Journal of Manufacturing Processes最新文献_第10页

A generalized parametric model for the bonding occurrence prediction in friction stir consolidation of aluminum alloys chips 用于预测铝合金切屑摩擦搅拌固结中粘结发生率的通用参数模型

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-19 DOI: 10.1016/j.jmapro.2024.09.049

{"title":"A generalized parametric model for the bonding occurrence prediction in friction stir consolidation of aluminum alloys chips","authors":"","doi":"10.1016/j.jmapro.2024.09.049","DOIUrl":"10.1016/j.jmapro.2024.09.049","url":null,"abstract":"<div><p>Over the last years solid state processing has been applied as an environmentally friendly recycling method for metal scrap. These approaches, by skipping the melting step, allow substantial energy and resource savings with respect to conventional remelting routes. Specifically, several processes relying on solid bonding phenomenon have been applied to recycle aluminum alloys chips. In this paper, the Friction Stir Consolidation recycling process is considered as solid-state recycling approach to turn chips of three different aluminum alloys namely AA2024, AA6082 and AA5083, into consolidated billet. The paper aims both at validating a new solid bonding criteria specifically designed for Friction Stir Consolidation as well as at proposing a general model to characterize the bonding criterion for each single considered material. In this regard, a correlation analysis and a new parametric model has been developed aiming to understand which material properties were involved in solid bonding occurrence and to predict the bonding limit curve vs temperature by means of material thermo-mechanical properties. The identified criterion and parametric model have been validated by implementing these on the bonding prediction occurrence in Friction Stir Consolidation of AA5083 aluminum chips. Results revealed that just on the basis of some mechanical and thermal properties of the material to be recycled it is possible to identify the threshold for the actual bonding of the material at different temperature levels and, therefore, properly design the recycling process by means of numerical simulation implementation.</p></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-09-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1526612524009666/pdfft?md5=23e0f2f27a5f4f8b00b906adbe18a69c&pid=1-s2.0-S1526612524009666-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142270923","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Adaptive threshold discrimination and synchronous squeezing transform for high-speed milling chatter detection 用于高速铣削颤振检测的自适应阈值判别和同步挤压变换

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-19 DOI: 10.1016/j.jmapro.2024.09.030

{"title":"Adaptive threshold discrimination and synchronous squeezing transform for high-speed milling chatter detection","authors":"","doi":"10.1016/j.jmapro.2024.09.030","DOIUrl":"10.1016/j.jmapro.2024.09.030","url":null,"abstract":"<div><p>The term “chatter” in the manufacturing process refers to the self-excited vibrations that arise during machining operations, which include drilling, turning, and milling. These vibrations can lead to several negative outcomes, such as low surface quality, shorter tool lifespans, and even possible machinery damage. In order to address these issues, this paper presents a novel technique called Adaptive Threshold Discrimination and Synchronous Squeezing Transform (ATD-SST). Adaptive thresholding and synchronous squeezing are innovatively combined in the ATD-SST technique to improve chatter detection and characterization, particularly in noisy and non-stationary conditions. The adaptive threshold discrimination components dynamically adjust threshold values to enhance signal discrimination, while the synchronous squeezing transform components synchronise the signal processing to maintain consistency throughout the dataset. It was discovered through a comparison between acceleration and sound signals that acceleration signals produced better chatter detection results. To efficiently identify chatter, eight different indicators were established. The proposed method yielded early detection durations of 0.46 s, 0.31 s, and 0.52 s for varying machining conditions (speeds, cutting widths, and feed rates per tooth), respectively. The experiment results validate the method's effectiveness and highlight its potential to identify chatter promptly, thereby lowering the risk of workpiece damage while improving product quality.</p></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-09-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142270801","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

Experimental investigation of edge preparation for cemented carbide profile cutting tools using flexible abrasive jet polishing 利用柔性磨料喷射抛光制备硬质合金成型刀具边缘的实验研究

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-18 DOI: 10.1016/j.jmapro.2024.09.032

引用次数: 0

Standoff-free vaporizing foil actuator welding: Process principle, experimental validation, and mechanisms analysis 无间隙蒸发箔致动器焊接：工艺原理、实验验证和机理分析

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-18 DOI: 10.1016/j.jmapro.2024.09.051

{"title":"Standoff-free vaporizing foil actuator welding: Process principle, experimental validation, and mechanisms analysis","authors":"","doi":"10.1016/j.jmapro.2024.09.051","DOIUrl":"10.1016/j.jmapro.2024.09.051","url":null,"abstract":"<div><p>This paper introduces a novel high-velocity impact welding process: the standoff-free vaporizing foil actuator welding (standoff-free VFAW). This technique employs a new type of driving mechanism, overcoming the geometric placement constraints between the flyer plate and the target plate inherent in conventional impact welding processes. It enables welding without requiring an initial standoff distance between the two plates. The feasibility and general applicability of the proposed process were validated through experiments. The welding performance was evaluated using shear tests, peel tests, and microstructural analysis. The results indicate that the proposed process can successfully weld T2 copper to 304 stainless steel and AA5083-H112 to 304 stainless steel. Additionally, this study verified that the proposed process can achieve progressive welding, making it possible to utilize standoff-free VFAW for large-area metal welding. Furthermore, microanalysis revealed the presence of a typical wavy interface characteristic at the joint. Key parameters influencing the welding results were also explored through experiments and finite element modeling, which suggest that the boundary constraints of the workpiece play a key role in the success of standoff-free VFAW. This implies that the initiation of the small and dynamic gap between the flyer and target plates could be the potential mechanism for the proposed process. In summary, standoff-free VFAW presents simplicity and efficiency as its advantages. Moreover, the insights gained from this technique are not limited solely to vaporizing foil actuator welding (VFAW) but could also provide reference points for other high-velocity impact welding techniques.</p></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142239268","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

Restraint of intermetallic compound and improvement of mechanical performance of Ti/Al dissimilar alloy by rotary friction welding based on laser powder bed fusion 基于激光粉末床熔化的旋转摩擦焊抑制金属间化合物并改善钛/铝异种合金的机械性能

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-18 DOI: 10.1016/j.jmapro.2024.09.021

{"title":"Restraint of intermetallic compound and improvement of mechanical performance of Ti/Al dissimilar alloy by rotary friction welding based on laser powder bed fusion","authors":"","doi":"10.1016/j.jmapro.2024.09.021","DOIUrl":"10.1016/j.jmapro.2024.09.021","url":null,"abstract":"<div><p>Due to titanium and aluminum alloys having the characteristics of low mass density and high specific strength, the welding of both has a unique advantage in the aerospace field. However, traditional friction welding is mainly used for casting and forging materials, and there are few studies on friction welding between Ti and Al alloys fabricated by laser powder bed fusion (L-PBF). Because L-PBF is a kind of rapid solidification methods, the microstructure evolution in rotary friction welding joints should be further studied. In this study, L-PBF was used to prepare Ti6Al4V and AlSi10Mg samples, and rotary friction welding (RFW) was used to prepare rod-shaped welding samples. OM, SEM, and XRD were employed to study the morphology and microstructure of the welding interface, and EDS was used to study the intermetallic compounds (IMCs) of the welding interface. Finally, the microhardness and other mechanical performance of the solder joints were investigated, and the optimal process parameters were obtained. The results showed that the interface grain size of the welded sample prepared by L-PBF and RFW is small, and the IMC produced is TiAl and TiAl<sub>3</sub>. It is found that the diffusion of Al-Ti elements is hindered by Si enrichment. When the ratio between friction to forging force of welded specimens was less than 2, the maximum tensile strength could reach 278 MPa, a 50 % improvement over using RFW directly. Moreover, SEM and EDS characterization results showed that the fracture mode of the welded end face was a typical brittle fracture, and the IMC was significantly reduced. This is because the formation of the Si particle networks at the interface inhibits the mutual diffusion of Ti and Al, and the microhardness increases. Therefore, in this research, L-PBF and RFW are combined to produce Ti-Al alloy with high mechanical performance, which provides a feasible strategy for welding dissimilar materials.</p></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142240157","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

Precision micro-particle removal from through-holes via laser-induced plasma shockwaves in additive manufacturing 在增材制造中通过激光诱导等离子体冲击波精确去除通孔中的微颗粒

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-18 DOI: 10.1016/j.jmapro.2024.09.046

{"title":"Precision micro-particle removal from through-holes via laser-induced plasma shockwaves in additive manufacturing","authors":"","doi":"10.1016/j.jmapro.2024.09.046","DOIUrl":"10.1016/j.jmapro.2024.09.046","url":null,"abstract":"<div><p>This study introduces a novel Laser-Induced Plasma (LIP) technique for the non-contact, rapid removal of nano and microparticles from through-holes in Additive Manufacturing (AM) components. This method is crucial for high-value applications, such as medical devices, compact heat exchangers, and aerospace engineering, which require efficient cleaning of intricate parts with holes and channels to address high failure costs. The technique leverages shockwaves generated by LIP to target and clean these complex geometries. The research focuses on two main areas: (i) characterizing the effects of shockwaves in semi-cylindrical channels to understand interactions with complex geometries, and (ii) quantitatively analyzing the removal of Fe-271 microparticles from semi-cylindrical channels of silicon (Si) wafers, selected for their consistent surface properties compared to the rough textures of AM-produced surfaces. Utilizing the experimental set-up Laser-Induced Plasma LIP Cleaning for Additive Manufacturing (LIPCAM), the study demonstrates that complete microparticle removal is achievable up to 20 mm from the plasma source with variable laser pulses. The results indicate that particles larger than 27 μm are entirely removed after a single pulse, and particles larger than 21 μm are removed after 50 pulses. These findings highlight the method's effectiveness in achieving high particle removal efficiency across different distances and particle sizes, thus ensuring thorough decontamination of complex internal structures. The study underscores the potential of this method to enhance the reliability and safety of critical AM builds, making it a viable solution for industries where precision and cleanliness are paramount.</p></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142239266","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

Control of hole rolling on 3D Servo Presses 三维伺服压力机的轧孔控制

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-18 DOI: 10.1016/j.jmapro.2024.09.015

引用次数: 0

Effect of continuous and discontinuous non-proportional loadings on formability of DX54 sheet material 连续和不连续非比例载荷对 DX54 板材成型性的影响

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-18 DOI: 10.1016/j.jmapro.2024.09.045

{"title":"Effect of continuous and discontinuous non-proportional loadings on formability of DX54 sheet material","authors":"","doi":"10.1016/j.jmapro.2024.09.045","DOIUrl":"10.1016/j.jmapro.2024.09.045","url":null,"abstract":"<div><p>Both continuous and discontinuous non-proportional loadings occur in multi-stage automotive stamping processes. Discontinuous loading is widely studied, but due to requiring sophisticated experimental procedures, continuous loading has been studied less. This study explores the impact of continuous loading on DX54 steel utilising an innovative experimental setup that enabled cruciform samples to undergo uniaxial to biaxial strain path change continuously without unloading. A similar two-stage discontinuous loading from uniaxial to biaxial with unloading in between was generated in DX54 to understand the differences in macro-strain, micro-strain, microstructure, and micro-texture evolution between the continuous and the discontinuous loadings. The stress state of the material during continuous loading was different to that during discontinuous loading. In this study, the occurrence of ‘pseudo-localisation’ was observed during continuous loading, and the observed rotation of high-strain bands differed between continuous and discontinuous loading. The discontinuous loading induced a higher strain, hardening rate, and increased elongation compared to the continuous loading. These results suggest the potential for higher formability during the discontinuous loading compared to the continuous loading.</p></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S1526612524009642/pdfft?md5=679899f5974904929fd189ede8498a79&pid=1-s2.0-S1526612524009642-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142239267","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

A novel process of chemical-mechanical fluid-solid coupling polishing with high-quality and high-efficiency for turbine blisk 用于涡轮机叶盘的优质高效化学机械流固耦合抛光新工艺

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-18 DOI: 10.1016/j.jmapro.2024.09.043

引用次数: 0

An investigation of ceramic shell thickness uniformity and its impact on precision in turbine blade investment casting 涡轮叶片熔模铸造中陶瓷壳厚度均匀性及其对精度影响的研究

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2024-09-18 DOI: 10.1016/j.jmapro.2024.09.006

{"title":"An investigation of ceramic shell thickness uniformity and its impact on precision in turbine blade investment casting","authors":"","doi":"10.1016/j.jmapro.2024.09.006","DOIUrl":"10.1016/j.jmapro.2024.09.006","url":null,"abstract":"<div><p>Investment casting plays a pivotal role in the fabrication of complex and precise components, notably turbine blades for aerospace and energy industries. During the casting process, the non-uniform shell thickness distribution affects the dimensional accuracy and surface quality, and further impact the performance and reliability of the products. This study delves into the effects of turbine blade casting system design, focusing on shell thickness uniformity and its correlation with casting dimensional accuracy. Through an experimental setup that manipulates wax pattern attitude angles and module diameters, coupled with the Industrial Computed Tomography (ICT) for non-destructive thickness measurement, this study uncovers the critical role of centrifugal effects during the slurry application in modulating shell thickness uniformity. Our findings reveal that strategic adjustments to the wax pattern attitude angle and module diameter can significantly enhance shell thickness uniformity, thereby potentially increasing the structural integrity and dimensional precision of turbine blades. In addition, a positive correlation between shell inhomogeneity and casting manufacturing deviation was found through casting profile inspection and correlation analysis. This research not only elucidates the relationship between manufacturing parameters and shell formation but also proposes practical adjustments to the casting system design, offering new pathways to refine investment casting processes for high-value components.</p></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":null,"pages":null},"PeriodicalIF":6.1,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142239270","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