Journal of Manufacturing Processes最新文献_第10页

An interior damage free approach for nanosecond pulsed laser ablation of single crystal diamond via metal film induced self-maintaining graphitization 通过金属膜诱导自保持石墨化实现单晶金刚石纳秒脉冲激光烧蚀的内部无损伤方法

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-26 DOI: 10.1016/j.jmapro.2024.09.083

Nian Liu , Ling Lei , Jingming Zhu , Hao Lu , Junfeng Xiao , Jianguo Zhang , Xiao Chen , Jianfeng Xu , Kazuya Yamamura

{"title":"An interior damage free approach for nanosecond pulsed laser ablation of single crystal diamond via metal film induced self-maintaining graphitization","authors":"Nian Liu , Ling Lei , Jingming Zhu , Hao Lu , Junfeng Xiao , Jianguo Zhang , Xiao Chen , Jianfeng Xu , Kazuya Yamamura","doi":"10.1016/j.jmapro.2024.09.083","DOIUrl":"10.1016/j.jmapro.2024.09.083","url":null,"abstract":"<div><div>When laser ablation was conducted on an uncoated single-crystal diamond (SCD) substrate, interior damage and random ablation were observed. Metal film-induced self-maintaining graphitization (MISG) was proposed as a generic approach to solve this problem. MISG was realized through coating a ∼ 100-nm-thick metal film on an SCD substrate. Experiments involving laser irradiation of metal films, such as Au-, Al-, Ti-, and Pt-coated SCD substrates, revealed that the material removal depths were the same when the output power was the same and that the surface was covered by graphite after laser irradiation. In addition, the laser-induced damage to the upper or lower surface in the case of the uncoated SCD substrate disappeared. A semitransparent model based on Beer-Lambert law and an opaque model based on modified Level-Set method were built to simulate laser irradiation on uncoated and metal–coated SCD substrates. In the case of the uncoated sample, the laser energy was largely absorbed by the areas with high-concentration defects, leading to preferential graphitization. In the case of the metal-coated sample, a graphite layer was thermally induced on the SCD surface via heat transition during the period of laser irradiation of the metal film. Subsequently, the graphite layer was self-maintaining, and the material removal acted like a graphite piston sinking to the interior of the SCD substrate. This study demonstrates the feasibility of MISG as a universal approach for avoiding interior damage during laser ablation of SCD substrates.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 958-972"},"PeriodicalIF":6.1,"publicationDate":"2024-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142323317","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

Digital twin for weld pool evolution by data-physics integrated driving 通过数据物理集成驱动实现焊池演变的数字孪生

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-26 DOI: 10.1016/j.jmapro.2024.09.022

Wenhua Jiao , Da Zhao , Xue Mei , Shipin Yang , Xiang Zhang , Lijuan Li , Jun Xiong

{"title":"Digital twin for weld pool evolution by data-physics integrated driving","authors":"Wenhua Jiao , Da Zhao , Xue Mei , Shipin Yang , Xiang Zhang , Lijuan Li , Jun Xiong","doi":"10.1016/j.jmapro.2024.09.022","DOIUrl":"10.1016/j.jmapro.2024.09.022","url":null,"abstract":"<div><div>Perception of the welding process is a widely recognized challenge in intelligent manufacturing. The critical issue involved is accurately detecting the evolution and state of the weld pool, with the weld backside width being a crucial parameter. A prevalent approach involves training deep learning algorithms with welding process data to uncover latent patterns for predicting the backside width of the weld pool. However, this data-driven method heavily relies on welding process data and label data, which are prone to systematic and cumulative errors during acquisition and fabrication processes. Consequently, traditional regression methods restrict both accuracy and generalization capabilities of these models. To address this limitation, this study proposed a loss function for a regression model estimating weld backside width based on maximum likelihood estimation principles, and prior functions and transfer learning strategies were employed to enhance the prediction accuracy of the regression model. In addition, the weld surface width, arc voltage, and welding current were combined with a simplified heat source model to effectively visualize the cross-section of the weld pool. A digital twin system was developed to record, analyze, and visually characterize weld pool evolution.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 947-957"},"PeriodicalIF":6.1,"publicationDate":"2024-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142323316","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

Thermal-fluid modeling and simulation of Ti-6Al-4V alloy filaments during shaping in the hot-end of material extrusion additive manufacturing 材料挤压增材制造热端成型过程中 Ti-6Al-4V 合金长丝的热流体建模与模拟

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.040

Gaius Chukwuka Nzebuka , Chukwuzubelu Okenwa Ufodike , Al Mazedur Rahman , Matthew B. Minus , Chijioke Peter Egole

{"title":"Thermal-fluid modeling and simulation of Ti-6Al-4V alloy filaments during shaping in the hot-end of material extrusion additive manufacturing","authors":"Gaius Chukwuka Nzebuka , Chukwuzubelu Okenwa Ufodike , Al Mazedur Rahman , Matthew B. Minus , Chijioke Peter Egole","doi":"10.1016/j.jmapro.2024.09.040","DOIUrl":"10.1016/j.jmapro.2024.09.040","url":null,"abstract":"<div><div>Continuous progress in material extrusion additive manufacturing is motivated by the need to produce functional parts at a low cost for medical, aerospace, and automotive applications. A significant innovation is impregnating a polymeric melt with metal powder (particle) to produce a filament that will be 3D printed using a low-cost desktop printer. The presence of metal particles affects the complex flow dynamic and temperature profile during processing through the hot-end of the 3D nozzle. The current study employs numerical simulation to analyze the effect of powder content on the outlet flow field during the melting of polymer-filled metal filament material extrusion additive manufacturing. Titanium 64-5 filament was experimentally measured to obtain thermophysical properties and another Titanium 64-5 filament thermophysical properties were empirically determined. Each filament was simulated using a finite element method to obtain temperature, viscosity, and shear rate data. A detailed discussion of the implementation of the thermal-fluid model was presented. The results obtained indicate that the two types of filaments' sensitivity to the feeding rates differ at a certain region of the extrusion regime. Also, further simulation was performed to investigate the response of the flow fields with the powder contents. The temperature and viscosity results obtained at the nozzle outlet indicate that at a high powder content, the printing of the polymer-filled metal filament can be performed at a high extrusion rate with possible extrudate shape stability. The thermal-fluid model and simulation can be used for selecting process parameters for any new binder-metal particle formulation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 866-878"},"PeriodicalIF":6.1,"publicationDate":"2024-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142319374","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 integrated simulation and experimental study of calendering process in water-based manufacturing of lithium-ion battery graphite electrode 锂离子电池石墨电极水基制造中压延工艺的综合模拟与实验研究

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.076

Yu Wang, Boman Su, Chris Yuan

引用次数: 0

Filtered kriging for improved interpolation of periodic manufacturing surfaces 改进周期性制造表面插值的过滤克里金法

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.002

Zhiqiao Dong , Sixian Jia , Chenhui Shao

{"title":"Filtered kriging for improved interpolation of periodic manufacturing surfaces","authors":"Zhiqiao Dong , Sixian Jia , Chenhui Shao","doi":"10.1016/j.jmapro.2024.09.002","DOIUrl":"10.1016/j.jmapro.2024.09.002","url":null,"abstract":"<div><div>High-resolution characterization of surfaces is essential in a variety of quality control tasks in modern manufacturing, such as surface quality inspection and tooling maintenance. However, direct high-resolution surface measurements often come with high cost and/or long measurement time. Interpolation based on spatial process models, especially kriging-type methods, has been used to obtain denser estimations from low-resolution and cheaper measurements. Periodic spatial correlations, which commonly exist in manufacturing applications, cannot be adequately captured by conventional spatial models, thereby causing potential performance degradation or numerical issues. To address these challenges, we propose a new procedure termed as filtered kriging (FK), which separates the periodic component using a bandpass pre-filter, such that the residual can be well fitted with common models. Through frequency-domain analysis, conditions under which FK is effective are identified, and a practical bandpass filter design strategy is devised. A new theorem is proven to show that, when measurements are free from aliasing, perfect reconstruction guaranteed by the Nyquist-Shannon sampling theorem is achieved by FK estimations under certain assumptions. Finally, the effectiveness of FK is demonstrated by case studies using real-world periodic surfaces from two-photon lithography and ultrasonic metal welding. FK is shown to capture spatial correlation more adequately than conventional methods, and achieves better interpolation accuracy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1-12"},"PeriodicalIF":6.1,"publicationDate":"2024-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142319471","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

Achieving excellent properties of laser tailor-welded thin Al-Si coated press-hardened steel joint via controlling dilution rate 通过控制稀释率实现激光定制焊接薄铝硅涂层压硬钢接头的优异性能

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.065

S. Guo , Z.Q. Jin , Y.Q. Liu , F.R. Wang , Y.Q. Wang , Z.X. Li , H.L. Yi , G.M. Xie

{"title":"Achieving excellent properties of laser tailor-welded thin Al-Si coated press-hardened steel joint via controlling dilution rate","authors":"S. Guo , Z.Q. Jin , Y.Q. Liu , F.R. Wang , Y.Q. Wang , Z.X. Li , H.L. Yi , G.M. Xie","doi":"10.1016/j.jmapro.2024.09.065","DOIUrl":"10.1016/j.jmapro.2024.09.065","url":null,"abstract":"<div><div>In laser tailor welded traditional 25 μm thick Al-Si coated press-hardened steel (PHS), a lot of ferrite was easily formed in the weld, so filling with expensive high-alloys wire is usually necessary. In this work, a new thin Al-Si coated PHS with 18 μm thickness was laser tailor welded, and a cheap low alloy wire was attempted to fill into the weld to via control the dilution rate. At a high dilution rate of 94%, the weld contained a ferrite fraction of 38%, resulting in the fracture occurring in the weld during tension and bending. At a medium dilution rate of 85%, the ferrite fraction in the weld decreased to 18%, obtaining excellent tensile and bending properties. The tensile strength and elongation of the joint reached 1528 MPa and 5.6%, respectively, with fracture being in the base metal (BM). The maximum bending load and displacement were 1291 N and 7.0 mm, respectively, and cracks initiated and propagated in the BM. This is attributed to the small amount of ferrite and stress concentration in the narrow weld. At a low dilution rate of 76%, the ferrite reduced to 6%, and the bending cracks initiated and propagated in the BM. However, the tensile specimen fractured in the weld, which should be related to the relatively low C concentration and the stress concentration at the weld toe due to the weld reinforcements.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 879-890"},"PeriodicalIF":6.1,"publicationDate":"2024-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142319375","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

Research on manufacturing technology of nanoimprinted grating 纳米压印光栅制造技术研究

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-25 DOI: 10.1016/j.jmapro.2024.09.033

Jiawei Zhang , Jirigalantu , Shuo Yu , Yilong Wang , Hongzhu Yu , Wenhao Li

引用次数: 0

Development of an adaptive smith controller for cutting torque control in a milling process 开发用于铣削过程中切削扭矩控制的自适应史密斯控制器

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-24 DOI: 10.1016/j.jmapro.2024.09.048

Mao-Qi Hong, Meng-Shiun Tsai

{"title":"Development of an adaptive smith controller for cutting torque control in a milling process","authors":"Mao-Qi Hong, Meng-Shiun Tsai","doi":"10.1016/j.jmapro.2024.09.048","DOIUrl":"10.1016/j.jmapro.2024.09.048","url":null,"abstract":"<div><div>Optimizing the feedrate to regulate cutting force or torque not only enhances machining efficiency but also protects machines against wear and tear. Generally, most of the studies simplified the dynamic model of machining process as a first or second-order transfer functions and the effects of the interpolator and communication dead-time delay of control signals were not included. Neglecting these factors could lead to system instability or oscillations when machining conditions change. In this paper, a comprehensive machining process model that integrates interpolation, servo drive system, cutting model, and communication dead-time delay is developed. To address varying dynamic behaviors under different machining conditions, such as different cutting depths, an adaptive Smith controller was developed. The proposed controller integrates an online parameter estimator and a Smith predictor. The estimated parameter reflected the cutting process dynamics, including the effects of tool wear and system uncertainties. The Smith predictor architecture was used to solve the communication dead-time delay problem, which was neglected in previous studies. The performance of the adaptive Smith controller was experimentally validated on a workpiece with three different cutting depths. Compared to a conventional proportional-integral controller or a Smith predictor, the adaptive Smith controller could adjust the feedrate to maintain a constant torque with less oscillations. The proposed control architecture reduced machining time by 10.5 % compared to an uncontrolled case.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 815-826"},"PeriodicalIF":6.1,"publicationDate":"2024-09-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142314646","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

Influence of tool wear on geometric surface modeling for TC4 titanium alloy milling 刀具磨损对 TC4 钛合金铣削几何表面建模的影响

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-24 DOI: 10.1016/j.jmapro.2024.09.070

Xinyang Jiang , Jinfu Ding , Chengwu Wang , Ling Hong , Weifeng Yao , Wei Yu

{"title":"Influence of tool wear on geometric surface modeling for TC4 titanium alloy milling","authors":"Xinyang Jiang , Jinfu Ding , Chengwu Wang , Ling Hong , Weifeng Yao , Wei Yu","doi":"10.1016/j.jmapro.2024.09.070","DOIUrl":"10.1016/j.jmapro.2024.09.070","url":null,"abstract":"<div><div>Addressing the insufficient accuracy of milling surface roughness prediction model, the formation causes of different roughness were analyzed, and a surface roughness prediction model which takes tool wear into account was established based on an improved <em>Z</em>-MAP algorithm. Combining tool geometry and tool wear morphology, a mathematical model of surface profile was built; And the motion trajectory equations of the milling cutter teeth were established via machining kinematics. The servo rectangular encirclement and Newton iterative method were adopted to improve the <em>Z</em>-MAP algorithm. Combining the Z-MAP algorithm with the insert motion trajectory equations, the values at different height coordinates of the workpiece grid nodes were obtained, allowing numerical simulation of workpiece surface geometry and analysis of the effect of cutting trajectory overlap on the machined surface morphology. TC4 titanium alloy milling experiment was conducted to validate the simulation model. The simulated surface roughness <em>Sa</em> exhibited significant deviation from experimental values before tool wear, with a maximum error of 53.08 %. Nevertheless, the simulated values of <em>Sa</em> were closer to experimental values after tool wear, with a maximum error of 15.45 % and a minimum of only 3.07 %. Additionally, the predicted results for the bearing length ratio <em>Rmr</em>(c) were consistent with experimental values. The mathematical model for surface roughness taking tool wear into account effectively predicted the shape profile and surface roughness of the machined surface, providing theoretical guidance and technical support for practical production.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 797-814"},"PeriodicalIF":6.1,"publicationDate":"2024-09-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142314645","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

Topography prediction at boundaries between sub-regions in the 5-axis milling of Plexiglas based on dimension reduction method 基于尺寸缩减法的有机玻璃五轴铣削中子区域边界的形貌预测

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-24 DOI: 10.1016/j.jmapro.2024.09.071

Qiang Guo , Zonglin Liu , Yan Jiang , Yuwen Sun , Zi Yang , Wenbo Wang , Weisen Zhao , Cletus Okoye

{"title":"Topography prediction at boundaries between sub-regions in the 5-axis milling of Plexiglas based on dimension reduction method","authors":"Qiang Guo , Zonglin Liu , Yan Jiang , Yuwen Sun , Zi Yang , Wenbo Wang , Weisen Zhao , Cletus Okoye","doi":"10.1016/j.jmapro.2024.09.071","DOIUrl":"10.1016/j.jmapro.2024.09.071","url":null,"abstract":"<div><div>Sub-regional milling has become an important machining method in the production of free-form surface parts. However, due to complex tool paths, irregular surface topography can occur at the region boundaries, which in turn affects the performance of the part such as the light transmission, optical distortion and mechanical strength of non-metallic transparent material etc. It is vital for manufacturers and researchers to study the forming mechanism of topography at boundaries and then to control it to get the high quality of the machined surface. Therefore, this paper thoroughly investigates the formation of surface topography at the boundary of sub-regions in the five-axis machining process. First, the boundaries of sub-regions are classified. Simultaneously, swept surfaces of the cutting edge, taking into account the process parameters and tool path, are constructed. Then, the surface topography is calculated using an improved model based on dimension reduction theory. Furthermore, through simulation and experiments, the predicted surface topographies agree well with the measured ones. Finally, some conclusions are listed and the method in this paper can provide a reliable basis for manufacturing high-quality parts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 827-843"},"PeriodicalIF":6.1,"publicationDate":"2024-09-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142314647","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