages":"Pages 58-70"},"PeriodicalIF":6.1,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143716233","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel controlled high-dynamic braking effect-driven droplet transition in GMAW","authors":"Jun Xiao ,&nbsp;Wan You ,&nbsp;Shujun Chen ,&nbsp;Zhifei Xu ,&nbsp;Zhihao Wang","doi":"10.1016/j.jmapro.2025.03.087","DOIUrl":"10.1016/j.jmapro.2025.03.087","url":null,"abstract":"<div><div>As a conventional arc-depositing process, limited by the strong heat-mass coupling characteristics, gas metal arc welding (GMAW) is difficult to adapt to precision deposition requiring low heat input. To solve this problem, a novel high-dynamic locking-releasing wire feeding method driven by linear actuator was proposed and a compact mechanical structure was developed. The braking effect of the high-dynamic locking-releasing action of the wire feeding allows the molten droplets to acquire additional stronger drive forces, including the inertial force induced by the sudden locking of the wire and the elastic potential energy induced by the bending of the wire, both of which facilitate the droplet transition. The results show that the indirect ‘energy storage’ effect of the high-dynamic locking-releasing wire on the droplets enabled a stable one-droplet-per-pulse (ODPP) spray transfer with a transition frequency of 60 Hz at low heat input. The dynamic transition mechanism of the above ODPP process was revealed by kinetic simulations of the droplet. In addition, a new non-stationary re-locking (NSRL) control strategy was introduced, which further empowered droplets with greater inertial force through the sharp braking effect, thus significantly increased the transition frequency of the molten droplets (~150 Hz). Further, by combining the above strategy with the growth characteristics of droplets under the specific pulsed currents, ODPP spray transfer with frequencies up to 190 Hz was achieved. These promising results indicates the promise of this method for precision arc deposition and even wire arc additive manufacturing at low heat input.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"142 ","pages":"Pages 71-83"},"PeriodicalIF":6.1,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143716271","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Impact of lead on an axisymmetric, single bead blown powder DED overhung geometry","authors":"Lauren Heinrich ,&nbsp;Kenton B. Fillingim ,&nbsp;Peeyush Nandwana ,&nbsp;Rangasayee Kannan ,&nbsp;Alan Burl ,&nbsp;Christopher Saldaña ,&nbsp;Thomas Feldhausen","doi":"10.1016/j.jmapro.2025.03.046","DOIUrl":"10.1016/j.jmapro.2025.03.046","url":null,"abstract":"<div><div>Metal additive manufacturing can be utilized for the near net-shape manufacture of components in a layer wise technique. Traditionally, the buildup process is conducted in the direction of gravity or bottom to top in the vertical orientation; however, with the availability of commercial systems with additive heads or fixturing that can index from vertical, and the need to manufacture larger parts without modifying available systems, the limitation of manufacturing from bottom to top is removed enabling the buildup of larger components printed at an angle from vertical. The effect of gravity on the melt pool and as-deposited component quality when printing off vertical is unknown in literature, especially for axisymmetric components. This understanding is critical for the advancement of manufacturing components of increased size in 4 and 5-axis additive systems. This investigation utilizes blown powder directed energy deposition to evaluate the change in as-printed geometry when the start point is altered in relation to gravity while the part rotates to manufacture an axisymmetric component. The objectives of this work are to determine the impact of the deposition location on the geometric variability on axisymmetric components. This investigation tests the hypothesis that differences in layer height exist due to a change in catchment efficiency when the deposition location is moved to a tangent of the round geometry due to a change in the melt pool dynamics. It was found the ideal deposition location when printing at 26.6-degrees from vertical was at −90-degrees from the top center point of the component, along the tangent, where gravity was pushing the melt pool down, but the rotation of the part was pulling the deposited material towards the top center of the component. This work provides an understanding of layer height stability and catchment efficiency to guide print orientation strategy for high-aspect ratio components. It was found the −90-degree lead deposition had the best layer height stability at 0.6 % as compared to the top-center at 6.3 % and +90-degree deposition location at 9.2 % for the nominal programmed layer height. The change in layer height also effected the final diameter the greatest for the top center deposition location where the diameter diverged by 2.5 % during the overbuild condition and converged by 0.6 %. This finding will increase the manufacturing efficiency of axisymmetric components by increasing the passive stability of the printing process for the successful manufacture of parts without the need for perfectly calibrated manufacturing parameters.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"142 ","pages":"Pages 44-57"},"PeriodicalIF":6.1,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143716272","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Morphology and energy distribution characteristics of ultra-high frequency adjustable multi-pulse GTAW arc","authors":"Hongyan Zhao ,&nbsp;Yi Xing ,&nbsp;Jingzhang Zhang ,&nbsp;Shujun Chen ,&nbsp;Yue Yu ,&nbsp;Guangping He ,&nbsp;Tao Lv","doi":"10.1016/j.jmapro.2025.03.088","DOIUrl":"10.1016/j.jmapro.2025.03.088","url":null,"abstract":"<div><div>To address the limitations of conventional gas tungsten arc welding (GTAW), such as shallow penetration, low welding speed, and inefficiency, this paper proposes an ultra-high frequency adjustable multi-pulse GTAW (UFMP-GTAW) process. By introducing a medium-current phase, this process generates multi-pulse waveforms within a single cycle, achieving a welding current frequency of 100 kHz and a current change rate of 150 A/μs, with adjustable pulse duration and amplitude at each stage. An experimental platform for UFMP-GTAW was established to compare the morphology and energy distribution characteristics of ultra-high frequency arcs with conventional high-frequency pulsed arcs using high-speed imaging and spectral analysis. Results indicate that under the same average current, the high-frequency effect of ultra-high frequency current compresses the arc, concentrating its temperature distribution. The 100 kHz UFMP-GTAW arc exhibits a high-temperature region (&gt;14,000 K) proportion of 42.18 % and a 16.7 % increase in conductivity compared to conventional pulsed arcs. Welding tests demonstrate that the 100 kHz UFMP-GTAW process significantly refines weld grain structure and enhances joint strength. For Inconel 718 nickel-based alloy, grain size decreases from 1200 μm to 50–150 μm, with tensile strength and elongation improving by 12 % and 28 %, respectively. This study provides theoretical and experimental foundations for optimizing high-frequency pulsed arc welding processes and high-performance material welding.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"142 ","pages":"Pages 30-43"},"PeriodicalIF":6.1,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143697304","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Novel vase-shaped structure fabricated by progressive laser surface texturing for strengthening friction spot joints between 2219 aluminum alloy and PEEK","authors":"Feifei Xie ,&nbsp;Nannan Chen ,&nbsp;Xin Zou ,&nbsp;Zhenkun Cheng ,&nbsp;Yafei Pei ,&nbsp;Ninshu Ma ,&nbsp;Katsuyoshi Kondoh ,&nbsp;Ke Chen ,&nbsp;Min Wang ,&nbsp;Xueming Hua","doi":"10.1016/j.jmapro.2025.03.086","DOIUrl":"10.1016/j.jmapro.2025.03.086","url":null,"abstract":"<div><div>Surface texturing has emerged as a highly effective method for enhancing the interfacial properties of metal-polymer dissimilar joints. In this study, 2219 Al alloy/PEEK joints were fabricated by friction spot joining (FSpJ). Before joining, the 2219 Al alloy was subjected to progressive laser surface texturing using a nanosecond laser source, to create multi-scale interlocking structures to maximize the interfacial strength. Initially, full-power laser pulses were utilized to generate conventional cup-shaped craters through laser ablation. Subsequently, half-power laser pulses were employed to transform these cup-shaped craters into novel vase-shaped craters. During the half-power laser processing, the liquid metal partially solidified on the inwall to form a neck structure, and partially spilled out of the crater and solidified into a lotus-shaped structure encircling the opening. The vase-shaped craters and lotus-shaped structure provided micron and sub-micron interlocking at the interface of joints, with strength surpassing the group in cup-shaped by 28.8 %. Meanwhile, the fracture mode in the lap shear testing shifted from interfacial failure (i.e. PEEK was pulled out from the crater) to cohesive failure in the PEEK material near the interface. C-O-Al chemical bond at the joint interface was formed based on X-ray photoelectron spectroscopy (XPS) analysis. Numerical simulations revealed tensile stress components at the interface during crack initiation, which drove the PEEK structures in cup-shaped craters to pull out through tilting deformation. In contrast, the innovative vase-shaped crater prevented the PEEK pull-out failure by the interlocking effect from the neck structure on the crater's inwall.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"142 ","pages":"Pages 18-29"},"PeriodicalIF":6.1,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143697308","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Productive Energy Fluence (PEF) controller using feed and laser hybrid control for Directed Energy Deposition (DED)","authors":"Weijun Zhang,&nbsp;Muqing Yang,&nbsp;Geng Li,&nbsp;Masakazu Soshi","doi":"10.1016/j.jmapro.2025.03.047","DOIUrl":"10.1016/j.jmapro.2025.03.047","url":null,"abstract":"<div><div>In metal additive manufacturing (AM), the laser powder-based directed energy deposition (DED) process stands out as a highly promising approach, enabling rapid, layer-wise fabrication and repair of high-volume, complex geometries. DED supports not only custom-tailored designs with single materials but also enables the use of functionally graded materials. However, the process faces challenges due to the melt pool instability, repeated rapid heating and cooling cycles, uneven heat distribution as layers accumulate, and slower production speed compared to traditional milling processes. These factors complicate the management of geometric accuracy, material properties, residual stress, and overall productivity, thereby limiting broader industrial adoption. A real-time closed-loop energy control system is imperative to improve the general quality of DED parts and to promote a wider application. This study proposes and demonstrates a productive energy fluence (PEF) controller that integrates feed rate and laser power adjustments to enhance geometric accuracy and productivity through optimized temperature management. In this hybrid system, a feed rate (FR)-based energy control strategy was initially activated to maintain the layer’s median temperature while enhancing productivity by increasing both the FR and powder flow rate (PFR). This approach leverages the inherent energy accumulation of DED process to enhance productivity by reducing energy fluence (EF) input while maintaining powder fluence (PF) input. Once the FR-based control reached its temperature management limit, the system automatically switched to laser power (LP)-based energy control strategy, dynamically adjusting the EF by regulating LP to stabilize the layer’s median temperature and geometric accuracy with minimal LP adjustment. Experiments on step-thin wall geometries and high-aspect-ratio thin walls have demonstrated improved geometric accuracy and reduced production time, achieved by comparing a hybrid control strategy against single LP-based and FR-based energy control strategies, as well as an uncontrolled process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"142 ","pages":"Pages 1-17"},"PeriodicalIF":6.1,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143697307","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Determination of optimal temperature range and prediction of tool life to ensure hole quality during continuous drilling of CFRP composites","authors":"Junwei Yin ,&nbsp;Xingshu Wang ,&nbsp;Qunli Zhou ,&nbsp;Zixu Zhao ,&nbsp;Shuai Deng ,&nbsp;Yunxian Cui ,&nbsp;Haoyu Wang","doi":"10.1016/j.jmapro.2025.03.069","DOIUrl":"10.1016/j.jmapro.2025.03.069","url":null,"abstract":"<div><div>Drilling temperature significantly affects the quality of CFRP (Carbon Fiber Reinforced Polymer) composite processing, yet studies on its continuous measurement are limited. This paper addresses this gap by developing an enhanced material model within the VUMAT subroutine and a 3D mechanical-thermal coupling model to simulate continuous drilling. A wireless temperature measurement system is designed to collect real-time data, and experiments are conducted to identify the optimal temperature range for CFRP composites. To predict tool life and ensure hole quality, a hybrid Gaussian classifier and polynomial regression model are developed. The results show that the maximum temperature and damage factor errors are within 6.13 % and 15.28 %, respectively, confirming the model's reliability. The maximum temperature trend correlates with tool wear and hole roughness, establishing that temperature changes can reflect tool wear. The optimal temperature range is found to be 41.5 °C to 112 °C, with a goodness of fit of 0.944 and average variance of 0.002. This study enhances the efficiency and precision of continuous drilling in CFRP composites, offering valuable insights for industries like aerospace, automotive, and construction.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1535-1550"},"PeriodicalIF":6.1,"publicationDate":"2025-03-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143681958","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Vision-based penetration monitoring method for climbing helium arc welding using deep learning with multivariate time series forecasting","authors":"Yuxiang Hong ,&nbsp;Jing Xu ,&nbsp;Shengyong Li ,&nbsp;Longsheng Zhu ,&nbsp;Baohua Chang ,&nbsp;Dong Du","doi":"10.1016/j.jmapro.2025.03.050","DOIUrl":"10.1016/j.jmapro.2025.03.050","url":null,"abstract":"<div><div>Climbing helium arc welding is one of the key technologies in aerospace, military and other high-end equipment industries. Due to the time-varying position and pose of molten pool, the heat and mass transfer process during such welding are complicated and pose a challenge to ensure molten pool stability and weld penetration consistency. Recently, the weld penetration prediction based on molten pool images has shown great application potential in online weld monitoring. However, to accurately predict weld penetration is still a difficult task because of the high similarity of molten pool surface morphology under different weld penetration, especially during non-flat welding process of medium-thickness aluminum alloy plates. This paper proposes a novel vision-based two-phase framework for weld penetration prediction and applies it to climbing helium arc welding. The framework consists of multi-level characteristics extraction phase and deep time series forecasting phase. Firstly, the Deeplabv3+ is used to segment multi-region from molten pool image sequences, extracting the Molten Pool Region (MPR) and the Exposed Aluminum Liquid Region (EALR) within each image. Then, a time series comprising the extracted multi-level characteristics is constructed, and a Kansformer model is subsequently utilized to predict the weld back width based on this characteristic time series. The validity of the proposed method was verified by using data retained from an actual production platform of 2219 aluminum alloy rocket propellant canisters, and the experimental results showed that it was superior to existing methods. Moreover, its generalization ability is verified under varying process parameters, and the average inference speed of a single frame can reach 17.12 fps. In particular, SHAP analysis is utilized to explain the key role of the extracted dynamic characteristics in weld back width prediction.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1522-1534"},"PeriodicalIF":6.1,"publicationDate":"2025-03-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143681610","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of pre-straining on the forming limit of interstitial free high strength steel: Insights on microstructure and crystallographic texture evolution","authors":"Pavan Kumar ,&nbsp;Peeyush Mahajan ,&nbsp;Sushil K. Mishra ,&nbsp;Rahul Datta ,&nbsp;K. Narasimhan","doi":"10.1016/j.jmapro.2025.03.028","DOIUrl":"10.1016/j.jmapro.2025.03.028","url":null,"abstract":"<div><div>In the present work the forming behaviour and microstructure evolution of Interstitial free high strength (IFHS) steel have been investigated through Marciniak test (in-plane deformation) and miniature LDH test (out of plane deformation). Initially, the as-received IFHS steel sheet of 0.7 mm thickness has been deformed up to 2 % and 4 % strain in plane strain and biaxial condition through Marciniak test. Afterward, the miniature uniaxial, plane strain and biaxial specimens are fabricated from the bottom of the dome of the Marciniak test. The obtained samples are further deformed up to necking through miniature LDH test to generate the FLD. Thereafter, evolved microstructure has been investigated on the formed miniature samples at different strain levels and strain paths using electron backscattered diffraction (EBSD) and x-ray diffraction (XRD) techniques. The improved formability is noted due to the impact of pre-strain (both plane strain and biaxial pre-straining) on forming limit diagrams. The 2 % plane strain pre-straining increased uniaxial, plane strain, and biaxial responses by 17.12 %, 64.73 %, and 131.28 %, respectively, while 4 % resulted in 13.36 %, 49.02 %, and 64.94 %. Similarly, 2 % biaxial pre-straining caused 6.18 %, 56.39 %, and 129.88 %, whereas 4 % led to 26.78 %, 67.81 %, and 83.05 % increased formability. The microstructural analysis revealed that after 4 % pre-straining, the development of misorientations (KAM, GAM) and GOS is nearly negligible compared to 2 % pre-straining. At 2 % pre-strain, the development of dense dislocation structures and sub-grain boundaries caused more localized deformation and misorientation formation, explaining the higher levels of misorientation. However, as the strain increased to 4 %, the dislocations began to rearrange, forming a more stable structure, which reduced the overall misorientation and its distribution. XRD bulk texture analysis revealed that an increase in the fraction of copper orientation resulted in lower misorientation values, as observed in the near-neck region of the 2 % pre-strained specimen in comparison to that of neck-region. Another notable observation from the plot is that when the material was deformed from as-received condition to pre-straining the increase in Brass and Goss orientations led to higher misorientation under both uniaxial and biaxial strain conditions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1499-1521"},"PeriodicalIF":6.1,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143681609","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}