Journal of Manufacturing Processes最新文献

{"title":"Effects of single and multiple tool pass strategies of cryogenic assisted micro-milling for microchannel fabrication on soft polymers","authors":"Partha Sarathi Mallick,&nbsp;Karali Patra","doi":"10.1016/j.jmapro.2025.03.021","DOIUrl":"10.1016/j.jmapro.2025.03.021","url":null,"abstract":"<div><div>Soft polymers are difficult to cut material and are characterized by significant tearing and waviness during machining at room temperature due to their low stiffness values. While cryogenic assisted machining has been recently attempted to improve the machinability of such difficult to cut materials but there is no comprehensive understanding of the temperature effect on material removal mechanism of soft polymers yet. Due to the complexity in prediction of the point of phase transition along the thickness during cryogenic cooling, determining the choice of appropriate cutting technique of soft polymer is still challenging. In this work, a paradigm is presented to show how machining of the soft polymer at higher channel depth could be materialize from multiple passes over single pass of larger cutting depth. But, there is an open question on how the temperature-dependent stiffness of the viscoelastic polymer would affect the cutting mechanism when considering the multi pass cutting strategy under cryogenic assisted cooling to improve the machinability up to a larger axial depth. To elucidate these aspects, here, by means of cutting different soft polymer samples, mainly two peculiarities of the cutting mechanism of these structures are reported. The first one is that the chip formation includes, up to now unobserved, extrusion of glassy phase of polymer at multi pass condition. Secondly, the formation of burrs and the deburring process, adjusted by increasing the number of tool passes, will impact the smooth initiation of the polymer surface beneath the machine. Thus, this work is unique in its approach of multiple tool pass strategy to maintain required stiffness at cryogenic conditions for cutting of micro channels with improved features.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 461-480"},"PeriodicalIF":6.1,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143562793","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 ultrafast laser ablation of fused silica filled epoxy molding compound (EMC) using an improved two temperature model: The effect of the processing parameters and the particle size","authors":"Sijie Zhang,&nbsp;Yung C. Shin","doi":"10.1016/j.jmapro.2025.02.081","DOIUrl":"10.1016/j.jmapro.2025.02.081","url":null,"abstract":"<div><div>Ultrafast laser-based dicing of fused silica-filled Epoxy Molding Compound (EMC) is a more efficient, effective, and flexible alternative to the conventional blade saw dicing method. However, the experimental study on the ultrafast laser ablation of fused silica-filled EMC is limited and presented limitations. In this study, an improved 3D Two Temperature Model (improved 3D-TTM) is developed for the ultrafast laser ablation of fused silica-filled EMC to study the ablation behavior. A level-set equation is added to the improved 3D-TTM to capture the ablation front. In the meantime, the method of modeling the fused silica particle embedded in the EMC in the improved 3D-TTM is also described. The improved 3D-TTM showed good agreement with the experimental results and was further used to explore the effect of processing parameters on ablation efficiency and material removal rate. Three ablation ranges at different laser powers were identified. The differences in ablation mechanisms behind those ranges are discussed. It was found that direct ejection can significantly improve the material removal rate. The effect of the filler size on the ablation efficiency is also discussed. It was found that larger filler size EMC will have a smaller ablation efficiency under the same processing conditions. The power thresholds for initiating the direct ejection material removal for different filler sizes were determined by the improved 3D-TTM.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 481-493"},"PeriodicalIF":6.1,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143562794","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":"Characteristic classification and extraction of robotic multi-layer multi-pass MAG welding pool—An extended UNet network implementation based on transfer learning","authors":"Hao Zhou ,&nbsp;Huabin Chen ,&nbsp;Yinshui He ,&nbsp;Shanben Chen","doi":"10.1016/j.jmapro.2024.12.016","DOIUrl":"10.1016/j.jmapro.2024.12.016","url":null,"abstract":"<div><div>The real-time and accurate acquisition of weld pool visual features during robotic multi-layer and multi-pass welding (MLMPW) of medium-thick plates is essential for controlling weld quality. To address the challenge of extracting pool information in complex welding environments, this study proposes a novel method for acquiring pool contours using the ResNet101-UNet architecture, with ResNet101 serving as the backbone. First, a custom dataset of MLMPW pool images (comprising seven different pool types) and their corresponding edge labels was used to train the network. Second, a comprehensive evaluation of different semantic segmentation models was performed, taking into account the inclusion of pre-trained modules from the ImageNet dataset. Experimental results demonstrated that the improved segmentation method can efficiently and effectively extract pool contours from 2D images captured by welding visual sensors. The designed ResNet101-UNet network architecture achieved an effective Mean Intersection over Union (MIoU) of 96.14 % and a Dice coefficient of 98.06 % on the self-constructed pool dataset. By defining the characteristic parameters of MLMPW molten pools and conducting statistical analyses on these parameters, seven classification standards for molten pools were established, including triangular (Type 1), trapezoidal (Types 2, 3, and 4), and parallelogram-shaped (Types 5, 6, and 7) weld formations. The MLMPW pool feature classification and extraction method presented in this paper can acquire richer pool visual features, thereby providing a data foundation for developing automated and intelligent models in the welding process of medium-thick plates.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 517-535"},"PeriodicalIF":6.1,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143562786","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":"Comprehensive analysis of corrosion resistance and micro-machinability properties of α + β and β phase novel Ti-30Zr-5Mo biomedical alloys","authors":"Burak Dikici ,&nbsp;Kubilay Aslantas ,&nbsp;Xiaoli Zhao ,&nbsp;Mitsuo Niinomi","doi":"10.1016/j.jmapro.2025.02.074","DOIUrl":"10.1016/j.jmapro.2025.02.074","url":null,"abstract":"<div><div>The biocompatibility and corrosion resistance of biomedical alloys are crucial to preventing adverse tissue reactions and maintaining implant integrity. Additionally, machinability is essential for producing implants with complex shapes and high surface quality. This study investigates the biocompatibility and micro-machinability of Ti-30Zr-5Mo alloys with different phase compositions: forged (mostly α), solution-treated at 600 °C (α + β), and 700 °C (only β). Biocompatibility was evaluated through electrochemical corrosion tests under <em>in-vitro</em> conditions, while machinability was assessed <em>via</em> micro-milling tests. The corrosion rate of the β-phase alloy was approximately 3.5 times lower than the forged (9.08 nm/year) and 600 °C-treated alloys (9.85 nm/year), attributed to its stable and uniform structure. The forged sample exhibited the lowest corrosion resistance due to its heterogeneous α + β structure, with microgalvanic corrosion observed. Additionally, the forged alloy, with a high α phase content, showed higher cutting forces (21.5 N) and burr widths (230 μm). As the solution treatment temperature increased, the α phase decreased, leading to lower cutting forces and burr widths. The β-phase alloy (700 °C) showed about a 60 % reduction in cutting forces (8.5 N) and an 8-fold decrease in burr widths (28 μm) in up-milling compared to forged sample, indicating superior machinability under micro conditions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 445-460"},"PeriodicalIF":6.1,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143562787","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":"Evolution mechanism of microstructure and properties for 2205 duplex stainless steel joints under “oscillation + pulse” laser-induced arc hybrid welding","authors":"Shengli Liu ,&nbsp;Taotao Li ,&nbsp;Ruifeng Li ,&nbsp;Kai Qi ,&nbsp;Xiaolin Bi ,&nbsp;Huawei Sun ,&nbsp;Gang Song","doi":"10.1016/j.jmapro.2025.02.067","DOIUrl":"10.1016/j.jmapro.2025.02.067","url":null,"abstract":"<div><div>The key to high efficiency welding and corrosion resistance of 2205 duplex stainless steel lies in balancing both properties during the welding process. Laser-induced arc hybrid welding effectively balances the relationship between microstructure and corrosion while pursuing welding efficiency. This study proposes a “oscillation + pulse” double hybrid effect laser to induce an arc and investigates its impact on the microstructure and properties of 2205 duplex stainless steel joints. The results indicate that “oscillation + pulse” laser-induced arc hybrid welding, with circular scanning, induces a more vigorous stirring effect on the molten pool, promoting the conversion from columnar to equiaxial crystal structures. This process also reduces the formation of hard brittle Widmanstätten austenite. In addition, fine and fragmented intragranular austenite precipitates within the ferrite grain boundaries, resulting in a significant increase in elongation, from 15.04 % to 26.91 %. Electron backscatter diffraction analysis reveals that, compared to TIG welding, the average grain size of the austenite decreases from 31.2 μm to 12.9 μm, while the ferrite grain size decreases from 224.5 μm to 110.6 μm. This grain refinement improves corrosion resistance, reducing the corrosion rate by 76.6 % compared to TIG welding.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 494-506"},"PeriodicalIF":6.1,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143562795","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":"Research status and tendency on cold expansion anti-fatigue manufacturing technology for aircraft structural fastening holes","authors":"Nian Wan ,&nbsp;Biao Zhao ,&nbsp;Wenfeng Ding ,&nbsp;Qiang He","doi":"10.1016/j.jmapro.2025.02.068","DOIUrl":"10.1016/j.jmapro.2025.02.068","url":null,"abstract":"<div><div>Cold expansion technology is extensively exploited in the strengthening of fastening holes in aircraft structures due to its exceptional efficiency and stability. The fatigue performance of perforated parts can be effectively improved without compromising the structural integrity, thus satisfying the durability design requirements of the modern aviation manufacturing industry. In recent years, the cold expansion strengthening technology has gradually matured. This present article provides a comprehensive review of the cold expansion strengthening mechanism, commonly employed methods for reinforcement, and fatigue gain control applied to fastening holes in aircraft structures. The basic principles of the cold expansion anti-fatigue manufacturing process are introduced, while also elaborating on the optimization of typical expansion process methods and their anti-fatigue effects, as well as discussing the factors contributing to any observed differences. Subsequently, the research progress and academic achievements are concluded, in terms of methodological enhancements, distributions of residual stress fields, investigations into microscopic deformation behavior and improvements in fatigue performance gain. In addition, the critical factors influencing the anti-fatigue performance are comprehensively discussed. Finally, the future development trend of cold expansion strengthening technology for fastener holes is highlighted, taking into account the existing limitations and challenges in current research.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 319-335"},"PeriodicalIF":6.1,"publicationDate":"2025-03-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143552374","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":"Multi-joint active excitation for automatically traversing structural dynamics of milling robot workspace using only output data","authors":"Xinyong Mao ,&nbsp;Wei Yuan ,&nbsp;Ming Zhao ,&nbsp;Qiang Huang ,&nbsp;Qian Wei ,&nbsp;Qiushuang Guo ,&nbsp;Wenlong Luo ,&nbsp;Yinghu Yang","doi":"10.1016/j.jmapro.2025.03.004","DOIUrl":"10.1016/j.jmapro.2025.03.004","url":null,"abstract":"<div><div>The real evaluation of the structural dynamics of a milling robot is essential for real-time monitoring and accurate vibration suppression. However, the multi-joint structure of the robot results in a large number of postures. Current dynamics analysis methods usually select a few postures at stationary state for hammering experiments, which makes it difficult to traverse the dynamics of the robot in the whole workspace, and it is difficult to characterize the dynamics of the robot in the operating state using the dynamics parameters in the stationary state. To achieve a complete vibration analysis, this paper proposes a multi-joint active excitation operational modal analysis. The proposed method meets the input white noise assumption and spatial uniformity requirements by controlling multiple joints simultaneously for random start-stop, uses the resulting random pulse signals excite the overall structure in multiple directions. Then, analyze and simulate the effect of joint control parameters on excitation frequency and energy. Finally, three multi-joint active excitation experiments with different postures are conducted. The results demonstrate that the proposed method can reliably identify the posture-dependent milling robot modal parameters in the operating state, which can be applied to milling robot chatter analysis, path optimization and other real-time process requirements.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 375-388"},"PeriodicalIF":6.1,"publicationDate":"2025-03-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143562796","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":"Formation and mechanical performance of the pre-counter bore resistance rivet welded joints for thick cast aluminum and ultra-high strength steel","authors":"Zixuan Chen ,&nbsp;Ming Lou ,&nbsp;Han Yu ,&nbsp;Bowen Zhang ,&nbsp;Cheng Liu ,&nbsp;Sizhe Niu ,&nbsp;Yongbing Li","doi":"10.1016/j.jmapro.2025.03.002","DOIUrl":"10.1016/j.jmapro.2025.03.002","url":null,"abstract":"<div><div>Al/steel dissimilar joining represents a crucial strategy for vehicle body lightweighting. However, the increasing adoption of integrated die-casting with thick aluminum components in automotive manufacturing has introduced unprecedented challenges for Al/steel joining technologies. A novel approach to address thick cast Al to steel joining was developed through an innovative modification of resistance rivet welding (RRW). By incorporating a presetting counter bore prior to the traditional RRW process, high-performance flat surface joining between thick cast aluminum and press hardened steel (PHS) was successfully achieved, as demonstrated with 3.0 mm and 1.5 mm thickness specimens respectively. Through systematic investigation of process parameters, a comprehensive process window was established and detailed analyses of joint geometry characteristics were conducted. Microstructural characterization revealed that Al elements were uniformly distributed throughout the Al/steel mixed nugget. Under low heat input conditions, the nugget consisted of ferrite with an average grain size of 135.9 μm, while under high heat input conditions, it was composed of martensite with an average grain size of 3.9 μm. The joints exhibited mechanical performance, with a peak microhardness of 580 HV, tensile-shear strength of 10,691 N and cross-tension strength of 4057 N achieved. This study provides an effective solution for joining thick cast aluminum to steel and expanding the capabilities of dissimilar metal joining technology.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 431-444"},"PeriodicalIF":6.1,"publicationDate":"2025-03-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143562799","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":"Development on shape and performance control of aeronautical parts in additive manufacturing","authors":"Guofu Gao,&nbsp;Yan Wang,&nbsp;Yi Wang,&nbsp;Kuan Zhang,&nbsp;Daohui Xiang,&nbsp;Junjin Ma","doi":"10.1016/j.jmapro.2025.03.015","DOIUrl":"10.1016/j.jmapro.2025.03.015","url":null,"abstract":"<div><div>The strong thermal-solidification-mechanical coupling in the additive manufacturing process makes it technically difficult to establish a reliable shape accuracy and performance control method in aerospace applications. Most of the existing shape and performance control methods are aimed at improving shape accuracy and mechanical performance separately. To understand the development trend of shape accuracy and performance control, this study reviews the progress covering mechanism analysis of shape and performance defects, prediction and compensation methods, process control, different assisted machining methods, application effects, heat-treat. The shape and surface defects are mainly caused by the design method and the instability of the molten pool and the high cooling rate during manufacturing process, and the mechanical performance defects are mainly formed by the special microstructure and internal defects formed during the manufacturing process. Before manufacturing, the shape and surface defects are predicted and compensated mainly by simulation and preheating. In the processing stage, key process parameters are controlled to ensure constant heat input and stability of the molten pool. Auxiliary technology and post-processing are important methods to optimize surface quality and microstructure to enhance shape accuracy and performance. The current deficiencies and future challenges of shape and performance collaborative control are summarized to lay the foundation for the further development of shape accuracy and performance control in AM.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 351-374"},"PeriodicalIF":6.1,"publicationDate":"2025-03-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143563434","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":"Easily creating slant microwall arrays by tailoring melt redistribution for directional liquid transportation","authors":"Chenxi Jia ,&nbsp;Pingmei Ming ,&nbsp;Yunyan Zhang ,&nbsp;Jianshu Wang ,&nbsp;Jinlong Song","doi":"10.1016/j.jmapro.2025.03.010","DOIUrl":"10.1016/j.jmapro.2025.03.010","url":null,"abstract":"<div><div>Driving directional liquid transportation on structured surfaces has garnered significant attention. Laser texturing technology is favored for its efficiency and flexibility in creating functional surfaces. However, existing laser texturing processes often struggle to form the complex structures required for customized functional surfaces. In this study, we propose a novel strategy called vertically incident high-frequency pulsed laser tailored melt redistribution (viHPLTMR) to rapidly fabricate slant microwall arrays. This strategy employs nanosecond (ns) pulsed laser direct writing (DLW) with repeated line-by-line unidirectional scanning to control the flow patterns of the melt microfluidics. Specifically, the redistribution direction of melt microfluidics aligns with the advancing direction of the laser and is regulated by thermal effects from multi-pulse and periodic energy input. Proper selection of machining parameters allows for the adjustment of microstructure unit sizes and the transformation of microwall slant angles from 34° to 65°. Additionally, based on the multi-process analysis of microstructure characterization, a mechanism model of melt redistribution driven by high-frequency pulsed laser is established. This model reveals the formation process of array structures and the reasons behind their regular behavior. It was found that the constructed surface exhibits excellent superhydrophobicity and anisotropy, with droplets (6.4 μL) achieving a maximum horizontal bounce distance of 1.92 mm and up to 22 consecutive jumps, demonstrating significantly favorable long-distance directional liquid transmission ability. Unlike traditional heterogeneous gradient surfaces, these structured surfaces are free from regional limitations, offering greater flexibility and higher transmission speeds (10.4 mm/s). Furthermore, the viHPLTMR strategy can similarly control melt microfluidic motion and surface wetting performance on different metallic materials such as titanium alloy, stainless steel, magnesium alloy, and aluminum alloy, offering the advantages of low cost, high flexibility, and suitability for large-scale manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 389-402"},"PeriodicalIF":6.1,"publicationDate":"2025-03-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143562797","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}