Journal of Manufacturing Processes最新文献

{"title":"Interpretable machine learning modeling of alloy composition-process-property relationships based on industrial big data in hot strip rolling","authors":"Jingdong Li ,&nbsp;Xiaochen Wang ,&nbsp;Fengxia Li ,&nbsp;Yamin Sun ,&nbsp;Youzhao Sun ,&nbsp;Quan Yang ,&nbsp;Xiangchen Wang","doi":"10.1016/j.jmapro.2025.06.059","DOIUrl":"10.1016/j.jmapro.2025.06.059","url":null,"abstract":"<div><div>Accurate mapping of the composition, process, and property relationship is essential for online predicting and controlling mechanical properties in hot-rolled alloy steel. However, this remains a challenge due to persistent data silos in hot strip rolling (HSR) and the limited interpretability of “black box” machine learning (ML) models in capturing complex multivariable interactions. This study developed a four-layer industrial digital twin platform to integrate multisource heterogeneous data into a unified dataset, including composition, process parameters and properties. A dataset reconstruction strategy was introduced to address the challenges posed by large-scale, nonlinear, and noise-prone data. Based on the reconstructed inputs, interpretable ML models were established to characterize the underlying composition-process-property relationships accurately. The light gradient boosting machine (LGBM) model, optimized using particle swarm optimization, achieved superior performance with an R² of 0.80 and a mean absolute error of 10.02 MPa on the test set. Shapley additive explanations and partial dependence plot analyses further revealed the combined effects of alloying elements, rolling temperature, and deformation on mechanical behavior. The proposed framework was successfully implemented on a 1422 mm HSR production line, providing real-time guidance for alloy design and reducing reliance on manual sampling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 299-316"},"PeriodicalIF":6.1,"publicationDate":"2025-06-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330211","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":"Investigation of the strengthening mechanism of thermal-assisted laser material processing on the cutting performance of micro-textured tools","authors":"Xinyu Li,&nbsp;Xin Tong,&nbsp;Shucai Yang,&nbsp;Dongqi Yu,&nbsp;Zhe Ning","doi":"10.1016/j.jmapro.2025.06.045","DOIUrl":"10.1016/j.jmapro.2025.06.045","url":null,"abstract":"<div><div>Surface texturing of tools is an effective method for enhancing their cutting performance. Research on micro-textured tools has evolved from a focus on applications to an emphasis on performance enhancement. Laser processing is the most widely used method for preparing micro-texture; however, processing defects that commonly occur during the preparation process, along with inherent limitations in the process, significantly hinder the broader application of the tool. Therefore, this study focuses on cemented carbide tools and investigates the combination of thermal-assisted processing and laser technology to explore the influence mechanism of thermal-assisted temperature on the surface morphology, element distribution, and mechanical properties of micro-textured cemented carbide. A milling test platform was developed to analyze the evolution of the milling performance of micro-textured tools under the thermal-assisted process. The optimization of thermal-assisted process parameters was achieved using the AHP-rank sum ratio comprehensive evaluation method. The results indicate that the thermal-assisted process effectively reduces residual stress and the temperature gradient during laser processing. It also helps to control the uneven material distribution caused by the Marangoni convection effect, preventing crack nucleation and reducing the formation of cracks. Additionally, the process improves the elastic modulus and microhardness of the surface, enhances the structural stability of the micro-texture, and strengthens the bonding with the coating. Furthermore, it improves the wear resistance and friction-reducing performance of the tool surface, while also reducing milling forces, noise, tool wear, and surface roughness of the workpiece. Using the AHP rank-sum ratio method for a comprehensive evaluation, it was found that the overall milling performance of the tool is optimal at a thermal-assisted temperature of 673.15 K. This study offers new insights for addressing the preparation process defects of high-performance tools and enhancing their cutting performance. Most of the research on thermal-assisted laser material processing technology only stays in the surface observation stage. This study not only focuses on repairing the defects caused by the micro-texture preparation process, but also focuses on how this repair can improve the actual working performance. Combining theory with practice to solve practical problems in the cutting process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 257-271"},"PeriodicalIF":6.1,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330208","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 strategy for AlN crystal processing: High - efficiency two step CMP technology","authors":"Yuzhu Wu ,&nbsp;Shouzhi Wang ,&nbsp;Ruixian Yu ,&nbsp;Guodong Wang ,&nbsp;Wenhao Cao ,&nbsp;Qiubo Li ,&nbsp;Yajun Zhu ,&nbsp;Jingliang Liu ,&nbsp;Xiangang Xu ,&nbsp;Lei Zhang","doi":"10.1016/j.jmapro.2025.06.051","DOIUrl":"10.1016/j.jmapro.2025.06.051","url":null,"abstract":"<div><div>Aluminum nitride (AlN) possesses outstanding physical and chemical properties, rendering it with promising prospects for application in various devices. However, the traditional processing technology cannot reach the atomic surface and the efficiency is low, which limits the performance of AlN-based devices. This work proposes a novel and efficient two step chemical mechanical polishing (CMP) method for AlN single crystals. The first-step CMP is the acid alumina slurry polishing, quickly remove surface damage. In the second step CMP, alkaline silicon oxide polishing is used to remove residual subsurface damage, reduce surface roughness, and achieve high-quality and efficient processing of single crystal AlN. Comparing the two step CMP with traditional mechanical polishing and the composite processing method of CMP, the research results show that the polishing efficiency of the two-step chemical mechanical polishing processing method is about 30 % higher than that of the traditional composite polishing method. Two step AlN compound polishing method was revealed from the perspective of material removal mechanism. Finally, the effects of mechanical polishing (MP) and two step CMP processes on the properties and quality of AlN substrates were studied. The proposed two step CMP method could rapidly transform the ground AlN wafer into an atomically smooth surface, which is expected to reduce the cost and manpower required for AlN wafer manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 272-281"},"PeriodicalIF":6.1,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330209","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":"Bio-inspired and recycled 316 L stainless steel surfaces prototyped by coupling vat photopolymerization and investment vacuum casting","authors":"Kevin Dourgaparsad ,&nbsp;Ion-Cosmin Gruescu ,&nbsp;Reyan Rasoli ,&nbsp;David Balloy ,&nbsp;Maude Jimenez","doi":"10.1016/j.jmapro.2025.06.064","DOIUrl":"10.1016/j.jmapro.2025.06.064","url":null,"abstract":"<div><div>Hydrophobic stainless steel (SS) is of particular interest for high-value applications, such as aeronautics or food industry. The present pioneering work aims at fabricating an intrinsic bio-inspired microtextured SS by combining vat photopolymerization (VPP) and vacuum casting. SS casting for under millimetric details constitutes a technical challenge due to the high surface tension, high dynamic viscosity and high working temperature of SS (1600 °C). Various microtextured surfaces inspired from natural shapes (fish scales, drops, honeycomb, etc.) were prototyped and successfully fabricated. A dendritic microstructure was formed during the solidification, that, combined with the microtextures, provides a highly hydrophobic SS, with a water contact angle of 120°. Finally, the SS used for casting was outsourced from laboratory waste, making the SS 100 % recycled, which is beneficial from an environmental point of view.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 203-212"},"PeriodicalIF":6.1,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144320909","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":"Dual-method approach of tool condition monitoring using sensor-based deep learning with vision-based image processing","authors":"Ahmed Abdeltawab ,&nbsp;Zhang Xi ,&nbsp;Zhang Longjia","doi":"10.1016/j.jmapro.2025.06.041","DOIUrl":"10.1016/j.jmapro.2025.06.041","url":null,"abstract":"<div><div>Accurate decision-making in cutting tool condition monitoring (TCM) is critical for maintaining efficiency and quality in modern manufacturing systems. Traditional detection methods, whether direct or indirect, face several limitations and challenges. Different cutting parameters and signal noise often affect indirect methods, which can compromise reliability. Direct approaches for TCM frequently require physically measuring tool wear by visually monitoring it after cutting a sufficient distance on the workpiece. This requires the process to be interrupted for tool condition evaluation, therefore negatively impacting production efficiency. This study proposes a novel dual-check approach that combines sensor-based and vision-based techniques to enhance tool condition monitoring. First, the indirect method utilizes scalogram images derived from acoustic emission signals, analyzed using transfer learning models, including pre-trained networks such as GoogLeNet, SqueezeNet, VGG19, ShuffleNet, and ResNet50. Despite achieving up to 70 % accuracy under certain conditions, sensor signal noise reduced identification accuracy to below 50 %. A direct vision-based method is introduced to address these limitations, using projected rotating tool images to capture individual cutting teeth for a more accurate assessment of tool conditions. This integrated approach improves tool condition identification by combining the strengths of both methods, enhancing overall accuracy and reliability. The study demonstrates the potential of Industry 4.0 technologies, such as advanced imaging and CNC control systems, to revolutionize manufacturing processes by increasing efficiency and ensuring high-quality automated production.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 224-256"},"PeriodicalIF":6.1,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330236","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":"Geometric error compensation through position feedback modification and comparison of correction strategies in 3- axis machine-tool","authors":"Flore Guevel ,&nbsp;Fabien Viprey ,&nbsp;Charly Euzenat ,&nbsp;Guillaume Fromentin ,&nbsp;Ugo Masciantonio","doi":"10.1016/j.jmapro.2025.06.021","DOIUrl":"10.1016/j.jmapro.2025.06.021","url":null,"abstract":"<div><div>In machine-tools, geometrical defects are unavoidable. They can greatly affect the dimensional accuracy of the final workpiece if not corrected. Software compensation strategies are less expensive than mechanical adjustments and they provide great improvement in volumetric accuracy. In this study, different compensation methods are compared in a 3-axis milling applications: Numerical Controller (NC) internal compensation tables, modification of the programmed tool-path (G-code) and modification of position feedback signals. The latter is the main purpose of this work, because it shows great potential and is not linked to one particular type of NC. It communicates with a custom software application that processes the position data and generates corrected signals according to a geometric model based on the rigid body assumption. The NC is then induced to perform volumetric error correction based on its default programming. The compensation methods are compared based on their ability to bring out or correct imposed geometric errors. The highlighted solution shows performances comparable to the G-code modification by correcting more than 96% of the imposed geometric errors without affecting the numerical chain from the program generation to its execution on the machine. It is also independent of the NC or the motors control cards.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 213-223"},"PeriodicalIF":6.1,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144320910","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":"Surface modification and fatigue mechanisms of laser powder bed fused components subjected to shot peening with varying shot diameters","authors":"Hongzhuang Zhang ,&nbsp;Xiaohao Li ,&nbsp;Shujie Cao ,&nbsp;Haonan Ma ,&nbsp;Changyou Li","doi":"10.1016/j.jmapro.2025.06.055","DOIUrl":"10.1016/j.jmapro.2025.06.055","url":null,"abstract":"<div><div>Shot peening is a promising post-processing technology that enhances the surface integrity and fatigue reliability of additively manufactured components by introducing compressive residual stress and surface hardening. This study utilized tempered martensitic steel shots with varying diameters (ASH 110, ASH 330, and ASH 550) to treat the laser-based powder bed fused (PBF-LB) 304L steel, systematically investigating their essential effects on surface quality, subsurface quality, and fatigue performance. Fatigue deformation behavior and hardening mechanisms were elucidated through self-heating effects, microstructural evolution, and fatigue fractography. Results indicate that medium shot diameters (ASH 330) approached optimal shot peening conditions, achieving a balance of surface roughness and gradient structures that enhance fatigue crack initiation resistance, support progressive strain hardening, and improve overall fatigue performance. Although larger shot diameters provided greater penetration depth and contact area, they led to increased surface imperfections and decreased structural heterogeneity, heightening stress concentrations and reducing dislocation hardening. Additionally, cyclic loading facilitated the recovery of pre-existing dislocations and twin boundaries, potentially restricting new twin boundary formation and reducing performance strengthening. These insights into fatigue damage mechanisms provide valuable guidance for optimizing shot peening in additively manufactured components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 48-62"},"PeriodicalIF":6.1,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144313654","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":"Investigation of edge damage of the hole and adhesive wear of the tool in ultrasonically assisted step drilling of SiCp/Al composites","authors":"Haohui Shi,&nbsp;Tao Chen,&nbsp;Xinlong Pan,&nbsp;Zhenyan Duan,&nbsp;Yuhao Suo","doi":"10.1016/j.jmapro.2025.06.046","DOIUrl":"10.1016/j.jmapro.2025.06.046","url":null,"abstract":"<div><div>Owing to their superior comprehensive performance, silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites are extensively utilized in various domains such as semiconductors, aerospace, transportation, and military applications. When drilling SiCp/Al composites using conventional methods, significant drilling force and high temperature often cause severe edge damage at the hole exit and adhesive wear on the flank face. In this paper, a step drill was designed and the effects of tool geometry and machining parameters during ultrasonically assisted drilling (UAD) of SiCp/Al composites were investigated. The tool geometry parameters include diameter ratio (0.6, 0.8, and 1), length of the first step drill (0 mm, 3 mm, and 6 mm), and point angle. As well as machining parameters such as spindle speed, feed rate and ultrasonic power supply voltage (which determines the amplitude of ultrasonic vibration). This paper focuses on the effects of tool geometry and machining parameters on drilling force, temperature and plasticity of the aluminum matrix, and then explores their combined effects on edge damage and adhesive wear. The results show that the diameter ratio and length of the first step drill are the primary factors influencing drilling force and temperature. The machining parameters have a limited effect on the drilling force but a larger effect on the drilling temperature. An appropriate drilling temperature enhances the plasticity of the Al matrix, reducing edge damage and adhesive wear. The experimental results show that when the thickness of SiCp/Al composites workpiece is 4 mm and the step drill with a diameter ratio of 0.8 and a length of a first step drill of 6 mm is used for drilling, the edge damage at the hole exit and the tool adhesive wear are the least. This study aims to provide theoretical and experimental basis for the improvement of drilling quality and reduction of tool wear in practical machining of UAD of SiCp/Al composites by taking into account the effects of more factors.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 88-110"},"PeriodicalIF":6.1,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144313551","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":"Combined two-temperature method and coarse-grained molecular dynamic model in femtosecond laser ablation at large spatiotemporal scale","authors":"Hengfeng Yang ,&nbsp;Hong Shen","doi":"10.1016/j.jmapro.2025.06.066","DOIUrl":"10.1016/j.jmapro.2025.06.066","url":null,"abstract":"<div><div>Molecular dynamics simulations represent a robust approach for investigating femtosecond laser ablation while facing significant limitations on the scale of simulation models. In this study, we address this challenge by employing coarse-grained methodologies to markedly reduce the computational expense of the model. The resultant one-dimensional model demonstrates material responses that closely approximate those of an all-atom model across various parameters. Building upon this foundation, a large-scale two-dimensional model is established, extending to hundreds of micrometers, which facilitates direct comparisons with experimental findings. Additionally, a long-duration model capable of simulating up to 10 ns is developed. The computational efficiency of this model is estimated to be 676 times greater than traditional approaches.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 191-202"},"PeriodicalIF":6.1,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144320908","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":"Arc instability in hybrid laser-GMAW welding process using Ni based filler wire NiCrMo-4","authors":"Zhenwen Zhu,&nbsp;Yu Shi,&nbsp;Gang Zhang,&nbsp;Chunkai Li,&nbsp;Ming Zhu,&nbsp;Ziyou Ren,&nbsp;Wenkai Wang,&nbsp;Yang Zhai","doi":"10.1016/j.jmapro.2025.06.029","DOIUrl":"10.1016/j.jmapro.2025.06.029","url":null,"abstract":"<div><div>NiCrMo-4 alloy, due to its excellent low-temperature properties and low ductile-to-brittle transition temperature, is widely used as a filler material for welding critical cryogenic structures such as large LNG storage tanks. However, the ER-NiCrMo-4 wire, with its high melting point, viscosity, and surface tension, tends to soften and exhibit irregular whipping at the wire tip during gas metal arc welding (GMAW) at currents far below the critical spray transfer current. This results in process instability and limits the application of GMAW in welding the inner tanks of LNG storage systems, where high safety and reliability are required. This study first investigates the instability mechanisms of ER-NiCrMo-4 wire during GMAW, and then examines the effects of laser assistance on droplet transfer behavior by analyzing the coupling between laser and arc plasma under different laser-wire distances. Results show that the laser can regulate the droplet transfer stability of ER-NiCrMo-4 wire, and arc stability is influenced by the degree of coupling between the laser and arc plasmas, as well as the competing effects of metal vapor reaction forces. When the laser-to-arc axial distance (D_LA) is set between 2 and 3 mm, a relatively stable arc is achieved.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 147-165"},"PeriodicalIF":6.1,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144321086","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}