Journal of Manufacturing Processes最新文献

{"title":"Theoretical and experimental analysis of temperature distribution in variable-depth reciprocating grinding process","authors":"Yuanqiang Luo,&nbsp;Weihua Liao,&nbsp;Weidong Tang,&nbsp;Xiaoran Wang,&nbsp;Cong Mao,&nbsp;Mingjun Zhang,&nbsp;Kun Tang,&nbsp;Wentao Wang,&nbsp;Bo Cheng,&nbsp;Abdur Razzak","doi":"10.1016/j.jmapro.2025.07.014","DOIUrl":"10.1016/j.jmapro.2025.07.014","url":null,"abstract":"<div><div>Grinding is widely utilized in minimally invasive surgery due to its handleability and high precision. However, the substantial heat generated during the grinding process can lead to localized temperature increases, which cause thermal damage to surrounding healthy tissues. This study investigates the temperature distribution in the variable-depth reciprocating grinding process by developing a heat flux density model for the spatially irregular grinding contact surface. A User Defined Function (UDF) subroutine was developed to numerically simulate temperature distribution based on this heat flux density model. To validate the model, bone grinding experiments were conducted under various spindle speeds and cutting depths, with temperature measurements taken from the bone. The simulation results demonstrated high accuracy in experimental temperatures. Additionally, numerical simulations were performed to visualize the thermal damage range during bone grinding. The findings indicate that, under specific grinding conditions—such as a cutting depth of 0.2 mm at 10,000 rpm and 0.1 mm at 30,000 rpm—the thermal damage depth is relatively shallow, measuring only 0.07 mm. These results provide valuable insights for orthopedic surgeons regarding the influence of grinding parameters on bone temperature and establish a solid foundation for selecting optimal grinding parameters in orthopedic robotic systems for clinical applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 89-102"},"PeriodicalIF":6.1,"publicationDate":"2025-07-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604610","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":"EMPR equipment development and research on EMPR process of titanium threaded hollow rivets","authors":"Mengchen Yu ,&nbsp;Xiao Lin ,&nbsp;Lu Yan ,&nbsp;Minghao Zhang ,&nbsp;Zengqiang Cao ,&nbsp;Lubin Huo","doi":"10.1016/j.jmapro.2025.06.099","DOIUrl":"10.1016/j.jmapro.2025.06.099","url":null,"abstract":"<div><div>To prevent the occurrence of substandard riveting, a handheld electromagnetic pull riveting (EMPR) device is developed based on electromagnetic technology for riveting titanium or titanium alloy rivets in closed/semi-closed structures to achieve high consistency connection quality. Installation process experiments were conducted using the device at different riveting voltages to get the forming conditions of titanium threaded hollow rivets, and the voltage range for forming without riveting defects using flat anvil and right-angle anvil riveting was obtained. Finally, through numerical simulation with ABAQUS and in conjunction with the riveting force waveform obtained through tests, the stress field distribution inside the rivet, and the failure risk area, the relationship between riveting voltage and riveting quality is established. The forming process of the rivet and the reasons for head failure and fracture during the forming process were analyzed. The results indicate that the numerical simulation results correspond well with the experimental results. The device has excellent riveting consistency, just like other types of electromagnetic riveting equipment, and can achieve high-quality single-direction forming in both conditions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1228-1240"},"PeriodicalIF":6.1,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144596955","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":"Continuously layer-by-layer assembled multilayer coating to achieve excellent tribological properties and electrical contact stability","authors":"Dao-Yi Wu,&nbsp;Xue Zhou,&nbsp;Guo-Fu Zhai","doi":"10.1016/j.jmapro.2025.07.037","DOIUrl":"10.1016/j.jmapro.2025.07.037","url":null,"abstract":"<div><div>Balance between mechanical properties and electrical contact stability is one of the most important challenges in the field of electrical contact. In this study, multilayer coatings were designed based on alternating soft/hard layer strategy using magnetron sputtering technology. The main intention was to investigate the effect of the alternating structure of soft and hard layers on the mechanical, tribological properties and electrical contact behavior of multilayer coatings. The results demonstrated that as the number of heterogeneous interfaces in the multilayer coating increases, the hardness and yield strength raised to 5.1 GPa and 875 MPa, respectively, while the contact resistance was only 5.3 mΩ at a low contact force of 10 gf. The as-obtained multilayer coating maintained good structural integrity after 3000 wearing cycles at an ultra-high contact force of 8 N. The superior wear resistance is attributed to the high-density heterogeneous interfaces which served as a barrier to stress distribution, inhibiting the propagation of deformation carriers, shear bands and dislocations, thereby achieving an outstanding wear resistance. This finding provides a novel design strategy for developing high-quality coating.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 66-74"},"PeriodicalIF":6.1,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604815","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":"Chatter-free process parameter optimization for robotic machining of pockets with the spiral tool path","authors":"Tengyu Hou,&nbsp;Yang Lei,&nbsp;Ye Ding","doi":"10.1016/j.jmapro.2025.07.018","DOIUrl":"10.1016/j.jmapro.2025.07.018","url":null,"abstract":"<div><div>Pocket machining is widely used in manufacturing industries such as aerospace, mold, and automotive. Pocket machining with the spiral tool path has become an effective method for efficient pocket machining. The current primary means of pocket machining, CNC machine tools, face challenges in adaptability, machining mode, and production cost, while industrial robots provide a new approach to achieving efficient and cost-effective pocket machining. However, as industrial robots are less rigid than machine tools, they are more prone to chatter vibrations. To achieve efficient and stable robotic machining of pockets with the spiral tool path, this paper proposes a new chatter-free process parameter optimization strategy. The feedrate optimization algorithm for pocket machining is first introduced. Further, this algorithm is extended to establish the chatter-free parameter optimization model for robotic machining of pockets with kinematics, cutting force, and milling stability constraints. The surrogate-based optimization (SBO) method is then employed to solve this optimization model efficiently. The effectiveness of the proposed chatter-free parameter optimization strategy for robotic machining of pockets is validated by analyzing optimization results and machining experiments.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1241-1259"},"PeriodicalIF":6.1,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144596956","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":"Impurity-induced phase transformations in AlMgZn(Cu) crossover alloys: Pathways to enhance recycling content and processability","authors":"Sebastian Samberger ,&nbsp;Irmgard Weißensteiner ,&nbsp;Matheus A. Tunes ,&nbsp;Lukas Stemper ,&nbsp;Christina Kainz ,&nbsp;Roland Morak ,&nbsp;Peter J. Uggowitzer ,&nbsp;Stefan Pogatscher","doi":"10.1016/j.jmapro.2025.06.106","DOIUrl":"10.1016/j.jmapro.2025.06.106","url":null,"abstract":"<div><div>Aluminum crossover alloys offer a broad property profile within a single composition, but due to the growing demand for recycling in the aluminium industry, they will be required to mitigate the impact of tramp elements such as Fe and Si. This study investigates the influence of Fe/Si ratios and cooling rates during solidification on phase transformations and microstructure evolution in AlMgZn(Cu) crossover alloys, aiming to increase recycling content and maintain processability. Thermodynamic simulations, coupled with experimental validation, reveal two critical phase transformations during homogenization: the 6-to-3 transformation (Al₆(Fe,Mn) → Al₁₃(Fe,Mn)₄) and the 6-to-α transformation (Al₆(Fe,Mn) → Al(Fe,Mn)Si). These transformations are governed by the Fe/Si ratio and cooling rate, significantly affecting intermetallic phase morphology. The 6-to-3 transformation can effectively decrease the size of intermetallic particles, facilitating processability in relevant industrial conditions. Higher cooling rates upon solidification (≈60 K/s) always result in small, spheroidized phases, ensuring rollability. In contrast, slow cooling rates (≤1 K/s) often promote coarse, stable phases that hinder processability. However, at cooling rates around 3 K/s the intermetallic phase morphology highly depends on the Fe/Si ratio. When Fe and Si levels are simultaneously high, the 6-to-α transformation yields hard-shell/soft-core structures that impair mechanical integrity, while a higher ratio governs a beneficial 6-to-3 transformation. This study provides new insights into impurity-induced phase transformations and their role in determining processability in industrially relevant conditions. By linking microstructural control to sustainable alloy design, the results serve as a foundation for the development of crossover aluminum alloys optimized for high scrap content.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1178-1193"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144588668","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":"Study on the WC structural evolution and wear behavior of the cemented carbide coatings by laser directed energy deposition","authors":"Chenguang Guo ,&nbsp;Shengli Xue ,&nbsp;Haitao Yue ,&nbsp;Weibing Dai ,&nbsp;Ning Lv ,&nbsp;Jianhua Zhai ,&nbsp;Qiang Li ,&nbsp;Jinhua Li","doi":"10.1016/j.jmapro.2025.07.035","DOIUrl":"10.1016/j.jmapro.2025.07.035","url":null,"abstract":"<div><div>At present, laser directed energy deposition (LDED) of cemented carbide faces critical problems, such as WC melting, porosity, and cracks, which severely affect the mechanical properties of cemented carbide. In this study, WC-NiFeCr cemented carbide coatings were prepared using the LDED technique at various laser powers (1800 W, 2100 W, 2400 W, and 2700 W) to investigate the evolution of the WC particles, crack formation, and wear behavior. The results show that the WC particles gradually melted (unmelted WC → slightly melted WC → completely melted WC) through two erosive effects: edge melting and internal infiltration of the nickel-based solvent. Microcracks initiate in the edge melting and internal infiltration regions of the WC particles, whereas fine eutectic carbides help prevent crack extension. When the laser power increased from 1800 W to 2400 W, the microhardness and wear resistance of the cemented carbide coating gradually increased. The maximum microhardness of the coating is 1457.19 HV_0.5, and the minimum wear-profile area is 2801.48 μm². When the power is further increased to 2700 W, owing to the increase in internal pore defects, the microhardness and wear resistance decrease slightly. The main wear mechanisms are three-body abrasive wear and brittle spalling, as well as a small amount of adhesive wear. The results provide a new method for optimizing the wear resistance of cemented carbide coatings by changing the process parameters to regulate the evolution of the WC structure.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 54-65"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604679","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":"Rolled-flatness deviation evolution mechanism induced by transverse inhomogeneous deformation resistance during tandem cold rolling","authors":"Xiaohua Li ,&nbsp;Xu Li ,&nbsp;Qinglong Wang ,&nbsp;Lei Cao ,&nbsp;Hao Yuan","doi":"10.1016/j.jmapro.2025.06.103","DOIUrl":"10.1016/j.jmapro.2025.06.103","url":null,"abstract":"<div><div>Frequent occurrences of flatness defects during cold rolling have emerged as a significant bottleneck limiting the production of wide-thin high-strength strip. Conventional flatness simulation methods, typically based on idealized and homogeneous material models, fail to capture defects caused by distribution in transverse mechanical properties inherent to the strip itself. In this study, an analytical approach of strip shape, which addresses the limitations of existing models by incorporating actual transverse mechanical property distributions, is pioneered. Compared with conventional methods, the proposed finite element model demonstrates improved accuracy and stability, as validated by industrial production data. The relative error between the calculated and measured rolling force is maintained within 7 %, and the absolute error of the center thickness of the rolled strip is less than 5 μm. It is observed that there is a strong correlation between flatness defects and the initial transverse property distribution, which significantly increases the complexity of flatness deviations control. Furthermore, the influence of transverse property distribution on the evolution of the elastic deflection, inter-roll pressure and 3D pressure distribution is comprehensively analyzed, and the control efficiency of strip shape under relevant conditions is also evaluated.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 24-40"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604677","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 thermal behavior and mechanical properties in hot stamping of aluminized 30MnB5 with an integrated process window design","authors":"Jea-Myoung Park,&nbsp;Kye-Jeong Park,&nbsp;Je-Youl Kong,&nbsp;Seung-Chae Yoon","doi":"10.1016/j.jmapro.2025.06.105","DOIUrl":"10.1016/j.jmapro.2025.06.105","url":null,"abstract":"<div><div>Hot stamping technology has emerged as an essential process for manufacturing lightweight and ultra-high-strength automotive components, particularly with the increasing adoption of electric vehicles. Among advanced materials, aluminized 30MnB5 steel, with tensile strengths exceeding 1.8 GPa, provides a compelling combination of crash safety enhancement and weight reduction. However, its mechanical properties are highly sensitive to processing conditions, necessitating systematic optimization. This study introduces an integrated Process Window (PW) that incorporates heating, transfer, and cooling stages to ensure efficient and reliable manufacturing. Experimental results identified 870 °C as the optimal heating temperature for 30MnB5 steel. At this temperature, the steel achieved a tensile strength exceeding 1.8 GPa, a yield strength of approximately 1.2 GPa, and an elongation of 6.8 %. Additionally, the interdiffusion layer thickness in the Al-Si coating was reduced to approximately 3.8 μm, the prior austenite grain size was refined to 9.6 μm, and hydrogen absorption was suppressed by about 45 % compared to higher heating temperatures. These conditions collectively enhance weldability and ensure consistent mechanical performance. The sheet thickness was shown to significantly influence thermal behavior, impacting heating times, ambient exposure, and die-cooling. The derived temperature-time relationship functions enable tailored process adjustments to achieve consistent strength and formability across varying sheet thicknesses. Unlike conventional PW, which primarily addresses heating conditions, the proposed integrated PW encompasses the entire hot stamping process. It aims to reduce inefficiencies and improve process stability. By quantitatively linking process parameters to microstructural evolution and mechanical properties, this study establishes a robust framework for the production of lightweight, ultra-high-strength automotive components. The findings also contribute to advancing sustainable manufacturing practices by optimizing energy consumption and process efficiency.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1216-1227"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144596954","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":"Resistance welding of thermoplastic composites using novel heating element of graphite film","authors":"Jixiao Han ,&nbsp;Hongchuan Zhang ,&nbsp;Yifan Liu ,&nbsp;Jianhui Su ,&nbsp;Xueyan Zhang ,&nbsp;Caiwang Tan ,&nbsp;Huatao Wang ,&nbsp;Xiaoguo Song","doi":"10.1016/j.jmapro.2025.07.026","DOIUrl":"10.1016/j.jmapro.2025.07.026","url":null,"abstract":"<div><div>The application of thermoplastic composites has advanced structural lightweight, necessitating effective methods for achieving stable joints. In this study, a laser-ablated graphite film was developed as a novel heating element, introducing an innovative approach to the resistance welding of carbon fiber-reinforced polyamide 66 (CF/PA66) thermoplastic composites. Systematic experiments and analyses verified the performance of the graphite heating element in providing uniform heat and efficient welding during the process. Through systematic experiments and analysis, the graphite heating element demonstrated uniform heat generation and high welding efficiency. The use of this heating element enhanced resin flow and improved the temperature distribution uniformity at the welding interface. Moreover, it eliminated the need for dissimilar metallic materials, thereby reducing stress concentrations and minimizing edge effects during the welding process. This novel heating element shows great potential for resistance welding of thermoplastic composites, offering a groundbreaking solution for joining high-performance and lightweight structures.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 41-53"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604678","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":"Ultrafast laser processing of shaped film cooling holes for aero-turbine blades: Surface integrity, parameter influence and forming mechanism","authors":"Meng Li ,&nbsp;Zhixun Wen ,&nbsp;Ping Wang ,&nbsp;Yuxing Liu ,&nbsp;Zhufeng Yue","doi":"10.1016/j.jmapro.2025.07.017","DOIUrl":"10.1016/j.jmapro.2025.07.017","url":null,"abstract":"<div><div>Shaped film cooling holes (FCHs) can effectively improve the film cooling efficiency of turbine blades, but due to their complex structure and precision requirements, there is currently no reliable and high-quality machining method. In this paper, a segmented processing method of fan-shaped FCHs is proposed, which realizes high-quality processing of fan-shaped FCHs. The effects of processing parameters on the machining efficiency, geometric accuracy and surface morphology of fan-shaped FCHs were analyzed. And the microstructure, composition, surface roughness and residual stress of the hole wall under specific processing parameters were characterized. The influence mechanism of processing parameters on the processed results is clarified by laser overlap rate and laser energy density of the processing area. The important role of focus compensation in the segmented machining method is discussed. The formation mechanism of microstructures was explained by the plasma exciton theory and the energy shielding effect. Furthermore, the process method is promoted through expansion section model segmentation and processing attitude adjustment to realize the processing of cat-ear-shaped and bat-face-shaped FCHs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1194-1215"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144596952","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}