Journal of Manufacturing Processes最新文献

{"title":"Asymmetric pore distribution in PBF-LB/M In718 thin-walled structures: Contour morphology and welding quality","authors":"Kai Zhou ,&nbsp;Deqiao Xie ,&nbsp;Zansong Li ,&nbsp;Dongsheng Wang ,&nbsp;Lida Shen","doi":"10.1016/j.jmapro.2025.04.030","DOIUrl":"10.1016/j.jmapro.2025.04.030","url":null,"abstract":"<div><div>Current research on In718 alloys produced by powder bed fusion-laser beam metals (PBF-LB/M) is mainly focused on the deformation challenges, while porosity has received less attention. This study focused on the porosity of the sub-surface of printed components, which is influenced by thickness, and the need to optimize the contour space to improve the print quality of thin-walled structures. The results illustrated that when the contour space was bigger than 0.04 mm, an asymmetry of contour melt tracks inevitably appeared for thin-walled structures, regardless of the placement angle. It was also found that asymmetric contour melt tracks were caused by the asymmetric hump effect of internal melt tracks. A localized collapse of one side of the internal melt tracks can cause breakage of the contour melt tracks. This is due to the lack of liquid metal at that location during contour melt track formation. Meanwhile, the contour melt track on the opposite side remains mostly undamaged. These broken contour melt tracks could cause asymmetric pore defects during the deposition process. Computational Fluid Dynamics (CFD) simulations were used to validate the contour scanning process. The results showed that a 0.04 mm contour space could significantly reduce the one-sided hump of the internal melt tracks and form a plump contour melt track, which would reduce the problem of local overthickness in the subsequent powder layer during powder spreading processes, thereby reducing the lack of fusion. This research provided valuable theoretical insights and practical guidance for optimizing the PBF-LB/M process for thin-walled In718 parts, with significant implications for engineering applications and academic innovation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 294-305"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829042","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":"New cooling system with hollow mandrel in cold pilgering","authors":"Hideaki Abe","doi":"10.1016/j.jmapro.2025.04.033","DOIUrl":"10.1016/j.jmapro.2025.04.033","url":null,"abstract":"<div><div>In cold pilgering, tube lubrication is critical to obtaining a high surface quality of the finished tube, long tool life, and high productivity, and addressing environmental concerns. To enhance lubrication, a new cooling system for the working tool was studied. The thermal balance between the heat generated and that removed during working was investigated, which is important for cooling the mandrel. The cooling system with a hollow mandrel and a coolant for the inner surface, which should have mechanical integrity and good cooling performance, is presented. The inner dimensions of the hollow mandrel were determined on the basis of mechanics of materials to prevent fissures on its inner surface. A fully developed turbulent flow in the inner coolant can remove the heat from the mandrel. The design procedure for the cooling system is described, including the determination of parameters, mechanical calculation, the calculation of heat transfer, and the determination of optimal designs. The mechanical integrity of the hollow mandrel was investigated by the finite element analysis of stress. The heat generated was calculated on the basis of the plastic deformation theory and the kinetics of cold pilgering, and heat transfer was calculated on the basis of the thermal conduction of the mandrel as well as the thermal convection of the inner coolant. The design results for a type 304 stainless steel tube indicated the feasibility of cold pilgering at mandrel temperatures below 100 °C. These findings indicate that the cooling system can be installed inside the tube for cold pilgering.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 335-350"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829115","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":"Coarse-grained molecular dynamics modelling of lithium-ion battery electrode drying: A sensitivity analysis","authors":"Xinxin Yao ,&nbsp;Hasnain Hafiz ,&nbsp;Lei Chen ,&nbsp;Wayne Cai ,&nbsp;Zirui Mao ,&nbsp;Shenyang Hu","doi":"10.1016/j.jmapro.2025.03.117","DOIUrl":"10.1016/j.jmapro.2025.03.117","url":null,"abstract":"<div><div>Understanding the electrode microstructure and cell performance plays a critical role in the Li-ion battery manufacturing process. In this work, a Coarse-Grained Molecular Dynamics (CGMD) method is employed to simulate the electrode drying process, and a sensitivity analysis is conducted to assess the effects of the carbon binder domain (CBD) and active material (AM) on the physical and structural properties of the dried microstructure. The simulations demonstrate that the size and density of the CBD, along with AM sampling, significantly impact the physical properties of the electrode, such as slurry density, viscosity, and thickness of the dried electrode, thereby influencing the overall mechanical and electrochemical performance of the cell. Our sensitivity analysis provides optimal selections of these parameters for further development of the manufacturing process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 54-59"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834772","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":"Material removal and defect evolution in nano-cutting of γ-TiAl alloy: The effect of twin boundary","authors":"Huiming Wang ,&nbsp;Haiyan Li ,&nbsp;Hui Cao ,&nbsp;Zhaoting Guo ,&nbsp;Zehai Ren ,&nbsp;Wenke Chen ,&nbsp;Ruicheng Feng ,&nbsp;Tao Chen","doi":"10.1016/j.jmapro.2025.04.043","DOIUrl":"10.1016/j.jmapro.2025.04.043","url":null,"abstract":"<div><div>Nano-twinned materials have attracted considerable attention due to their unique plastic deformation mechanisms and the formation of prismatic dislocation loops (PDLs). However, the impact of twins on nano-cutting behavior remains inadequately understood. This paper conducts molecular dynamics simulations to investigate the material removal behavior and the evolution of PDLs in twin single-crystal γ-TiAl alloy during nano-cutting. The results show that during the cutting process of twinned TiAl alloys, PDLs are generated through multiple dislocation reactions and cross-slips, and there are two types of chips, namely regular and serrated, as well as two dislocation reaction paths, namely slip along the twin boundary and break through the twin boundary. When the cutting direction is <span><math><mfenced><mrow><mover><mn>1</mn><mo>¯</mo></mover><mover><mn>1</mn><mo>¯</mo></mover><mn>2</mn></mrow></mfenced></math></span>[111], a significant number of atoms migrate into the matrix interior, the material undergoes extrusion removal, forming regular chips and generating a large number of PDLs. When the PDLs slip to the twin boundary, they are completely blocked and slip along the twin boundary, resulting in detwinning. However, when the cutting direction is <span><math><mfenced><mrow><mover><mn>1</mn><mo>¯</mo></mover><mover><mn>1</mn><mo>¯</mo></mover><mn>2</mn></mrow></mfenced><mfenced><mrow><mover><mn>1</mn><mo>¯</mo></mover><mover><mn>1</mn><mo>¯</mo></mover><mover><mn>1</mn><mo>¯</mo></mover></mrow></mfenced></math></span>, a large number of atoms flow upward to form chips, the material undergoes shear removal, forming serrated chips and forming incomplete PDLs. When the incomplete dislocation loops reach the twin boundary, cross-slip occurs and successfully penetrates the twin boundary. This research not only enhances the understanding of the deformation mechanisms of twin single-crystal γ-TiAl alloy during nano-cutting, but also provides new insights into the interaction between dislocation loops and twin boundaries.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 78-92"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834780","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":"Autonomous learning of digital twins for intelligent extrusion optimisation in MEX","authors":"A. Rossi,&nbsp;M. Moretti,&nbsp;M.L. Fravolini,&nbsp;N. Senin","doi":"10.1016/j.jmapro.2025.04.006","DOIUrl":"10.1016/j.jmapro.2025.04.006","url":null,"abstract":"<div><div>The availability of a digital copy of themselves (digital twin) to experiment upon, may be a fundamental enabler of more autonomous decision-making capabilities for the next generation of intelligent manufacturing machines. A fundamental challenge remains, in that humans are still required to develop digital twins in the first place. Towards a more autonomous, data-driven learning of surrogate digital models, in this paper a new approach is presented where a material extrusion (MEX) machine learns its own extrusion dynamics by autonomously collecting sensor data during trial deposition runs and then develops its own digital twin by automated application of methods of system identification. Through constrained linear least-squares optimisation, the machine is also able to leverage the predictions of the digital twin to optimise its own part program ahead of execution, ultimately producing more uniform, deposited strands.</div><div>To demonstrate the approach, an experimental campaign is illustrated in which a prototype MEX machine is first instructed to develop its own digital twin of deposition dynamics using data from test deposition runs. After automated optimisation of the part program, performed using the predictor to evaluate improvements, width measurements on subsequent depositions show 35.8 % decrease of width variation (measured as root mean square cumulative error vs an ideally constant width) compared to the pre-optimised deposition behaviour.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 321-334"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829114","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":"Spatial Light Modulator-based printing technologies for optical elements fabrication with different materials","authors":"Shaoqing Zhao ,&nbsp;Han Zhang ,&nbsp;Yu-Qing Liu ,&nbsp;Long Huang ,&nbsp;Ruihua Guan ,&nbsp;Yanpin Chen ,&nbsp;Yuxuan Cong ,&nbsp;Zhihan Hong ,&nbsp;Zhi Wang ,&nbsp;Hua Liu","doi":"10.1016/j.jmapro.2025.04.019","DOIUrl":"10.1016/j.jmapro.2025.04.019","url":null,"abstract":"<div><div>Spatial Light Modulator (SLM)-based printing technologies, including Digital Light Processing (DLP) and Liquid Crystal Display (LCD), have emerged as transformative solutions for the fabrication of high-precision optical elements. These technologies address the increasing demand for customizable, high-performance optical components in fields like telecommunications, biomedical optics, imaging systems, and optical computing. By enabling the rapid production of complex structures with exceptional accuracy and scalability. This review aims to provide a comprehensive analysis of recent advancements in SLM-based printing technologies, with a particular focus on innovations that enhance fabrication precision, material versatility, and production efficiency. Key innovations (developments) such as overlapping superposition, volumetric additive manufacturing, and Continuous Liquid Interface Production (CLIP) are examined for their role in improving profile fidelity, reducing process-induced artifacts, and expanding the range of manufacturable optical geometries. Additionally, this review explores the wide range of photo-curing materials, from organic polymers to advanced hybrid composites such as “Liquid Glass” and SOL-GEL materials, which are expanding the material capabilities including optical and mechanical properties for SLM technologies. The review also addresses critical challenges in critical manufacturing techniques and investigates precision-enhancing strategies, such as defocus DLP stereolithography, fluid-forming, and frame constraint molding, which tackle challenges in precision, surface smoothness, and scalability. Finally, the review examines the future directions of SLM-based printing technologies, emphasizing their potential to revolutionize optical component fabrication and drive innovations in next-generation optical devices.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 60-77"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834773","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":"Influence of high-pressure die casting parameters on bonding characteristics of aluminium-steel hybrid-castings for automotive lightweight structures","authors":"Florian Mielke,&nbsp;Damian Sulik,&nbsp;Xiangfan Fang","doi":"10.1016/j.jmapro.2025.04.032","DOIUrl":"10.1016/j.jmapro.2025.04.032","url":null,"abstract":"<div><div>For automotive lightweight design, aluminium and steel bi-metallic structures are being increasingly applied. Aluminium-steel hybrid-casting is one of the coming technologies. To achieve a firm bonding between both materials, a new AlSi(Fe) coating was developed and analysed in previous works showing approximately 10 MPa shear strength and high ductility. In this work, a systematic study has been conducted on hybrid-casting of DP800 steel in an AlSi10MnMg alloy using high-pressure die casting (HPDC) trials, its thermal analysis, and mechanical tests on different types of hybrid-cast specimens along with finite element (FE) casting simulation and scanning electron microscopy (SEM) analysis on tested specimens to understand the entire process chain. It was found that the mould temperature is the most important parameter, and the second one is the preheating temperature for the steel insert. With 280 °C mould and 500 °C preheating temperature, and &gt;40 m/s injection gate velocity, the shear strength can be increased to 15 MPa with considerable plastic deformation of the bonding layer and small scatters. Three fracture surface types can be observed by SEM, and clearly understood by considering the temperature profile of the steel inserts during the casting process that can be determined using FE casting simulation calibrated by die casting tests. These findings on shear specimens were further validated by pullout tests with overlapped metallurgical and force-fit bonding, as well as cross-tension tests. Together with force-locking the total bonding strength achieves 25 MPa.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 351-368"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829116","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":"Towards defect-free lattice structures in additive manufacturing: A holistic review of machine learning advancements","authors":"Numan Khan ,&nbsp;Hamid Asad ,&nbsp;Sikandar Khan ,&nbsp;Aniello Riccio","doi":"10.1016/j.jmapro.2025.04.035","DOIUrl":"10.1016/j.jmapro.2025.04.035","url":null,"abstract":"<div><div>Additive manufacturing has transformed modern production by enabling the fabrication of complex and lightweight structures, particularly lattice geometries, which are widely used in aerospace, automotive, medical, and energy industries. Renowned for their superior strength-to-weight ratios and energy absorption properties, lattice structures have unlocked new possibilities for weight-critical, high-performance applications. However, their intricate geometries and susceptibility to defects, such as surface roughness, voids, and porosity, pose significant challenges to ensuring mechanical integrity and functional reliability. Traditional methods of defect mitigation, process control and optimization, are often constrained by high computational costs and limited adaptability to complex defect mechanisms. To address these challenges, machine learning (ML) has emerged as a transformative tool, offering data-driven solutions for defect prediction, detection, and minimization. These techniques excel in optimizing designs, tuning process parameters, and enabling real-time adjustments to mitigate defects, thereby enhancing manufacturing outcomes. While numerous studies have explored ML applications in additive manufacturing, current literature lacks a specific focus on its use for defect minimization in lattice structures, which require defect-free fabrication to achieve optimal performance. This review paper fills this critical research gap by investigating the application of advanced ML techniques across key areas: design optimization, properties prediction, process parameter tuning, and defect detection and real-time monitoring for lattice structures. In doing so, it gives a comprehensive outline of lattice structures, the challenges posed by manufacturing defects, and state-of-the-art ML applications in AM. This study paves the way for defect-free lattice structures, maximizing their industrial potential.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 1-53"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143828238","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":"Skiving method for chamfering and deburring of cylindrical gears using two disk tools","authors":"Erkuo Guo ,&nbsp;Hongchuan Zhang ,&nbsp;Wenzheng Ding ,&nbsp;Boxiang Wang ,&nbsp;Yayun Yuan","doi":"10.1016/j.jmapro.2025.04.025","DOIUrl":"10.1016/j.jmapro.2025.04.025","url":null,"abstract":"<div><div>Gear chamfering and deburring are widely employed in manufacturing to remove burrs or smooth sharp edges from gear parts using a specialized tool, which minimizes the stress concentration on the tooth surface. In recent years, gear chamfering and deburring have become indispensable processes in high-performance gear manufacturing for new-energy vehicles and industrial robots. This study presents a novel skiving method for chamfering and deburring cylindrical gears based on tooth profile generation using a cutting tool edge. A mathematical model is proposed to calculate the cutting edges of a chamfering tool for skiving gear tooth profiles. By developing an evaluation method for chamfering results, various concerns regarding gear skiving chamfers are discussed, including the description of the evaluation method, impact of tool parameters on chamfering results, analysis of the flank interference of the tool, and versatility of chamfering tools when machining different gears. An experimental skiving chamfer is designed on a specialized machine using two high-speed steel chamfering tools with an AlCrN Pro coating. The obtained results demonstrate deviations between the theoretical and measured values &lt;13 %, confirming the validity of the proposed approach. These findings offer theoretical support for optimizing cylindrical gear chamfering processes and guidance for designing skiving chamfer tools.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 93-103"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834781","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 of the effect of functional porous support structures on part quality and removal properties in laser powder bed fusion","authors":"Halil İbrahim Erol ,&nbsp;Ahmet Can Günaydın ,&nbsp;Umut Can Gülletutan ,&nbsp;Sertaç Altınok ,&nbsp;Metin Uymaz Salamci","doi":"10.1016/j.jmapro.2025.04.037","DOIUrl":"10.1016/j.jmapro.2025.04.037","url":null,"abstract":"<div><div>This study explores the design and evaluation of support structures in laser powder bed fusion additive manufacturing, with a particular focus on developing functionally graded support structure designs to overcome the limitations of traditional supports. Although traditional support structures are assumed to offer mechanical stability, they typically demand significant removal forces. High removal forces can jeopardize delicate features, particularly in components with thin structures, like those used in lightweight aerospace applications and heat exchangers. Proposed novel approach by integrating gradual transitions among porous support structures, which not only enhance the stability but also penetrate the part to improve surface quality while reducing the required effort for removal. The findings reveal that functionally graded support structure designs significantly outperform traditional supports. The functionally graded support structure design achieved a remarkable 95.91 % reduction in removal force, minimizing displacement at fracture by 88.94 %, and 29.0 % lower part deviation compared to conventional designs. This innovative approach minimizes post-processing requirements, allowing for the manufacture of thinner components that fulfil the strict performance and weight standards of aerospace and other high-performance sectors.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 120-135"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834783","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}