Journal of Manufacturing Processes最新文献

{"title":"A high-throughput approach for statistical process optimization in Laser Powder Bed Fusion","authors":"Jiahui Ye ,&nbsp;John Coleman ,&nbsp;Gerald L. Knapp ,&nbsp;Amra Peles ,&nbsp;Chase Joslin ,&nbsp;Sarah Graham ,&nbsp;Alex Plotkowski ,&nbsp;Alaa Elwany","doi":"10.1016/j.jmapro.2025.04.079","DOIUrl":"10.1016/j.jmapro.2025.04.079","url":null,"abstract":"<div><div>Process variability is inherent in metal additive manufacturing (AM). However, it is often overlooked in process optimization frameworks, constraining the understanding of process uncertainties and their influence on parameter selection. To address this, we present an integrated framework that combines high-throughput single-track experiments, GAN-based melt pool geometry extraction, robust statistical and machine learning modeling, and uncertainty-quantified process mapping. Process variability is characterized through single-track melt pool behaviors, and its influence on defect formation is systematically quantified to enable statistically guided process parameter optimization. This approach is demonstrated on Laser Powder Bed Fusion (L-PBF) of stainless steel 316L, effectively capturing the interplay between process parameters, melt pool variability, and defect probability. By integrating uncertainty quantification into process optimization, this study provides a structured methodology for addressing variability challenges in AM quality control, ultimately contributing to enhanced manufacturing reliability.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 88-99"},"PeriodicalIF":6.1,"publicationDate":"2025-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143946802","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":"Optimization of overhang printing in ceramic binder jetting additive manufacturing","authors":"Wenchao Du,&nbsp;Tianchen Hu,&nbsp;Quinn MacKenzie ,&nbsp;Dileep Singh","doi":"10.1016/j.jmapro.2025.04.095","DOIUrl":"10.1016/j.jmapro.2025.04.095","url":null,"abstract":"<div><div>Cylindrical-shaped horizontally-hanging overhangs with different heights on a solid cubic body were printed via binder jetting additive manufacturing with sililcon carbide powder feedstock. Cracking on the overhang neck and sagging on the overhang body were observed both pre- and post-curing, especially on printed design with a smaller particle size of 10 μm. It was found that the width of cracking and depth of sagging were dependent on the height relative to the solid body in the powder bed, and elevated position of overhang with large volume of underneath loose powder led to increased extend of cracking and sagging. Overhang diameter and weight were varied, which were found with no apparent effects on its deformation extend. To mitigate cracking and sagging, contactless support was designed and tested, which could significantly improve the overhang stability and avoid any overhang deformations. Support gap and support distance were studied for their effects on support capability. The printing processes with and without contactless support were simulated by a finite element modeling approach to understand the stress distribution and evolution of the overhang structures, which revealed stress concentrations on the upper neck point of the designed overhang.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 100-111"},"PeriodicalIF":6.1,"publicationDate":"2025-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144069606","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 screening of rare large pit anomalies on polished surfaces using a minimalist sampling scheme","authors":"Sampson Canacoo ,&nbsp;Shashank Galla ,&nbsp;Yuhao Zhong ,&nbsp;Saikiran Chary Nalband ,&nbsp;Sean Michael Hayes ,&nbsp;Monika Biener ,&nbsp;Suhas Bhandarkar ,&nbsp;Satish T.S. Bukkapatnam","doi":"10.1016/j.jmapro.2025.03.115","DOIUrl":"10.1016/j.jmapro.2025.03.115","url":null,"abstract":"<div><div>Lawrence Livermore National Laboratory (LLNL) has made significant strides in generating clean energy through its inertial confinement fusion (ICF) experiments. These experiments rely on high-density carbon (HDC) coated shells to encapsulate the fusion fuel. The success of these experiments is heavily dependent on the surface quality of these shells, as even minor imperfections, such as deep pits, can negatively impact fusion yield. Ensuring the required smoothness involves an extensive surface-finishing process that spans approximately 20 stages, making it both time-intensive and resource-demanding. A critical challenge in this process is the need for high-resolution scans to detect rare deep pits, which can be costly and impractical if performed on every shell. This highlights the necessity of developing more efficient scanning methods to optimize time and cost without compromising accuracy. To address these challenges, we introduce a novel approach that employs the multivariate Dvoretzky–Kiefer–Wolfowitz (DKW) inequality to provide a probabilistic upper bound on the error in estimating pit distribution characteristics via a Kernel Density Estimator (KDE). This error bound enables efficient and reliable estimation of pit distribution characteristics at a specified statistical confidence level using a minimal number of surface scans. The integrated DKW-KDE approach was validated through surface-finishing experiments across two batches of HDC-coated shells, demonstrating consistent and robust performance across multiple stages of the surface-finishing experiments. The validation studies suggest that the integrated DKW-KDE approach achieves comparable accuracy in estimating the risk of deleterious large pits with six scans, thus conserving time and resources. Further evaluations show that performance remains consistent across batches and over multiple polishing stages. Based on these findings, one can leverage the minimal-scan insights to strategically improve the bottleneck inspection process, thus enhancing the productivity and quality of shell polishing and similar challenging manufacturing processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 80-87"},"PeriodicalIF":6.1,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143943246","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":"Microstructures and wear properties of directed energy deposited materials on substrates containing FCCZ structures","authors":"Kook Hwa Choi ,&nbsp;Jong-Rae Cho ,&nbsp;Do Sik Shim","doi":"10.1016/j.jmapro.2025.04.081","DOIUrl":"10.1016/j.jmapro.2025.04.081","url":null,"abstract":"<div><div>In this study, we investigated the effect of the internal lattice structure of a substrate on the heat transfer properties and deposited material during the directed energy deposition (DED) process. A substrate containing a face-centered cubic with <em>Z</em>-axis (FCCZ) structure was fabricated by powder bed fusion (PBF). We fabricated single-layered and double-layered lattice substrates according to the number of layers of the lattice structure, and employed DED to deposit heterogeneous materials on the substrate. Experimental results showed that the lattice substrate exhibited excellent thermal and cooling properties owing to its small volume and large surface area. In particular, the high heating rate of the double-layered lattice substrate increased the temperature near the melting pool on the substrate, thereby increasing the width and depth of the deposited beads. Conversely, fast cooling of the lattice substrate led to the formation of a dense microstructure with uniform cellular grains in the deposited material. Furthermore, it suppressed the formation of laves phases, resulting in an increase in the hardness of the deposited part on the lattice substrate compared to that of the solid substrate. The high surface hardness of the deposited part on the lattice substrate minimized the deformation of wear tracks and reduced wear loss. Therefore, the results obtained in this study reveal that the quality and mechanical properties of materials deposited by DED can be controlled through the structure of the substrate.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 70-79"},"PeriodicalIF":6.1,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143936285","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Analysis and experimental study on the contact characteristics of spherical roller ring groove lapping based on finite line contact theory","authors":"Gao Qian ,&nbsp;Su Yongxiang ,&nbsp;Chen Guang ,&nbsp;Sun Yongquan ,&nbsp;Wei Changxu ,&nbsp;Wang Hongtao ,&nbsp;Ren Chengzu","doi":"10.1016/j.jmapro.2025.04.097","DOIUrl":"10.1016/j.jmapro.2025.04.097","url":null,"abstract":"<div><div>Analyzing the contact characteristics of spherical rollers during lapping is crucial for understanding the formation mechanism of their rolling surfaces in ring groove lapping processes. Based on the contact line characteristics between spherical rollers and lapping tools in ring-shaped straight groove machining, this paper uses finite-length contact theory based on the influence coefficient method to solve the contact stress distribution between spherical rollers and lapping surfaces. The accuracy of the solution is verified through finite element simulations. This paper analyzes the contact stress distribution under load between spherical rollers and lapping surfaces of various sizes, and discusses the influence of load and roller size on contact characteristics. Spherical roller ring-and-slot lapping experiments were conducted, and the rationality and accuracy of the contact model were verified by analyzing the experimental results of surface morphology and roundness changes. Research shows that the contact area between the roller rolling surface and the linear groove working surface forms a “saddle surface,” while the contact area with the circular groove forms a “cross-shaped” surface, with significant stress concentration at the roller ends. Increasing load results in proportional growth of contact area and deformation. Both the cross-sectional and axial cross-sectional radii of spherical rollers directly govern contact stress distribution. Regions with elevated contact stress during grinding exhibit accentuated wear, accompanied by intensified roundness variations and diameter deviations. This contact theory model can serve as a theoretical basis for analyzing the accuracy evolution of bearing rollers in ring-and-slot lapping processes and predicting wear on lapping tool surfaces.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 49-69"},"PeriodicalIF":6.1,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143936829","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"MULTI-3: A GPU-enhanced meshfree simulation framework for multi-track, multi-layer, and multi-material laser powder bed fusion processes","authors":"C. Lüthi,&nbsp;M. Bambach,&nbsp;M. Afrasiabi","doi":"10.1016/j.jmapro.2025.04.087","DOIUrl":"10.1016/j.jmapro.2025.04.087","url":null,"abstract":"<div><div>Multi-material laser powder bed fusion (MM-LPBF), especially with materials of contrasting properties, presents both exciting potential and significant challenges in additive manufacturing. Detailed modeling is essential for further development of these processes due to the difficulty of in-situ monitoring and control of inter-material interfaces, given the small spatiotemporal scales involved. To address this need, we present MULTI-3, a high-fidelity, GPU-accelerated computational framework designed to simulate MM-LPBF processes, including multiple tracks, layers, and materials. MULTI-3 combines a hybrid meshfree approach, leveraging a modified discrete element method (DEM) for efficient powder application and a stabilized smoothed particle hydrodynamics (SPH) technique to capture melt pool dynamics. The framework’s GPU-accelerated runtime enables the completion of a single-track LPBF simulation with modest resolution in about 29 min using a single consumer-grade graphics card. We demonstrate MULTI-3’s capabilities through a series of LPBF simulations with 316L and CuCr1Zr, employing varied deposition patterns and geometries to analyze melt pool behavior and morphology across different processing conditions. Results from these numerical experiments indicate that: (1) the SPH-DEM approach effectively addresses material mixing and interface challenges in MM-LPBF, primarily due to its Lagrangian formulation; (2) diffusion effects on interfacial material concentration remain negligible at the powder scale within the millimeter range of processing; and (3) high-fidelity, meshfree simulations of MM-LPBF processes involving multiple tracks and layers are currently achievable only through parallel computing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 29-48"},"PeriodicalIF":6.1,"publicationDate":"2025-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143936903","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 framework for advancing machine vision in wire arc directed energy deposition manufacturing system","authors":"Fengyang He ,&nbsp;Lei Yuan ,&nbsp;Haochen Mu ,&nbsp;Junle Yang ,&nbsp;Donghong Ding ,&nbsp;Huijun Li ,&nbsp;Zengxi Pan","doi":"10.1016/j.jmapro.2025.05.005","DOIUrl":"10.1016/j.jmapro.2025.05.005","url":null,"abstract":"<div><div>Deep learning-driven machine vision technologies are revolutionizing numerous industries, including metal additive manufacturing (AM). Wire arc directed energy deposition (WA-DED), a key branch of metal AM, has increasingly adopted these technologies to enhance process monitoring and defect detection. However, the development of accurate and reliable deep learning models for WA-DED machine vision applications is challenged by the extensive manual effort required for labelling large image datasets, which becomes even more labour-intensive when changes in deposition processes or metal feedstock necessitate new model training. To address this challenge and promote machine vision application in metal AM industries, this study proposes a novel framework that integrates a semi-automatic labelling method based on unsupervised learning (UL) techniques to improve model training efficiency while maintaining high accuracy. The framework comprises a semi-automatic labelling module, which leverages t-SNE for efficient dataset annotation, and a classifier construction module, which utilizes a ResNet-based architecture for image classification. The effectiveness of the proposed framework is validated through classification accuracy and efficiency assessments, achieving 94.65 % accuracy across nine molten pool image categories, along with a 94.3 % improvement in data labelling efficiency and 30.5 % improvement in the entire classifier construction efficiency. Additionally, the classifier is further evaluated through defect detection in a real-world WA-DED road barrier part. The detection results demonstrate that the types and locations of multiple observable defects, as well as a variety of other subtle defects, have been accurately identified. Overall, these outcomes confirm the effectiveness of the proposed framework in promoting machine vision applications in WA-DED manufacturing systems.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 1-15"},"PeriodicalIF":6.1,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143931345","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":"On mechanism of tool-workpiece separation in multi-dimensional vibration-assisted milling","authors":"Bowen Song ,&nbsp;Dawei Zhang ,&nbsp;Xiubing Jing ,&nbsp;Fujun Wang ,&nbsp;Yun Chen ,&nbsp;Huaizhong Li","doi":"10.1016/j.jmapro.2025.05.008","DOIUrl":"10.1016/j.jmapro.2025.05.008","url":null,"abstract":"<div><div>As an innovative manufacturing technique, vibration-assisted milling (VAMILL) can enhance machining performance like improving cutting efficiency, surface quality, and tool life through controlling tool-workpiece separation. Available analyses on mechanism of VAMILL primarily focus on one-dimensional vibration assistance and often ignore the crucial influence of tool geometry on the cutting trajectories, leading to incomplete characterization of tool-workpiece separation conditions. This paper comprehensively investigates the mechanisms of tool-workpiece separation in multi-dimensional VAMILL through theoretical analysis and finite element simulation. A novel kinematic model is developed to identify the separation phenomena across one-, two-, and three-dimensional (1-D, 2-D, and 3-D) vibration configurations, incorporating the effects of tool geometry and rotation. Specific mathematical models are developed for distinct separation mechanisms, and quantitative formulas are derived to calculate separation time, re-engagement time, and separation time ratio across various trajectory patterns and vibration parameters. The calculation results are validated through finite element simulations, demonstrating excellent agreement with theoretical calculations with errors below 12 %. The findings provide quantitative criteria for initiating and controlling tool-workpiece separation in multi-dimensional VAMILL, enabling precise process parameter selection for optimal machining performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"146 ","pages":"Pages 445-459"},"PeriodicalIF":6.1,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143928709","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":"Auxiliary support path planning for robot-assisted machining of thin-walled parts with non-uniform thickness and closed cross-section based on a neutral surface","authors":"Wen-Tao Xie ,&nbsp;De-Ning Song ,&nbsp;Wen-Cai Tang ,&nbsp;Jian-Wei Ma ,&nbsp;Jing-Hua Li","doi":"10.1016/j.jmapro.2025.05.002","DOIUrl":"10.1016/j.jmapro.2025.05.002","url":null,"abstract":"<div><div>The robot-assisted support machining is useful in avoiding machining deformation and chatter for thin-walled parts. However, existing research mainly focus on support machining of thin-walled parts with equal thickness, such as the aircraft skin, and it is challenging for parts with non-equal thickness because the machining and supporting paths can hardly be harmonized. This paper proposes an auxiliary support path scheduling method for machining of thin-walled parts with non-equal thickness and closed section, such as blades, based on a defined “neutral surface”. A spatial convolution algorithm is presented to generate the neutral surface, reflecting the weighted average of the parts on the thinnest direction, and bridging the machining and supporting paths. With the proposed method, the planned auxiliary support path without frequent reciprocation, self-intersections, and interference can be generated, which makes the robot-assisted support machining strategy applicable for thin-walled parts with non-equal thickness and closed section. Both simulation and experimental tests are conducted. It can be seen from the results that the proposed method can effectively reduce the machining deformation and chatter, and the surface roughness is reduced by &gt;50 %.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"147 ","pages":"Pages 16-28"},"PeriodicalIF":6.1,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143931346","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 on machining mechanism and surface integrity of Sip/Al composites with ultrasonic vibration-assisted epoxy coating cutting","authors":"Dachuan Chen ,&nbsp;Zhengding Zheng ,&nbsp;Jixiang Ding ,&nbsp;Jianguo Zhang ,&nbsp;Xiao Chen ,&nbsp;Junfeng Xiao ,&nbsp;Jianfeng Xu","doi":"10.1016/j.jmapro.2025.05.009","DOIUrl":"10.1016/j.jmapro.2025.05.009","url":null,"abstract":"<div><div>Due to the significant mechanical differences between the plastic Al matrix and the brittle Si particles, the ultra-precision machining of Sip/Al composites is considered a major challenge. To overcome this challenge, this paper proposes a new cutting strategy, namely ultrasonic vibration-assisted epoxy coating cutting (UV-ECC). By analyzing the groove morphology, cutting force, chip morphology, residual stress, and surface roughness, the effect of UV-ECC on the machining mechanism and surface integrity of Sip/Al composites is investigated. Research results indicate that epoxy coating can provide compressive stress to the surface of Sip/Al composites, thereby suppressing the formation and propagation of cracks as well as the pull-out or rotation of particles. After the introduction of ultrasonic vibration, the vibrating tool can compensate for the shortcomings of the epoxy coating in terms of chip removal. Furthermore, the intermittent separation reduces the damage to both the Sip/Al composites and the epoxy coating. Finally, the space gap created by the elliptical trajectory allows the crack suppression effect of the epoxy coating to be seen as a significant improvement. Overall, compared to traditional cutting and epoxy coating cutting, UV-ECC offers significant advantages in enhancing surface integrity, reducing specific cutting force, and achieving a uniform residual stress distribution. Among them, the surface roughness decreased by 75.4 % and 59.0 %, respectively, and the specific cutting force decreased by 75.01 % and 64.89 %, respectively. The current research provides a promising cutting strategy for achieving efficient and low-damage machining of Sip/Al composites.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"146 ","pages":"Pages 427-444"},"PeriodicalIF":6.1,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143928710","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}