Journal of Manufacturing Processes最新文献

{"title":"Achievement of ductile-regime removal in fabricating Gaussian curved microstructure processed by micro ball-end milling on soft-brittle KDP surface","authors":"Jian Cheng ,&nbsp;Hongqin Lei ,&nbsp;Yong Xiao ,&nbsp;Linjie Zhao ,&nbsp;Mingjun Chen ,&nbsp;Youwang Hu ,&nbsp;Qi Liu ,&nbsp;Dinghuai Yang ,&nbsp;Wenyu Ding ,&nbsp;Guang Chen","doi":"10.1016/j.jmapro.2024.09.103","DOIUrl":"10.1016/j.jmapro.2024.09.103","url":null,"abstract":"<div><div>Laser-induced damage points (known as defects) would seriously reduce the service life of large-aperture KDP optics in high-power laser devices. The ball-end milling procedure is recognized as an efficient method for creating a Gaussian mitigation pit (GMP) to restore the optical transmission performance of functional KDP crystals by removing defects. Nevertheless, achieving smooth and flawless Gaussian curved microstructures is a massive challenge for soft-brittle KDP crystals. Herein, a judging criterion of the ductile-regime machining for the GMP is developed by the models of uncut chip thickness (UCT) and critical milling depth. Simultaneously, the obtained judging criterion can be validated by the microstructure fabrication experiments. Besides, considering the spindle vibration, plowing effect, and machined surface texture, the influence of spindle speed (<em>n</em>), feed rate (<em>f</em>), and tool mark interval (<em>d</em>) on the surface formation mechanism of the GMP is analyzed, respectively. It can be discovered that the <em>n</em> of up to 60,000 r/min can lead to severe velocity fluctuation of the motion system, increasing the UCT and causing brittle fractures on the KDP surface. A low <em>f</em> can result in an undesirable plowing phenomenon, and a large number of crystal materials are accumulated in the up-cut process. Once the <em>f</em> reaches 72 mm/min, the tool path would fluctuate significantly, resulting in poor GMP surface texture. When the <em>d</em> exceeds 15 μm, the surface quality of the GMP can no longer meet the engineering requirements of the <em>Ra</em> ≤ 50 nm. Moreover, the optimized processing parameters of the microstructure fabrication are 47,800 r/min in the <em>n</em>, 30 mm/min in the <em>f</em>, and 5 μm in the <em>d</em>. This study can provide crucial guidance for obtaining the ultra-smooth and defect-free GMP processed in the ductile regime, which would resultantly possess significant theoretical importance and practical value in enhancing the optical properties of flawed KDP crystals.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1230-1239"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423658","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A GPU-based approach for 5-axis flute grinding of end-mills with complex grinding wheel","authors":"Jianping Yang,&nbsp;Liming Wang,&nbsp;Yang Fang,&nbsp;Fangyi Li,&nbsp;Jianfeng Li","doi":"10.1016/j.jmapro.2024.09.075","DOIUrl":"10.1016/j.jmapro.2024.09.075","url":null,"abstract":"<div><div>End-mills are used widely in industry, in which efficient chip evacuation and enhanced tool performance are directly influenced by the flute shapes. Generally, complex grinding wheels are employed to create intricate flute shapes with CNC grinding. In the kinematic of flute grinding, several transcendental equations with high non-linearity is derived and required to be solved. In some cases, the explicit expression for flute cannot be derived and the numerical method are generally applied, which requires various derivation or numerical program for different flute shapes. To address these challenges, this paper proposed a GPU-based approach for 5-axis flute grinding of end-mills with complex grinding wheel. In this method, a mesh model of the grinding wheel was established to transform the above complex equations into finding a set of point cloud which satisfied the envelope condition. To accelerate the computation time for searching those point cloud, a generalized GPU parallel processing algorithm were used to execute multiple compute threads. The validity of the approach was verified through a series of experiments. It demonstrated that this method achieved remarkable precision and broad applicability, fulfilling the diverse requirements of various grinding wheels and flute shapes. Furthermore, the high efficiency and versatility of this approach make it have great potential in the application of flute-grinding with various complex wheel in real-time path planning.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1250-1262"},"PeriodicalIF":6.1,"publicationDate":"2024-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423660","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":"An investigation of the formability of ultra-thin CP-Ti-Gr2 foils considering thickness-to-grain-size effects under controlled heat treatment in μ-ISF","authors":"Mainak Pal,&nbsp;Anupam Agrawal,&nbsp;Chandrakant K. Nirala","doi":"10.1016/j.jmapro.2024.09.107","DOIUrl":"10.1016/j.jmapro.2024.09.107","url":null,"abstract":"<div><div>Micro-forming is an emerging micro-manufacturing process for the fabrication of miniature parts/components made of ultra-thin sheets (foils), forged billets, rods, etc. Achieving high formability in the micro-incremental sheet forming (μISF) process is difficult due to the size-effect and non-optimal selection of process parameters viz. step depth (∆z). The major sources of size-effects are pure volume source, surface-to-volume ratio, thickness-to-grain-size (t/d ratio), surface structure scalability, etc. In the micro-scale processes, studying the grain size of the material is crucial to understand the deformation behaviour. Additionally, the anisotropy is very prominent in thin foils and affects the micro-forming process adversely. In the present work, the intrinsic anisotropy of the foils is minimized through controlled heat treatment, and varying grain sizes, having different microstructures, are generated to investigate their effect on the formability of CP-Ti-Gr2 foils. Initially, the properties of the received material are tested along different directions through the uniaxial tensile test, followed by furnace annealing to produce equiaxed recrystallized grains and reduce the anisotropy of the foils. Subsequently, the specimens are heat-treated at different temperatures to generate a wide spectrum of grain sizes. Through extensive μISF experiments, it was established that higher annealing temperature and increase in grain size assisted in improving the ductility of the foils, leading to enhanced formability. Therefore, the combined effect of the grain size and step depth on the formability of the components is investigated. A relationship between formability and t/d ratio was established and its critical value was obtained. Interesting observations, contrary to those in macro-ISF process were observed, e.g. higher step depth in μISF helped in improving the formability of the micro-parts. The results were confirmed by measuring the forming forces during the process, and it presented a strong correlation with the yield stress values, further correlated with varying grain sizes of the foil. This work could pave the way for designing the μISF process parameters considering the size-effects at micro-scale deformation, through optimum t/d ratio, for maximizing the formability.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1202-1218"},"PeriodicalIF":6.1,"publicationDate":"2024-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423736","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A defect classification algorithm for gas tungsten arc welding process based on unsupervised learning and few-shot learning strategy","authors":"Qiang Liu ,&nbsp;Runquan Xiao ,&nbsp;Yuqing Xu ,&nbsp;Jingyuan Xu ,&nbsp;Shanben Chen","doi":"10.1016/j.jmapro.2024.09.084","DOIUrl":"10.1016/j.jmapro.2024.09.084","url":null,"abstract":"<div><div>Welding defect prediction is the foundation for ensuring welding quality in gas tungsten arc welding (GTAW). In the prediction process, method based on molten pool vision is the most effective. Since the classification of molten pool defects relies on a substantial volume of labeled data, it is challenging for the models to be applied industrially. This paper presents an algorithm, FS-Classifier, that can achieve high prediction accuracy based on a limited amount of labeled data. The FS-Classifier comprises two stages: Firstly, an unsupervised training approach named RaP is designed to pre-train the feature extractor using extensive unlabeled daily datasets. The RaP consists of a rotation angle prediction task and a position prediction task, which ensure that the network focuses on salient features and precise elements, respectively. Secondly, the support vectors constructed from limited labeled data are used for the feature classifier. The input data is classified to certain class by computing its distances to support vector. The model achieves an accuracy of 94.5 % on the private dataset and 92.8 % on the public dataset for the six classes of defects using 5 % of labeled data volume. In addition, comparative experiments show that our method only requires 5 % of labeled data to achieve accuracy comparable to traditional supervised learning methods. The proposed algorithm addresses the issue of relying on a substantial amount of labeled data in welding process defect classification.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1219-1229"},"PeriodicalIF":6.1,"publicationDate":"2024-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423737","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":"Metal additive manufacturing: Principles and applications","authors":"S. Patel,&nbsp;Y. Liu,&nbsp;Z. Siddique,&nbsp;I. Ghamarian","doi":"10.1016/j.jmapro.2024.09.101","DOIUrl":"10.1016/j.jmapro.2024.09.101","url":null,"abstract":"<div><div>Additive manufacturing (AM) of metals has gained massive attention due to its salient features, such as a tool-free process, near-net shape product development, less fabrication time, and no restriction on product size. This paper provides a brief overview of common metal AM processes, including powder bed fusion, binder jetting, directed energy deposition, and sheet lamination. The advantages of each metal AM technology and their limitations are compared and addressed with examples. Critical steps to ensure the successful 3D printing of metal structures are discussed for each metal AM approach. The effect of each processing parameter is critically analyzed to enhance fabrication characteristics. The metal AM mechanisms, optimization of processing parameters, powder preparation techniques and their effects on the powder morphology, and applications of metal AM are discussed.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1179-1201"},"PeriodicalIF":6.1,"publicationDate":"2024-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423735","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":"Machining performance and wear mechanism of CVD diamond-coated micro-grinding tools in micro-grinding of fused silica","authors":"Wei Li ,&nbsp;ChangJin Long ,&nbsp;Zhenyang Deng ,&nbsp;XuDong Guo ,&nbsp;YingHui Ren ,&nbsp;Qiang Lin ,&nbsp;Bin Shen","doi":"10.1016/j.jmapro.2024.09.037","DOIUrl":"10.1016/j.jmapro.2024.09.037","url":null,"abstract":"<div><div>This paper investigates the fabrication and application of chemical vapor deposition (CVD) diamond-coated micro-grinding tools in machining fused silica. The study innovatively fabricated four diamond-coated micro-grinding tools (10,000#, 6000#, 3000#, 1500#) using hot filament chemical vapor deposition and explored their formation mechanism, grinding performance, as well as wear and failure mechanism. The results revealed that a larger grain size leads to a flatter film surface with prominent planar features, columnar growth characteristics, and fewer internal defects. Machining experiments revealed that the grinding quality increases with increasing feed rate and grinding depth. On the other hand, it decreases with increasing spindle speed. Nevertheless, the dominant failure mechanism of 1500# and 3000# micro-grinding tools is primarily brittle fracture. Meanwhile, 6000# micro-grinding tools are featured with both brittle fracture and ductile domain removal. Micro-grinding tools with grind size 10,000# are featured with ductile domain removal and demonstrated the best machining quality. The results showed that crack generation and extension caused by abrasive and bonded wear are the leading causes of diamond film failure in micro-grinding tools, and the larger the average grain size, the better the wear resistance. This research provides new insight into the wear mechanism of diamond-coated micro-grinding tools and contributes to developing CVD diamond-coated micro-grinding tools for precision machining hard and brittle materials.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1168-1178"},"PeriodicalIF":6.1,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142359669","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":"Bionic design and optimization of cutting tools: Applications and processability","authors":"Shuai Huang ,&nbsp;Sheng Liu ,&nbsp;Dazhong Wang ,&nbsp;Akiyama Takao ,&nbsp;Shujing Wu ,&nbsp;Chen Li ,&nbsp;Daohui Xiang ,&nbsp;Changhe Li","doi":"10.1016/j.jmapro.2024.09.058","DOIUrl":"10.1016/j.jmapro.2024.09.058","url":null,"abstract":"<div><div>Cutting is a fundamental machining method extensively utilized across various fields, including mechanical engineering, agriculture, forestry, biomedical instrumentation, mineral exploration, and extraterrestrial missions. However, during cutting operations, tools are exposed to high temperatures and friction, which result in diminished cutting efficiency, reduced tool life, and compromised workpiece quality. Advances in bionics are gradually mitigating these challenges. Bionic design provides rich, reliable, and efficient prototypes that enhance tool performance while promoting environmentally friendly, harmonious, and sustainable tool development. In the bionic optimization of cutting tools, the selection of appropriate bionic prototypes and models is crucial. However, the complexity and ambiguity inherent in bionic prototype functions impede the development and widespread adoption of bionic tools. This paper initially focuses on the classification of bionic tools, subsequently proposing five categories of bio-inspired design elements and topological models from the perspective of bio-inspired cutting tools. The second section discusses the applications, advantages, and cutting performance of five types of bionic tools, with an emphasis on both the biomimetic optimization of the tool body and non-tool bodies. These tools are designed by emulating the diverse biological characteristics exhibited by various organisms. Additionally, the underlying mechanisms of the five categories of bionic tools, as well as the corresponding optimization strategies, are explored. Finally, this paper summarizes research on bionic tools and analyzes the current opportunities and challenges they face. In summary, compared to traditional tools, bionic tools demonstrate superior performance in energy efficiency, friction reduction, wear resistance, lubrication, extended service life, and multifunctionality. This offers valuable insights for researchers involved in the design and development of cutting tools.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1086-1131"},"PeriodicalIF":6.1,"publicationDate":"2024-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142359670","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":"Online monitoring method for chip pin with minor deformation defects based on depth-histogram modalities and target-oriented multimodal self-attention mechanism","authors":"Changdu Du,&nbsp;Lei Xu,&nbsp;Jun Chen,&nbsp;Nachuan He","doi":"10.1016/j.jmapro.2024.09.063","DOIUrl":"10.1016/j.jmapro.2024.09.063","url":null,"abstract":"<div><div>In the process of chip SMT (surface mounting technology), the quality of the chip pins determines the success rate of the mounting process. However, existing target detection algorithms present poor performance when dealing with deformations in the pins, which is insufficient to meet the industrial demands for accuracy and speed of online monitoring. To solve this problem, a real-time detection method based on D<img>H (Depth-Histogram) Modalities and TMSM (Target-oriented Multimodal Self-attention Mechanism) is proposed. There are three parts in this method, including feature extraction, feature fusion, and decision module. Firstly, a lightweight network for feature extraction and fusion is employed to extract geometric information from the depth images. Subsequently, the Decision Module is used to determine whether there are defects in the pins. Within this framework, the HIEF (Histogram-Integrated Embedding Function) is utilized to extract a one-dimensional vector with height information from the histogram, which is then aligned with the flattened depth image to form D<img>H Modalities. To validate the effectiveness of the proposed algorithm, two datasets are constructed. Experimental results demonstrate that the proposed method has a good performance to meet the speed and accuracy requirements of online monitoring.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1158-1167"},"PeriodicalIF":6.1,"publicationDate":"2024-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142359668","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":"Strip deviation analysis and prediction based on time series methods in hot rolling process","authors":"Han Gao ,&nbsp;Xu Li ,&nbsp;Shuren Jin ,&nbsp;Yumei Qin ,&nbsp;Jianzhao Cao ,&nbsp;Feng Luan ,&nbsp;Dianhua Zhang","doi":"10.1016/j.jmapro.2024.09.012","DOIUrl":"10.1016/j.jmapro.2024.09.012","url":null,"abstract":"<div><div>Strip deviation presents a significant challenge in hot rolling processes, affecting both product quality and manufacturing efficiency. Currently, most of the strip deviation correction operations rely on manual adjustments, which are labor-intensive and error-prone. This study pioneers the integration of a strip deviation measurement system with a time series prediction model to predict strip deviation and provide operators with timely warning signals. It introduces a novel time series prediction model utilizing dual attention mechanisms: one to identify feature-level correlations and another to capture temporal-level dependencies and patterns. An optimized version of the traditional Multi-Head Attention mechanism, named Compact Multi-Head Attention, is incorporated. To further boost the model's predictive accuracy, a shuffle operation is also integrated. Additionally, the dataset is augmented with rolling force difference and roller gap difference, based on an analysis of strip deviation principles, leading to notable improvements in predictive accuracy. Comprehensive testing with actual data from a hot strip mill confirms the model's outstanding performance in predicting strip deviation, surpassing several baseline models. The results highlight the effectiveness of this approach in strip deviation prediction in industrial environments.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1143-1157"},"PeriodicalIF":6.1,"publicationDate":"2024-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142359667","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":"The effects of TiC particle on microstructure and mechanical properties of Inconel 718 fabricated by selective arc melting","authors":"Weiran Xie ,&nbsp;Xiaodong Yang ,&nbsp;Haiou Yang ,&nbsp;Xiaoming Duan","doi":"10.1016/j.jmapro.2024.09.050","DOIUrl":"10.1016/j.jmapro.2024.09.050","url":null,"abstract":"<div><div>Adding titanium carbide reinforcement particles into Inconel 718 matrix is considered to be an effective way of further improving the mechanical properties of Inconel 718 components fabricated by selective laser melting (SLM). However, SLM-fabricated TiC/Inconel 718 composite components typically exhibit the pore defects caused by poor wettability between the matrix and the TiC particles, which attributed to the low heat input of laser during deposition. A powder bed based additive manufacturing method using arc plasma as heat source, named selective arc melting (SAM), was developed in previous study by the authors. Significantly higher heat input from the arc heat source contributes to inhibiting the generation of pore defects in TiC/Inconel 718 composite components during SAM. In this paper, thin-walled parts of Inconel 718 and TiC/Inconel 718 composites were first fabricated by the SAM method. Then, the deposition geometry, microstructure, tensile properties and hardness of as-fabricated Inconel 718 and TiC/Inconel 718 composites components were systematically studied and compared. Results showed that a large number of dispersed carbides and fine equiaxed grains were observed in the TiC/Inconel 718 composites. Most of the added TiC particles were melted and the Inconel 718 matrix bonded well to the carbide precipitation phases. The TiC/Inconel 718 composite part exhibited better surface quality, tensile strength, ductility and hardness than that of Inconel 718. The combined effects of precipitation strengthening and fine grain strengthening were the main reasons for the better mechanical performance of the TiC/Inconel 718 composite part.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1132-1142"},"PeriodicalIF":6.1,"publicationDate":"2024-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142359671","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}