Journal of Manufacturing Processes最新文献

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Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies 在模拟油漆烘烤条件下减轻铝/钢部件的变形:实验和数值模型研究
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-12 DOI: 10.1016/j.jmapro.2024.11.003
Hui Huang , Yanli Wang , Yong Chae Lim , Eric Boettcher , Zhili Feng
{"title":"Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies","authors":"Hui Huang ,&nbsp;Yanli Wang ,&nbsp;Yong Chae Lim ,&nbsp;Eric Boettcher ,&nbsp;Zhili Feng","doi":"10.1016/j.jmapro.2024.11.003","DOIUrl":"10.1016/j.jmapro.2024.11.003","url":null,"abstract":"<div><div>Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. In the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 494-505"},"PeriodicalIF":6.1,"publicationDate":"2024-11-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657385","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
A novel cast & wrought FGH4096 superalloy with refined microstructures prepared by electron beam drip melting technology and its homogenization behavior 利用电子束滴熔技术制备的具有精细微观结构的新型铸锻 FGH4096 超合金及其均匀化行为
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-12 DOI: 10.1016/j.jmapro.2024.11.002
Kai Chang, Yi Tan, Rusheng Bai, Lidan Ning, Gengyi Dong, Pengting Li, Yinong Wang
{"title":"A novel cast & wrought FGH4096 superalloy with refined microstructures prepared by electron beam drip melting technology and its homogenization behavior","authors":"Kai Chang,&nbsp;Yi Tan,&nbsp;Rusheng Bai,&nbsp;Lidan Ning,&nbsp;Gengyi Dong,&nbsp;Pengting Li,&nbsp;Yinong Wang","doi":"10.1016/j.jmapro.2024.11.002","DOIUrl":"10.1016/j.jmapro.2024.11.002","url":null,"abstract":"<div><div>The first proposal of using Electron beam drip melting (EBDM) technology to prepare 〈001〉 oriented columnar grain superalloy was prepared. The study investigated the effects of the EBDM on the microstructure of FGH4096 alloy and the evolution of microstructure during the homogenization process, providing a solid foundation for subsequent thermal deformation processes. Compared to traditional melting methods, the secondary dendrite arm spacing of the EBDM alloy has been significantly reduced by over 40 %, with a 47.5 % decrease in the size of the γ’ phase in the dendrite arm regions. The size of the γ’ phase in the interdendritic regions has decreased by 28.9 %. The size and number of pores in superalloys produced by EBDM are significantly reduced, with a decrease in porosity of approximately one order of magnitude. The high temperature gradients and melt convection effects in the EBDM process promote an increase in the solute boundary layer thickness, significantly reducing both macroscopic and microscopic segregation. The EBDM process can generate relatively high internal residual stresses. By conducting homogenization treatment to control crystal orientation, it is possible to retain the advantages of columnar grain thermal deformation while using the residual stresses that are retained to provide activation energy for subsequent thermal deformation processes. This significantly enhances the thermal deformation capabilities of FGH4096 alloy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 451-466"},"PeriodicalIF":6.1,"publicationDate":"2024-11-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657388","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
Machining of Invar 36 alloy: Chip-flow behaviors and formation mechanisms 因瓦 36 合金的加工:切屑流动行为和形成机制
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-11 DOI: 10.1016/j.jmapro.2024.10.070
Peng Zhang , Zheming Chen , Liuwei Guo , Chaoran Li , Shuyang Lu , Jianfei Sun
{"title":"Machining of Invar 36 alloy: Chip-flow behaviors and formation mechanisms","authors":"Peng Zhang ,&nbsp;Zheming Chen ,&nbsp;Liuwei Guo ,&nbsp;Chaoran Li ,&nbsp;Shuyang Lu ,&nbsp;Jianfei Sun","doi":"10.1016/j.jmapro.2024.10.070","DOIUrl":"10.1016/j.jmapro.2024.10.070","url":null,"abstract":"<div><div>This investigation delves into the plastic deformation mechanisms responsible for the distinctive chip formation of Invar 36 alloy, marked by features of cleavage and folding instabilities during machining. This study unveils the flow characteristics of Invar 36 alloy by conducting cutting experiments and material property tests, leading to the formulation of flow stress models. Employing polycrystalline finite element simulation, the research illuminates how intergranular compression can induce surface bulging, subsequently triggering the initiation of cracks under tensile stress. As cutting speeds escalate, an intensification in plastic flow begets increasingly pronounced and frequent chip serrations. When speeds surpass 200 m/min, elevated temperatures and strain rates foster material buckling and adhesion to the tool's rake face, fostering the emergence of large-scale and subsidiary folds. This “fan-like” chip architecture precipitates a self-blocking effect, which in turn generates significant cutting forces and severe oscillations. An analysis via a mathematical-physical model reveals that the oscillation in cutting force incite the material's inertial responses, catalyzing abrupt shifts in shear strain and shear strain rate, and eventually leading to cracks and segmentation within the cutting zone. Finally, the research briefly discussed on the ramifications of these alterations in the cutting flow mechanism on tool wear and surface quality in the practical machining of Invar 36 alloy, alongside an outline of prospective research.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 477-493"},"PeriodicalIF":6.1,"publicationDate":"2024-11-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657386","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
Inverse kinematics model and trajectory generation of a dual-stage micro milling machine 双级微型铣床的逆运动学模型和轨迹生成
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-09 DOI: 10.1016/j.jmapro.2024.10.057
Yifei Hu , Xiaoliang Jin , Xin Jiang , Zhiming Zheng
{"title":"Inverse kinematics model and trajectory generation of a dual-stage micro milling machine","authors":"Yifei Hu ,&nbsp;Xiaoliang Jin ,&nbsp;Xin Jiang ,&nbsp;Zhiming Zheng","doi":"10.1016/j.jmapro.2024.10.057","DOIUrl":"10.1016/j.jmapro.2024.10.057","url":null,"abstract":"<div><div>Multiaxis micromachining centers, designed for precision in miniature parts due to their high degrees of freedom, face significant challenges in motion planning to achieve high accuracy and speed. This paper presents a trajectory generation algorithm for a novel dual-stage 9-axis micro milling machine, comprising a Cartesian 3-axis stage and a high-bandwidth 6-degree-of-freedom magnetically levitated table. To address the inherent challenge of kinematic redundancy, the inverse kinematics model is developed to determine the position of each axis corresponding to the desired tool position and orientation. The feedrate is determined by considering the kinematics constraints of all nine axes. With the tool paths in the machine coordinate system fitted using B-spline curves, two linear optimization problems are formulated and solved to obtain the feedrate profile. Finally, interpolation points are calculated using a feedback method to obtain the position commands. The proposed method outperforms traditional methods using the Moore Penrose pseudoinverse of the Jacobian matrix, reducing cycle time by up to 44.55 % and contour error by up to 15.64 %, demonstrating significant efficiency and accuracy improvements.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 425-450"},"PeriodicalIF":6.1,"publicationDate":"2024-11-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657315","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
Numerical simulation of surface structures in single and multi-track laser polishing of NiP alloy 单轨和多轨激光抛光 NiP 合金表面结构的数值模拟
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-09 DOI: 10.1016/j.jmapro.2024.10.086
Hang Zhang , Xiaoyu Sun , Xuebo Xu , Feng Zhao , Jianglong Cai , Xin Guo , Ziye He , Dichen Li
{"title":"Numerical simulation of surface structures in single and multi-track laser polishing of NiP alloy","authors":"Hang Zhang ,&nbsp;Xiaoyu Sun ,&nbsp;Xuebo Xu ,&nbsp;Feng Zhao ,&nbsp;Jianglong Cai ,&nbsp;Xin Guo ,&nbsp;Ziye He ,&nbsp;Dichen Li","doi":"10.1016/j.jmapro.2024.10.086","DOIUrl":"10.1016/j.jmapro.2024.10.086","url":null,"abstract":"<div><div>Laser polishing represents an advanced surface treatment method that decreases surface roughness by utilizing the interaction between the laser beam and the material. Nevertheless, the laser polishing process often introduces new surface structures with certain fluctuations, which affect the final polishing outcome. In this paper, a two-dimensional cross-sectional numerical model integrating fluid flow, heat transfer, and material vaporization was developed to simulate the temperature field, momentum and surface morphologies of the polished sample. This model was used to investigate the generation mechanism of “M”-shaped surface structures induced by Gaussian continuous-wave (CW) laser scanning on Ni<img>P alloy. The surface structure was significantly influenced by the combined effects of material properties, laser energy distribution, and various surface forces. Comparison between simulated and experimental surface structures showed a deviation of 2.81 % in the distance between two bulges of the “M”-shaped surface structure (<span><math><mi>d</mi></math></span>) and a deviation of 6.24 % in the bulge height (<span><math><mi>h</mi></math></span>). The model was further employed to simulate the profiles of laser multi-track polishing at different track offsets. The research indicated that the optimal polishing occurs when the laser scanning track offset (<span><math><mo>∆</mo><mi>d</mi></math></span>) equals <span><math><mi>d</mi><mo>/</mo><mn>2</mn></math></span>. Multi-track laser experiments confirmed the simulation predictions and revealed the potential of CW laser in surface configuration. This study successfully advances theoretical research on laser polishing and enhances the efficiency of selecting laser polishing process parameters.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 404-415"},"PeriodicalIF":6.1,"publicationDate":"2024-11-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657390","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
A novel strategy for reducing sheet springback by coupled with high strain rate and shear deformation via impact hydroforming 通过高应变率和剪切变形耦合的冲击液压成形减少板材回弹的新策略
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-09 DOI: 10.1016/j.jmapro.2024.10.076
Xia Liangliang , Xu Yong , Xie Wenlong , Li Jie , Liu Xuefei , Artur I. Pokrovsky , Zhang Shi-Hong
{"title":"A novel strategy for reducing sheet springback by coupled with high strain rate and shear deformation via impact hydroforming","authors":"Xia Liangliang ,&nbsp;Xu Yong ,&nbsp;Xie Wenlong ,&nbsp;Li Jie ,&nbsp;Liu Xuefei ,&nbsp;Artur I. Pokrovsky ,&nbsp;Zhang Shi-Hong","doi":"10.1016/j.jmapro.2024.10.076","DOIUrl":"10.1016/j.jmapro.2024.10.076","url":null,"abstract":"<div><div>Springback is a critical factor in controlling the tolerance of thin-walled, curved components during manufacturing. This study proposes a strategy that utilizes impact hydroforming to eliminate springback instead of the traditional method of modifying the die for compensation. Bending tests were conducted on the 2024 aluminum alloy sheet with a bending angle of 120° and bending radius of 30 mm under three different loading modes, i.e. quasi-static rigid punch bending (QSR), high-speed rigid punch bending (HSR), and impact hydroforming (IHF) bending. Corresponding finite element simulations of these loading modes were also performed, and the simulated springback variations closely matched the experimental results. The experiments revealed that springback decreased with an increase in strain rate, and the use of a liquid medium further facilitated or even eliminated springback. The deformation sequence, strain neutral layer, principal stress, and equivalent plastic strain distribution of the sheet were analyzed under each loading mode. Two primary reasons for the reduction in springback were identified: the high strain rate induced stress relaxation and energy release, and the liquid medium altering the deformation sequence of the sheet, leading to shear deformation. These findings offer a new strategy for achieving forming precision, high efficiency, and low-cost manufacturing complex thin-walled components of made from aviation aluminum alloy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 392-403"},"PeriodicalIF":6.1,"publicationDate":"2024-11-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657313","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
Innovating 4D-printed microstructures via gas metal arc welding assisted wire-arc additive manufacturing 通过金属气弧焊辅助线弧增材制造创新 4D 打印微结构
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-09 DOI: 10.1016/j.jmapro.2024.11.005
Nadeem Fayaz Lone , Namrata Gangil , Dhruv Bajaj , Amit Arora , Daolun Chen , Arshad Noor Siddiquee
{"title":"Innovating 4D-printed microstructures via gas metal arc welding assisted wire-arc additive manufacturing","authors":"Nadeem Fayaz Lone ,&nbsp;Namrata Gangil ,&nbsp;Dhruv Bajaj ,&nbsp;Amit Arora ,&nbsp;Daolun Chen ,&nbsp;Arshad Noor Siddiquee","doi":"10.1016/j.jmapro.2024.11.005","DOIUrl":"10.1016/j.jmapro.2024.11.005","url":null,"abstract":"<div><div>4D printing refers to the additive manufacturing of a component by incorporating smart materials. The smart materials add the “4th dimension” to 3D-printing by altering the shape/functionality/configuration of the part in response to external stimulus such as heat, stress, pH, electric field, etc. In the current study, shape memory alloy (SMA) plugs were implanted into mild-steel via gas metal arc welding (GMAW) assisted wire-arc additive manufacturing (WAAM). The NiTi SMA powder was employed as secondary addition within the printed layers, while the FeMnSi based alloy evolved in-situ during the 4D-printing process. Significant elemental heterogeneity was found in the Fe-Mn-Si based SMA plugs containing Ni<img>Fe rich solidified droplets, owing to the composition of the wire used for deposition. The Ni<img>Fe rich phases depicted the substitution of Ti by Fe in the NiTi pre-cursors. The large SMA plugs incorporated into the printed mild steel depicted the formation of a macro composite structure. The presented results are expected to considerably reduce the cost of SMA application through the printing of novel monolithic SMA-steel composites using wires and SMA powders as raw materials.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 416-424"},"PeriodicalIF":6.1,"publicationDate":"2024-11-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657389","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
Effect of printing parameters on the mechanical and piezoresistive response of cellular structures manufactured with a conductive polylactic acid nanocomposite through a material extrusion process 印刷参数对通过材料挤压工艺用导电聚乳酸纳米复合材料制造的蜂窝结构的机械和压阻响应的影响
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-08 DOI: 10.1016/j.jmapro.2024.10.074
Carlos Rubio-González , José de Jesús Ku-Herrera , Jyhwen Wang , Albert Patterson , Jorge A. Soto-Cajiga , Oscar Olvera-Silva
{"title":"Effect of printing parameters on the mechanical and piezoresistive response of cellular structures manufactured with a conductive polylactic acid nanocomposite through a material extrusion process","authors":"Carlos Rubio-González ,&nbsp;José de Jesús Ku-Herrera ,&nbsp;Jyhwen Wang ,&nbsp;Albert Patterson ,&nbsp;Jorge A. Soto-Cajiga ,&nbsp;Oscar Olvera-Silva","doi":"10.1016/j.jmapro.2024.10.074","DOIUrl":"10.1016/j.jmapro.2024.10.074","url":null,"abstract":"<div><div>The piezoresistive response of specimens made by electrically conductive polylactic acid (PLA) under monotonic and cyclic flexural loading was experimentally investigated. A material extrusion process was utilized to 3D print the conductive PLA/carbon black nanocomposite samples using three infill patterns and three infill ratios. Then three-point bending tests, and electrical resistance measurements, were simultaneously conducted on beam-type specimens. The results of the electromechanical tests demonstrated that the 3D printed samples show outstanding piezoresistive sensing characteristics with excellent cyclic stability and reproducibility suitable for in-situ damage detection and strain monitoring through their electrical resistance change. Determination of gauge factors of specimens with different infill ratios and patterns exhibited a significant sensitivity even at low infill ratio. The potential of the piezoresistive property of conductive PLA/carbon black nanocomposite was examined by proposing 3D printed sensors for strain monitoring. The results demonstrated that conductive feedstock can be successfully processed by this material extrusion technique to develop advanced 3D printing sensing solutions. The applicability of the piezoresistive property of conductive cellular structures 3D printed with PLA/carbon black feedstock as a suitable technique for structural health monitoring was demonstrated.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 375-391"},"PeriodicalIF":6.1,"publicationDate":"2024-11-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657314","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
Surface evolution mechanism for atomic-scale smoothing of Si via atmospheric pressure plasma etching 通过常压等离子体蚀刻实现硅原子尺度平滑的表面演化机制
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-06 DOI: 10.1016/j.jmapro.2024.10.080
Bing Wu , Rong Yi , Xuemiao Ding , Tom Chiu , Quanpeng He , Hui Deng
{"title":"Surface evolution mechanism for atomic-scale smoothing of Si via atmospheric pressure plasma etching","authors":"Bing Wu ,&nbsp;Rong Yi ,&nbsp;Xuemiao Ding ,&nbsp;Tom Chiu ,&nbsp;Quanpeng He ,&nbsp;Hui Deng","doi":"10.1016/j.jmapro.2024.10.080","DOIUrl":"10.1016/j.jmapro.2024.10.080","url":null,"abstract":"<div><div>Atmospheric plasma etching-based machining methods generally suffer from surface roughness deterioration. To achieve an atomic-scale smooth surface of Si via purely plasma etching, clarifying the etching evolution and mechanism is essential. In this study, we study surface evolution and smoothening mechanisms from the perspective of plasma etching modes comprehensively. The morphology and roughness evolutions of isotropic, orientation-selective, and atom-selective etching are investigated, respectively. The semi-finishing effect is realized through the growing and merging of hemispherical pits during isotropic etching, with the surface roughness being reduced from 103 nm to 0.79 nm. Orientation-selective etching is a roughening process, transforming square-opening pits into pyramid structures. Under the atom-selective mode, an atomically smooth surface with <em>S</em>a 0.17 nm can be obtained. The top-down smoothing process of atom-selective is much more efficient than isotropic etching. Atom-selective etching with a maximum removal rate of 22 μm/min enables the rapid thinning of Si substrate thickness from 715 μm to 90.4 μm within 45 min. Additionally, atom-selective etching is a universal polishing approach regardless of pre-processed methods and is a damage-less process. This paper provides a promising strategy for atomic and close-to-atomic scale manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 353-362"},"PeriodicalIF":6.1,"publicationDate":"2024-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142593908","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
Developing the optimized control scheme for digital light processing 3D printing by combining numerical simulation and machine learning-guided temperature prediction 结合数值模拟和机器学习引导的温度预测,开发数字光处理 3D 打印的优化控制方案
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-11-06 DOI: 10.1016/j.jmapro.2024.10.049
Lidong Zhao , Zhi Zhao , Limin Ma , Shuyi Li , Zening Men , Lifang Wu
{"title":"Developing the optimized control scheme for digital light processing 3D printing by combining numerical simulation and machine learning-guided temperature prediction","authors":"Lidong Zhao ,&nbsp;Zhi Zhao ,&nbsp;Limin Ma ,&nbsp;Shuyi Li ,&nbsp;Zening Men ,&nbsp;Lifang Wu","doi":"10.1016/j.jmapro.2024.10.049","DOIUrl":"10.1016/j.jmapro.2024.10.049","url":null,"abstract":"<div><div>Digital light processing (DLP) 3D printing has attracted significant attention for its rapid printing speed, high accuracy, and diverse applications. However, the continuous DLP printing process releases substantial heat, resulting in a swift temperature rise in the curing area, which may lead to printing failures. Due to the lack of effective means to measure real-time temperature changes of the curing surface during continuous DLP 3D printing, the prevailing approach is to predict temperature variations during printing via numerical simulation. Nevertheless, temperature prediction methods relying solely on numerical simulation tend to be slow and overlook heat exchange dynamics during printing, potentially resulting in prediction inaccuracies, particularly for complex models. To address these issues, this paper proposes a method to combine numerical simulation and a machine learning approach for temperature prediction in the DLP 3D printing process, along with a printing control scheme generation method. Firstly, the <span><math><msup><mrow><mfenced><mrow><mtext>m</mtext><mo>+</mo><mtext>n</mtext></mrow></mfenced></mrow><mrow><mi>t</mi><mi>h</mi></mrow></msup></math></span> order autocatalytic kinetic model considering the light intensity and the Beer–Lambert law are employed to formulate the heat calculation equation for the photopolymer resin curing reaction. Subsequently, a heat exchange calculation equation is established based on Fourier heat conduction law and Newton’s cooling equation. A numerical simulation model for temperature changes during the printing process is then developed by integrating the heat calculation equation, heat exchange calculation equation, and measurement data from Photo-DSC. Furthermore, a temperature measurement device for the printing process is designed to validate the accuracy of the numerical simulation. Following this, an improved Long Short-term Memory (LSTM) network is proposed, using temperature change data generated by the numerical simulation model to train the network for rapid (<span><math><mrow><mn>2</mn><mo>×</mo><msup><mrow><mn>10</mn></mrow><mrow><mo>−</mo><mn>4</mn></mrow></msup></mrow></math></span> <span><math><mrow><mtext>s</mtext><mo>/</mo><mtext>layer</mtext></mrow></math></span>) prediction of temperature changes during printing. Finally, aiming for the shortest printing time, an optimized control scheme planning algorithm and a target function are designed based on the model’s temperature change data and the monomer’s flash point to ensure the temperature remains below this threshold. This algorithm can automatically generate the optimal printing control scheme for any model. Experimental results demonstrate that the proposed temperature prediction method can predict temperature variation accurately. Based on this, the generated printing control scheme can guarantee efficient and high-quality manufacturing for anymodel.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 363-374"},"PeriodicalIF":6.1,"publicationDate":"2024-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142593965","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
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