Journal of Manufacturing Processes最新文献

{"title":"Spatiotemporal prediction and mechanisms of molten pool instability in variable polarity plasma arc robotic welding via CNN-LSTM","authors":"Fan Jiang ,&nbsp;Penglin Xiang ,&nbsp;Jingbo Liu ,&nbsp;Shujun Chen ,&nbsp;Shibo Li ,&nbsp;Lipeng Guo","doi":"10.1016/j.jmapro.2025.04.052","DOIUrl":"10.1016/j.jmapro.2025.04.052","url":null,"abstract":"<div><div>This study proposes a method for spatiotemporal prediction of molten pool states via an end-to-end CNN-LSTM model, addressing the dynamic and complex manufacturing scenarios under variable polarity plasma arc (VPPA) robotic welding. The model utilizes CNN to extract spatial features from molten pool images and employs LSTM to extract temporal features in image sequences of the molten pool. This enables early warning of transition from stability to instability of the molten pool states. Experimental results show that when predicting molten pool states at a 1.5 s prediction time using a 0.5 s image sequence sample, the CNN-LSTM model achieves a prediction accuracy of 99.21 %, with a false negative rate of only 0.72 %. In real manufacturing scenarios, the model predicts molten pool that was not part of the training data, achieving a prediction accuracy of 90.61 %. The prediction accuracy was improved to 96.43 % by fine-tuning the model with data not included in the training process. Grad-CAM visualization analysis reveals that the CNN-LSTM model primarily focuses on the rear wall region of the molten pool during the prediction of molten pool states. Insufficient molten metal supply in this region is identified as the key cause of molten pool instability. The proposed model demonstrates well performance in prediction accuracy, false negative rate, and applicability. It provides a robust method for enhancing the intelligence and reliability of VPPA robotic welding processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 116-132"},"PeriodicalIF":6.1,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859948","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":"High-quality machining of thin copper plate based on error proofing method","authors":"Di Wu","doi":"10.1016/j.jmapro.2025.04.061","DOIUrl":"10.1016/j.jmapro.2025.04.061","url":null,"abstract":"<div><div>The response characteristics of target materials under dynamic compression have been a focused topic in the fields of shock wave physics and explosion dynamics. Thin copper plate with high-quality surface is frequently applied as flyer in detonation or plate impact experiments to study these characteristics. Nevertheless, existing mechanical machining method is hard to achieve high-quality surface for copper flyer due to ductile property and residual stress. To settle this problem, a technology based on error proofing is proposed to realize thinning, surface shape error control and improving surface quality in turn. Firstly, an isopotential control method is proposed in electrochemical lapping process to suppress stray current corrosion, which lays the foundation for high-efficiency low-stress thinning with <em>MRR</em> = 1 μm /min. Secondly, a chemical mechanical lapping method considering pressure and speed distribution is applied to control surface shape error deterministically with acceptable roughness <em>S</em>_a ≤ 350 nm (measure size: 0.36 mm × 0.27 mm). Then electrochemical mechanical polishing at low pressure (<em>P</em> = 0.27 psi) is applied to obtain surface roughness of <em>S</em>_a ≤ 5 nm with maintained flatness. Finally, a high-quality machining technology for thin copper plate is developed. By the low-stress machining method, copper plate (Φ100 mm × 3 mm) achieves flatness of PV 2 μm and moderate roughness <em>S</em>_a 4.2 nm.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 172-189"},"PeriodicalIF":6.1,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143863430","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of anisotropic property on machining response of selective laser melted Ti6Al4V alloys in high-speed milling","authors":"Dejian Liu ,&nbsp;Chenbing Ni ,&nbsp;Youqiang Wang ,&nbsp;Lida Zhu ,&nbsp;Wei Lu ,&nbsp;Xingbao Huang","doi":"10.1016/j.jmapro.2025.04.066","DOIUrl":"10.1016/j.jmapro.2025.04.066","url":null,"abstract":"<div><div>Selective laser melted (SLMed) technology provides an advanced manufacturing method for many complicated and sophisticated components due to the advantage of near-net shape and high-efficiency. However, post-machining SLMed parts is greatly essential for obtaining high-quality surface due to their poor surface integrity. This paper studies the effect of anisotropic property on machining response of SLMed Ti6Al4V alloy fabricated by three laser scanning strategies (0°, 67.5° and 90°). Especially, the effects of needle-like martensitics α′ and melt-pool boundary are considered in this study. High-speed milling experiments are conducted on the top and front surfaces of samples for studying the relationship among anisotropic microstructure, mechanical property and machinability. The cutting force, surface and chip characteristic are applied to evaluate the anisotropy of machinability. The results show that the cutting forces of top surface are larger than those of front surface, which leads to higher surface quality and lower surface roughness of front surface. This can be associated with the distinct melt-pool boundary of similar block grain boundary (top surface) and columnar grain boundary (front surface). The laser scanning strategy changes the distribution of needle-like martensitics α′ and further influences the evolution of microstructure, mechanical property and machinability. The surface formation experiences a coordinated deformed process of melt-pool boundary, plastic flow, grain distortion, dislocation accumulation and entanglement induced by complex thermo-mechanical coupled effect. This paper systematically revealed the underlying mechanism of the surface integrity during milling SLMed Ti6Al4V alloy with different laser scanning strategy and machined surface. The researched results can provide in-depth insights for improving the surface quality and performance of additive manufactured (AMed) parts by post machining technology.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 158-171"},"PeriodicalIF":6.1,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143863433","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":"Particle-on-demand electrohydrodynamic printing from a reciprocating tip","authors":"Ji-hun Jeong ,&nbsp;Seong Jae Kim ,&nbsp;Sanha Kim ,&nbsp;A. John Hart","doi":"10.1016/j.jmapro.2025.04.011","DOIUrl":"10.1016/j.jmapro.2025.04.011","url":null,"abstract":"<div><div>While inkjet printing has revolutionized manufacturing of graphics and decorations, flexible electronics, and has enabled new additive manufacturing (AM) technologies, direct micro-scale deposition of metals remains challenging. Here, we present a particle-on-demand electrohydrodynamic printing approach, using a reciprocating tip mechanism that enables particles to be fed and ejected individually from an oil-coated membrane, and then printed to a target substrate. We examine the mechanism of printing using high-speed imaging and study the limiting mechanisms via controlled experiments with a range of particle sizes and materials, and then extract representative scaling laws for the ejection behavior. Based on this understanding, we demonstrate printing of two-dimensional patterns of stainless steel microparticles over a wide size range (50–700 μm particle diameter). With envisioned improvements to the tip geometry and particle-fluid interaction, and via parallelization, this particle-on-demand approach would be a versatile addition to high-resolution printing technologies for metals, including for manufacturing of intricate miniature components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 133-141"},"PeriodicalIF":6.1,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859750","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":"Efficient fabrication of low-damage, high-quality diamond microgrooves with high adhesion graphite-graphene layers on their surfaces using LIPAA technology","authors":"Zhuo Li ,&nbsp;Keyi Zhu ,&nbsp;Shajiu Le ,&nbsp;Ahmed Mohamed Mahmoud Ibrahim ,&nbsp;Baodong Wang ,&nbsp;Yangjian Chen ,&nbsp;Haoyu Su","doi":"10.1016/j.jmapro.2025.04.002","DOIUrl":"10.1016/j.jmapro.2025.04.002","url":null,"abstract":"<div><div>The fabrication of highly adhesive graphene layers on the surface of diamond microstructures can greatly promote the application of diamonds in high-performance sensors and ultra-precision manufacturing. However, this technology remains a significant challenge and is difficult to achieve efficient preparation. To overcome this challenge, the effect of target-substrate distance on microgroove morphology and material removal rate was investigated by ablating single crystal diamond using laser-induced plasma-assisted ablation (LIPAA) technology. Through precise target-substrate distance tuning, the efficient fabrication of low-damage, high-quality diamond microgrooves with high adhesion graphite-graphene layers on their surfaces has been achieved. The graphitization evolution on the surface of diamond microgrooves was detected using Raman and TEM, and the formation mechanism of graphite layer and graphene structure on the microgroove surface was analyzed by combining molecular dynamics (MD) simulation. An optimal target-substrate distance range was established for the efficient processing of diamond microgrooves with graphene attached to the surface through process optimization. These results offer valuable insights for advancing the application of single-crystal diamonds in sensor and semiconductor technologies.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 71-84"},"PeriodicalIF":6.1,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143854510","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":"Hybrid manufacturing of a 3D-shaped fiber metal laminate","authors":"Matthias Merzkirch ,&nbsp;Erwan Juin ,&nbsp;Jesper Eman ,&nbsp;Jocke Pettersson ,&nbsp;Magdalena Juntikka ,&nbsp;Fredrik Ahlqvist ,&nbsp;Olof Säfvenberg","doi":"10.1016/j.jmapro.2025.04.031","DOIUrl":"10.1016/j.jmapro.2025.04.031","url":null,"abstract":"<div><div>This contribution presents a methodology for designing, manufacturing, and testing of a multi-material solution demonstrator of a lower control arm for electric vehicle (EV) chassis made of a three-dimensional Fiber reinforced polymer-Metal Laminate (FML). The Integrated Computational Materials Engineering (ICME) approach includes simulation methodology for process modeling, i.e. forming and draping, and part performance with the aim to reduce the developing time and related trial and errors.</div><div>The challenges, besides a limited availability of resources and material input data for numerical models, include the combination of different forming methods for Glass Fiber Reinforced Polymers (GFRP) and sheet metals (aluminum alloy) with the aim of simultaneous forming of both materials. Especially the sheet metal forming needed several improvement steps regarding heat treatment state to increase the ductility and reduce crack propagation, as well as optimization of the shape of the blanks to be formed into an asymmetric, three-dimensional geometry. Assembly includes adhesive bonding of the flat FML to the curved structure, and adapters for the testing to be performed. The quasi-static misuse testing is in good agreement to the results obtained from the simulated structural performance, with the weakest location being the adhesive bond line. An outlook on potential improvements regarding process simulation for manufacturing Fiber Metal Laminates, including necessary input data, is provided.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 85-98"},"PeriodicalIF":6.1,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859947","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":"Advancing the machinability and tribological characteristics of AISI 9310 steel using a novel ultrasonic vibration-assisted MQL approach","authors":"Syed Hammad Ali ,&nbsp;Minxiu Zhang ,&nbsp;Guoliang Liu ,&nbsp;Biao Zhao ,&nbsp;Wenfeng Ding ,&nbsp;Muhammad Jamil ,&nbsp;Makesh Mohan ,&nbsp;Hussain Waris ,&nbsp;Ahmar Khan ,&nbsp;Sadam Hussain","doi":"10.1016/j.jmapro.2025.04.022","DOIUrl":"10.1016/j.jmapro.2025.04.022","url":null,"abstract":"<div><div>High production machining of low alloyed hardened steel AISI 9310 generates elevated cutting temperatures due to material's hardness and toughness causing dimensional deviations, premature failure of cutting tools, material softening, poor surface finish, rapid oxidation, and corrosion. This study proposes the implementation of an indigenously developed cooling and lubrication approach named ultrasonic atomization-based minimum quantity lubrication (UMQL) technique using eco-benign sunflower oil as a lubricant during finish milling, to control the cutting heat and to improve the machinability. To assess machinability of the AISI 9310 steel under UMQL, milling tests are carried out at varying machining parameters such as cutting speed, feed per tooth and radial depth of cut and each with three levels, and varied as a single-factor variable, and results were compared to dry and conventional MQL cutting. Subsequently, UMQL effectiveness is evaluated in terms of cutting forces, temperature, surface integrity (average surface roughness, 3D surface topography and surface texture) and chip morphology. The experimental results indicated that UMQL exhibited 18 %, 48 %, and 50 % reduction in milling forces, temperature and surface roughness compared to dry and MQL, respectively. Furthermore, in terms of topography and surface texture, UMQL produced relatively less peaks and valleys with more uniform surface features showcasing better heat and friction management at the machining zone due to its superior cooling, lubrication and chip flushing characteristics. Finally, the chip formation was studied in different environments, and UMQL showed the least number of friction tracks with uniform folds and minimal serration. Overall, the results indicated that UMQL provided the best performance regarding machinability, by forming a stable tribo-film with droplets effectively penetrating the cutting zone. Lastly from this study, the manufacturing industry will gain valuable insights into how certain cutting processing parameters and efficient lubrication will impact the mechanical behaviour in machining AISI 9310 parts and will offer a valuable resource for engineers and researchers to enhance machining processes while reducing environmental impact and operational expenses.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 99-115"},"PeriodicalIF":6.1,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859949","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel tool design for magnetic pulse welding of sheet metal using compression coil","authors":"Khushwant Singh Gavel ,&nbsp;Meraj Ahmed ,&nbsp;Ayisha Ali ,&nbsp;Hari Narayan Bhargaw ,&nbsp;Sanjay Kumar Panthi ,&nbsp;Amit Bhargav","doi":"10.1016/j.jmapro.2025.03.111","DOIUrl":"10.1016/j.jmapro.2025.03.111","url":null,"abstract":"<div><div>The Magnetic Pulse Welding (MPW) process is becoming more popular due to its advantages over conventional joining. Although sheet metal joining using MPW is reported, but not as extensively as circular geometry joining. Generally, a single or double-sided H-type coil is used for sheet metal joining using MPW. Relatively poor workability and low durability of such coils raise the need for further innovation in the design of tools. The present study proposes a novel concept of using a compression coil of bitter type with a conceptually designed field shaper to join sheet metal using MPW. Further, this study aims to demonstrate sheet metal joining using the proposed tooling and investigate the weld quality through mechanical pull-out tests and metallurgical analysis (SEM and fractography) of joint samples. The sheet metal samples are successfully joined, and an estimation of energy requirements for the joining is evaluated. Finite element analysis has also been carried out to analyze the variation of process parameters like magnetic field, Lorentz force, stress, velocity, etc., on tools and workpieces. The findings of the same are correlated with experimental results.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 261-277"},"PeriodicalIF":6.1,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143855959","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A review on modeling strategies in understanding the process mechanism of 3D printed continuous fiber-reinforced thermoplastic composites","authors":"Shenru Wang ,&nbsp;Xin Yan ,&nbsp;Baoning Chang ,&nbsp;Jiae Zhang ,&nbsp;Siqin Liu ,&nbsp;Fei Liu ,&nbsp;Junfan Shang ,&nbsp;Li-Hua Shao ,&nbsp;Sha Yin ,&nbsp;Wuxiang Zhang ,&nbsp;Yingdan Zhu ,&nbsp;Xilun Ding","doi":"10.1016/j.jmapro.2025.04.014","DOIUrl":"10.1016/j.jmapro.2025.04.014","url":null,"abstract":"<div><div>Continuous fiber 3D printing (CF3DP) has emerged as a promising technique that deposits continuous fiber alongside resin, offering numerous functional and intelligent applications. CF3DP involves rapid heating and cooling of materials, characterized by multiscale and multiphase nature, which complicates the understanding of the underlying process mechanisms. This difficulty hinders the prediction and control of the manufacturing defects and may lead to the compromise of mechanical properties. Although significant efforts have been made in process modeling to establish the relationship between process parameters and manufacturing performance, a systematic review of these studies remains absent. In this work, we attempted to provide an overview of the modeling strategies in understanding the process mechanism of CF3DP. The various physical phenomena involved in the CF3DP process are systematically analyzed and the corresponding modeling studies are summarized. Then, special attention is devoted to exploring how multiscale modeling approaches can establish a relational framework between the CF3DP process and the prediction of mechanical properties. This article also discusses the modeling strategies of failure behaviors considering the manufacturing defects. Finally, this paper discusses emerging applications of CF3DP and highlights the critical role of process modeling in driving future advancements. With the discussion of the process modeling strategies in CF3DP, researchers can identify appropriate methods tailored to their specific interests while gaining deeper insights into the underlying process mechanism.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 46-70"},"PeriodicalIF":6.1,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143854364","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":"Creep performance and microstructure of grade 91 steel weldments with integrated welding and thermal processing","authors":"Daniel Codd ,&nbsp;Joseph McCrink ,&nbsp;Timothy Lach ,&nbsp;Xiang (Frank) Chen","doi":"10.1016/j.jmapro.2025.04.049","DOIUrl":"10.1016/j.jmapro.2025.04.049","url":null,"abstract":"<div><div>Ferritic-Martensitic steel welds typically require post weld heat treatment (PWHT) to restore toughness and high temperature performance. This off-line thermal process reduces disparities between weld and base metal, but can cause distortion, cracking, or simply be impractical due to assembly size and joint non-uniformity. Here we show integrated welding and thermal processing applied to modified 9Cr-1Mo (Grade 91) steel, favored for advanced power generation applications, performed in real time through the addition of a secondary heat source near the primary weld head. Optimal integrated processing reduces weld fusion and heat affected zone hardness by 125 HV, approaching performance of conventional 730 °C, 60 min PWHT processing. Microstructures and mechanical performance are compared for mechanized GTAW welds, with equivalent lifetimes noted in cross-weld creep rupture tests up to 234 MPa at 550 °C, and up to 104 MPa at 650 °C. The integrated process was validated on a Grade 91 pressure vessel with multipass cold wire feed GTAW. After 550 °C, 71.4 bar thermomechanical cyclic testing, the maximum weld hardness is &lt;350 HV.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 34-45"},"PeriodicalIF":6.1,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143852302","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}