Journal of Manufacturing Processes最新文献

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An investigation on subsurface generation in ultra-precision milling of nickel with multiscale crystal plasticity FE model
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-11 DOI: 10.1016/j.jmapro.2025.03.027
Sujuan Wang, Shuai Zhao, Ronghuan Xu, Leyang Huang, Zhanwen Sun
{"title":"An investigation on subsurface generation in ultra-precision milling of nickel with multiscale crystal plasticity FE model","authors":"Sujuan Wang,&nbsp;Shuai Zhao,&nbsp;Ronghuan Xu,&nbsp;Leyang Huang,&nbsp;Zhanwen Sun","doi":"10.1016/j.jmapro.2025.03.027","DOIUrl":"10.1016/j.jmapro.2025.03.027","url":null,"abstract":"<div><div>The subsurface microstructure affects the mechanical properties, the service performance and reliability of the workpiece components especially in ultra-precision machining. This study proposes a multiscale crystal plasticity finite element (CPFE) model to study subsurface generation in ultra-precision raster milling (UPRM) of FCC alloy by considering the microscale chip thickness variations and size effect in ultra-precision milling process, the microstructure evaluation as well as the macroscopic mechanical behavior of FCC alloy. Ultra-precision diamond milling experiments are conducted to verify the developed CPFE model and study the subsurface damage characteristics of the raster milled pure nickel, including dislocation distribution and microstructure variation of pure nickel under different milling conditions. The effects of cutting speed and depth of cut on the subsurface features including the subsurface microstructure variation, distributions of Mises stress and cumulative shear strain as well as the strain gradient of subsurface are qualitatively and quantitatively evaluated by the established CPFE model.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 815-828"},"PeriodicalIF":6.1,"publicationDate":"2025-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592625","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
Stability analysis of finite amplitude chatter in turning considering tool wear and process damping effects
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-11 DOI: 10.1016/j.jmapro.2025.03.019
Youhui Cai , Kejia Zhuang , Kang Zhu , Xiao Wang
{"title":"Stability analysis of finite amplitude chatter in turning considering tool wear and process damping effects","authors":"Youhui Cai ,&nbsp;Kejia Zhuang ,&nbsp;Kang Zhu ,&nbsp;Xiao Wang","doi":"10.1016/j.jmapro.2025.03.019","DOIUrl":"10.1016/j.jmapro.2025.03.019","url":null,"abstract":"<div><div>Due to the nonlinear characteristics of tool wear and process damping, these factors are often neglected when establishing the differential equations for machining chatter dynamics, resulting in the predicted stability lobe diagrams (SLD) not accurately guiding the actual machining. Furthermore, the influence of tool wear on turning stability and its relationship with process damping effect are still unclear. Based on the traditional turning machining dynamics model, this paper establishes a dynamics model suitable for sharp tools and worn tools, producing SLD that evolve with cutting time. Considering the influence of process damping effect, the calculation formula of process damping coefficient is derived based on the energy equivalence principle, and both process and system damping are incorporated into the dynamic differential equations. According to the limit loop theory, this paper proposes a construction method of finite amplitude chatter SLD, which features both upper and lower boundaries instead of the traditional single-boundary SLD. In the region between the upper and lower boundaries, the machining process is in a finite amplitude stable state. Finally, the results are verified by turning experiments, which show that the finite-amplitude chatter SLD proposed in this paper can guide the machining more accurately and efficiently compared with the traditional SLD. At the same time, this paper reveals the evolution law of the influence of tool wear on the machining stability, and the interaction relationship between tool wear and process damping.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 773-788"},"PeriodicalIF":6.1,"publicationDate":"2025-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592622","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
Additively manufactured materials: A critical review on their anisotropic mechanical properties and modeling methods
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-11 DOI: 10.1016/j.jmapro.2025.02.038
Shi Dai , Kaiyang Zhu , Shuheng Wang , Zichen Deng
{"title":"Additively manufactured materials: A critical review on their anisotropic mechanical properties and modeling methods","authors":"Shi Dai ,&nbsp;Kaiyang Zhu ,&nbsp;Shuheng Wang ,&nbsp;Zichen Deng","doi":"10.1016/j.jmapro.2025.02.038","DOIUrl":"10.1016/j.jmapro.2025.02.038","url":null,"abstract":"<div><div>Additive manufacturing (AM) technology has attracted wide attention from various industries worldwide due to its ability to rapidly fabricate complex three-dimensional structures. Additively manufactured materials (AMMs, including metals, alloys, polymers, inorganic nonmetal materials, and composites) and structures are currently being applied in important fields such as aerospace, construction, and healthcare. However, AM technology still faces challenges, particularly the mechanical anisotropy of AMMs, which can hinder its further applications. Specifically, because of the layer-by-layer manufacturing process, AMMs inevitably possess numerous defects and heterogeneous microstructures, leading to unpredictable anisotropic mechanical behavior. Currently, there is a lack of comprehensive and in-depth views and comparison regarding the mechanisms of anisotropic mechanical properties and constitutive modeling methods for different AMMs. To fully exploit the advantages of AM technology in the design and manufacturing of complex structures, a thorough understanding of the anisotropic mechanical behaviors of different types of AMMs, as well as their mechanical anisotropy modeling and control methods is necessary. This article reviews and compares the mechanisms influencing the anisotropic mechanical behavior of various AMMs, as well as the research progress in developing their anisotropic constitutive models and control methods. This review also proposes future research directions, providing a reference for researchers and engineers to understand, apply, and continuously develop this field of study.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 789-814"},"PeriodicalIF":6.1,"publicationDate":"2025-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592624","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
Numerical simulation of molten pool-particle behavior in magnetic field-assisted laser welding of SiCp/Al composites
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-10 DOI: 10.1016/j.jmapro.2025.03.039
Libo Wang , Chuncheng Zhai , Zhijia Hua , Gaoyang Mi , Xiuquan Ma , Guang Zeng
{"title":"Numerical simulation of molten pool-particle behavior in magnetic field-assisted laser welding of SiCp/Al composites","authors":"Libo Wang ,&nbsp;Chuncheng Zhai ,&nbsp;Zhijia Hua ,&nbsp;Gaoyang Mi ,&nbsp;Xiuquan Ma ,&nbsp;Guang Zeng","doi":"10.1016/j.jmapro.2025.03.039","DOIUrl":"10.1016/j.jmapro.2025.03.039","url":null,"abstract":"<div><div>Magnetic field-assisted welding is a widely utilized technique that effectively controls the flow of the molten pool and reduces particle phase agglomeration in the welding of SiC<sub>p</sub>/<em>Al</em> matrix composites. Despite its advantages, challenges related to process monitoring and a lack of clarity regarding the underlying mechanisms have hindered its broader application. This study investigates molten pool flow dynamics and SiC<sub>p</sub> particle distribution through simulations of magnetic field-assisted welding for SiC<sub>p</sub>/<em>Al</em> matrix composites. Without the magnetic field, two primary circulations are observed in the molten pool, where particle inertia drives particles toward the outer regions of the circulations. Particles also cluster and deposit in low-velocity regions at the circulation junctions. In contrast, during magnetic field-assisted laser welding, the Seebeck effect between the particles and the magnetic field induces a thermal current, generating significant perturbations near the fusion line and around the keyhole. These perturbations promote a more uniform particle distribution, improving particle homogeneity by ∼13 % and ∼ 10 % under transverse and longitudinal magnetic fields, respectively. Additionally, the magnetic field reduces the velocity in the molten pool's central region by approximately 40 %, leading to a more stabilized Marangoni flow. This work provides both theoretical insights and practical approaches to address SiC particle agglomeration in laser welding of metal matrix composites.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 694-708"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143577752","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
Impact variation of workpiece stiffness on drilling of CFRP/Ti thin stacks
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-10 DOI: 10.1016/j.jmapro.2025.03.001
Changlin Du, Rao Fu, Wenhao Zhai, Jinlong Liu, Guanping Cui, Meng Zhao, Fuji Wang
{"title":"Impact variation of workpiece stiffness on drilling of CFRP/Ti thin stacks","authors":"Changlin Du,&nbsp;Rao Fu,&nbsp;Wenhao Zhai,&nbsp;Jinlong Liu,&nbsp;Guanping Cui,&nbsp;Meng Zhao,&nbsp;Fuji Wang","doi":"10.1016/j.jmapro.2025.03.001","DOIUrl":"10.1016/j.jmapro.2025.03.001","url":null,"abstract":"<div><div>High-quality drilling Carbon Fiber Reinforced Polymer (CFRP)/Titanium alloy (Ti) stacks is a significant challenge in the aerospace industry, especially for thin stacks. This study investigates the drilling behavior of CFRP/Ti thin stacks under various stiffness conditions and reveals the impact of stiffness variation. Various quantified stiffness conditions were set for drilling tests and analysis. The results indicate that when the drill bit fully penetrates CFRP and still cuts Ti, an interlayer gap will be formed between CFRP and Ti layers, and lower stiffness will enlarge the interlayer gap. The maximum thrust force was found to decrease linearly by 3–4 % with every 70 % increase in clamping length, even though the thrust force increased over a longer period in low-stiffness cases. Ti cutting chips were consistently extruded into the interlayer in low stiffness cases, which consequently caused scratching and damaged the interlayer surface. In addition, the extruded chips lead to a reverse deformation of CFRP, which enlarges the gap and further aggregates chip extrusion and interlayer damage. Meanwhile, three additional CFRP removal phenomena caused by deformation and Ti chip scratching were observed, chip scratching was the most serious, and the mechanism of hole-shape formation was revealed. Compared to the CFRP hole, the shape of the Ti hole was barely affected by its deformation, but its position error was enlarged due to in-suit changing deformation and the position-based cylindricity errors of the stacks were also affected. More importantly, the beginning of Ti chip extrusion was proposed as a critical condition for low-stiffness stack drilling when the gap exceeds the Ti chip curl height, which has been proved by integrated simulation and experiment analyses. This critical condition and its correlated clamping distribution could be adopted as free interlayer damage drilling instruction for low stiffness CFRP/Ti stack.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 627-637"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578255","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
Numerical modelling of material fracture caused by the Mannesmann effect
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-10 DOI: 10.1016/j.jmapro.2025.03.035
Zbigniew Pater
{"title":"Numerical modelling of material fracture caused by the Mannesmann effect","authors":"Zbigniew Pater","doi":"10.1016/j.jmapro.2025.03.035","DOIUrl":"10.1016/j.jmapro.2025.03.035","url":null,"abstract":"<div><div>This paper relates to the problem of modelling material fracture caused by the so-called Mannesmann effect, a phenomenon that frequently occurs in cross and skew rolling processes. First, previous studies on numerical modelling fracture in rotary tube piercing and cross wedge rolling processes are described. The literature review shows a lack of studies investigating the propagation of cracks due to the Mannesmann effect. To fill this knowledge gap, a study involving both numerical analyses and experiments was undertaken. The study used a test based on rotary compression of a cylindrical specimen; the test is used for material damage function calibration. Rotary compression was performed under cold forming conditions for aluminium alloy Al99.7 and under hot forming conditions for steel C45. Based on results of the rotary compression test for aluminium, a new method was developed for determining the critical value of damage using cylindrical specimens with initiated fracture. Following the establishment of the critical damage value for alloy Al99.7, the rotary compression process was simulated numerically, which consisted of 3D modelling the axial crack propagation caused by the Mannesmann effect. In addition to that, the effect of the formed crack on the state of stress in the workpiece was determined. After that, the critical damage of steel C45 in the temperature range 950 °C–1100 °C was determined. The obtained critical damage value was validated by simulating material fracture in a cross wedge rolling process that was earlier conducted under laboratory conditions. The numerical and experimental results of material fracture showed very high agreement.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 650-666"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578256","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
Synchronously tailoring of residual stress and surface quality of high-strength titanium alloy tube using magnetic field-assisted finishing
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-10 DOI: 10.1016/j.jmapro.2025.02.085
Dong Wei , Heng Yang , Jingchao Yang , Jiagang Xue , Pei Zhang , Heng Li
{"title":"Synchronously tailoring of residual stress and surface quality of high-strength titanium alloy tube using magnetic field-assisted finishing","authors":"Dong Wei ,&nbsp;Heng Yang ,&nbsp;Jingchao Yang ,&nbsp;Jiagang Xue ,&nbsp;Pei Zhang ,&nbsp;Heng Li","doi":"10.1016/j.jmapro.2025.02.085","DOIUrl":"10.1016/j.jmapro.2025.02.085","url":null,"abstract":"<div><div>High-strength titanium alloy tubes are widely used as key materials in hydraulic and fuel systems in aeronautic industries, which are subjected to harsh conditions such as alternating loads and oil erosion during the service process. The residual stress state and the surface quality of the tubes are crucial to their service performance. However, these tubes are primarily prepared through a cold pilgering process, and the finished tube exhibits significant residual tensile stress on the outer surface, which cannot be changed with the variation of the process parameters. Moreover, the conventional shot peening process can only achieve the outer surface treatment while causing surface roughening, thereby reducing the fatigue strength and stress corrosion resistance. Accordingly, this study aims to achieve the synchronous tailoring of the residual stress and surface quality of high-strength titanium alloy tubes by introducing magnetic field-assisted finishing (MAF) technology, as well as to investigate the residual stress evolution mechanisms during the MAF process. The effects of MAF parameters on the residual stress and surface quality of the tubes are revealed firstly. With the increase in magnetic needle diameter and disk rotational speed, the residual compressive stresses exhibit a gradually increasing trend on the inner and outer surfaces of the tubes, with the maximum residual compressive stress reaching −600 MPa. While the surface roughness of the inner and outer surfaces of the tubes firstly decreases and then increases, with the lowest Ra values of 0.24 μm and 0.52 μm for the outer and inner surfaces, respectively. Secondly, the residual stress evolution mechanisms during the MAF process are elucidated. During the MAF process, significant plastic deformation occurs in the region near the surface of the tube with a depth of approximately 90 to 100 μm. The dislocation densities along the wall thickness direction show gradient distribution characteristics, with a gradual decrease trend from the surface to the middle layer. The increase in the difference in dislocation density between the area near the surface and the middle layer results in the distribution characteristics of residual compressive stress on the surface of the tubes after MAF. It can be concluded that MAF can effectively tailor the residual stress on the outer and inner surfaces of high-strength titanium tubes by adjusting the magnetic needle diameter and disk rotational speed, without reducing the surface quality of the tubes, and is of great significance for improving the fatigue service performance of the tubes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 638-649"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143577757","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
Microstructure evolution and grain refinement mechanism of ultrasonic-assisted low-frequency pulse VPPA welded joint of AA2195-T8 Al-Cu-Li alloy AA2195-T8 Al-Cu-Li 合金超声波辅助低频脉冲 VPPA 焊接接头的显微组织演变和晶粒细化机理
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-10 DOI: 10.1016/j.jmapro.2025.03.026
Guihan Cui, Chunli Yang
{"title":"Microstructure evolution and grain refinement mechanism of ultrasonic-assisted low-frequency pulse VPPA welded joint of AA2195-T8 Al-Cu-Li alloy","authors":"Guihan Cui,&nbsp;Chunli Yang","doi":"10.1016/j.jmapro.2025.03.026","DOIUrl":"10.1016/j.jmapro.2025.03.026","url":null,"abstract":"<div><div>Variable polarity plasma arc welding is a widely utilized welding technique for the AA2195-T8 alloy. However, coarse grains adversely affect the weld's mechanical properties. This study integrates ultrasonic-assisted and low-frequency pulse welding processes to achieve grain refinement and enhance mechanical properties. The results indicated that high-amplitude ultrasound produced a superior grain refinement effect. However, this method also introduced numerous microscopic defects in the weld, compromising the mechanical properties. In contrast, low-frequency pulse welding exhibited less effective grain refinement than ultrasonic assistance without microscopic defects. The optimal grain refinement was achieved when low-amplitude ultrasound was combined with the high-difference pulse welding process, resulting in the best grain refinement effect. The weld grain morphology primarily consisted of refined equiaxed grains, with an average size reduction of 82 % (18.8 μm). The coarse second phase near the grain boundary was the Al-Cu-Mg-Ag eutectic phase. T1 and σ phases, along with dislocation lines, were prevalent in the grains. Compared to conventional welds, the tensile and yield strengths improved. However, the presence of some microcracks led to a reduction in elongation. The cavitation and acoustic streaming effects induced by ultrasonic assistance facilitated liquid convection and oscillation, resulting in more uniform second phases and disrupting coarse dendritic structures. Furthermore, the chilling effect of the pulse current promoted grain nucleation and accelerated molten pool flow, compensating for the limited grain refinement effect associated with low-amplitude ultrasound. At the late stage of solidification, the plasticity of the intercrystalline liquid film decreased, while the ultrasonic oscillation increased the strain, contributing to the formation of microscopic defects.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 679-693"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578258","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 gradient polishing depth on material removal mechanism of silicon wafer polishing by silicon dioxide abrasive based on molecular dynamics
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-10 DOI: 10.1016/j.jmapro.2025.03.022
Jianbo Le , Juan Liu , Miao Mei , Hu Chen , Hong Jiang , Dongling Yu
{"title":"Effect of gradient polishing depth on material removal mechanism of silicon wafer polishing by silicon dioxide abrasive based on molecular dynamics","authors":"Jianbo Le ,&nbsp;Juan Liu ,&nbsp;Miao Mei ,&nbsp;Hu Chen ,&nbsp;Hong Jiang ,&nbsp;Dongling Yu","doi":"10.1016/j.jmapro.2025.03.022","DOIUrl":"10.1016/j.jmapro.2025.03.022","url":null,"abstract":"<div><div>To study the effect of gradient polishing depth on the material removal mechanism of silicon wafers, the LAMMPS molecular dynamics method is utilized, combined with Lennard-Jones (LJ), Tersoff, and Stillinger-Weber (SW) potential functions. The nano-polishing process is investigated through gradient depth polishing experiments, with five different polishing depths of 2.2 <em>nm</em>, 2.4 <em>nm</em>, 2.6 <em>nm</em>, 2.8 <em>nm</em>, and 3.0 <em>nm</em> selected for analysis. By analyzing physical quantities such as polishing force, crystal structure, dislocation, radial distribution function, and coordination number, the effect of gradient polishing on material removal is revealed. The results show that at a polishing depth of 2.6 <em>nm</em>, the polishing force is stable, and the surface roughness reaches its minimum value (S<em>a</em> = 8.109 <em>nm</em>). Subsurface damage is minimized, and the Si-I phase structure remains intact, avoiding amorphization and phase transformation. This depth effectively removes material while preserving surface quality, making it the ideal polishing depth for enhanced processing efficiency. At polishing depths of 2.2–2.4 <em>nm</em>, shear strain begins to concentrate, and surface roughness starts to decrease. When the polishing depth increases to 2.4 <em>nm</em>, subsurface damage intensifies, and the roughness value becomes S<em>a</em> = 10.01 <em>nm</em>. At polishing depths of 2.8–3.0 <em>nm</em>, roughness reaches its highest value (S<em>a</em> = 11.843 <em>nm</em>), and the original silicon wafer structure Si-I transforms into Si-II phase, bct5-Si phase, and an amorphous state due to extrusion and shearing, resulting in decreased surface quality. This study provides an important theoretical foundation and practical guidance for optimizing the polishing process of silicon wafers and improving material removal efficiency and surface quality.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 746-759"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143577756","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 modeling of process parameters from data to predict the cooling behavior in injection molding
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2025-03-10 DOI: 10.1016/j.jmapro.2025.02.057
Manuel Wenzel , Sven Robert Raisch , Christian Hopmann , Mauritius Schmitz
{"title":"Inverse modeling of process parameters from data to predict the cooling behavior in injection molding","authors":"Manuel Wenzel ,&nbsp;Sven Robert Raisch ,&nbsp;Christian Hopmann ,&nbsp;Mauritius Schmitz","doi":"10.1016/j.jmapro.2025.02.057","DOIUrl":"10.1016/j.jmapro.2025.02.057","url":null,"abstract":"<div><div>AI methods, especially Deep Learning Methods (DLMs), present an excellent opportunity for the surrogate modeling of complex processes, like the injection molding process, based on simulation or measurement data. To overcome the need for large data sets DLMs usually require, the integration of domain knowledge into the learning process e.g., in the form of Partial Differential Equations (PDEs), is rising in popularity. In this study, an inverse approach based on Physics Informed Neural Networks (PINNs) is explored for parameterizing the influence of material and process parameters on the cooling behavior of an injection molded part. With the proposed method, the PDE, Initial Condition (IC), and Boundary Condition (BC) of the underlying physical process can be automatically parameterized based on data. To reduce modeling effort, a simplified generic representation of the physical process description is used. The effectiveness of the method is demonstrated by utilizing the inversely learned physical process model to regularize the surrogate model. When predicting the spatiotemporal temperature evolution dependent on different materials and process settings, a 25% lower Root-Mean-Squared-Error (RMSE) was achieved by the hybrid approach in comparison to a purely data-driven model. The use of the simplified process physics highlights the generalizability of the approach to other data types and processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 760-772"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592621","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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