Journal of Manufacturing Processes最新文献

{"title":"Quasicrystal-enriched fluids as lubricants for machining processes","authors":"J. Saelzer ,&nbsp;G. Polus ,&nbsp;A.L. Meijer ,&nbsp;T. Wolf ,&nbsp;J.F. Gerken ,&nbsp;J. Baumann ,&nbsp;A. Zabel ,&nbsp;D. Biermann ,&nbsp;M. Sipura ,&nbsp;N. Piljic","doi":"10.1016/j.jmapro.2025.04.023","DOIUrl":"10.1016/j.jmapro.2025.04.023","url":null,"abstract":"<div><div>In metal-cutting, where high contact normal stresses and temperatures occur in the contact between tool and workpiece/chip, stable lubrication provides a challenge. Solid lubricants offer lubrication potential under high mechanical loads. However, most solid lubricants only work for limited temperatures and the supply into the contact zones in cutting provides a general challenge. Quasicrystals represent an exceptional class of materials and have friction-reducing properties due to their atomic structure. However, their application has so far mainly been investigated for coatings or as tribologically effective reinforcement in composite materials. Nevertheless, their use as a solid-state additive remains largely unexplored. This paper presents the first utilisation of quasicrystals as a solid additive for cooling lubricants in machining. In fundamental investigations, it was initially determined that the addition of quasicrystals to an oil-water emulsion resulted in a significant increase in lubrication during cutting, meaning that the process forces could be reduced to a greater extent than in the case of MQL-oil. Based on these findings, a micromilling process was selected as an application example. In these investigations, it was found that tool wear could be reduced by &gt;60 % by adding the quasicrystals. In total, the potential of quasicrystals as solid lubricant for machining could be proved.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 86-95"},"PeriodicalIF":6.1,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143808434","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 role of crystal orientation in atomic-scale material removal mechanisms in single crystal aluminum nitride","authors":"Yongqiang Wang ,&nbsp;Jian Guo ,&nbsp;Zhihang Hu ,&nbsp;Yunpeng Wang ,&nbsp;Yueqin Wu ,&nbsp;Han Huang","doi":"10.1016/j.jmapro.2025.04.003","DOIUrl":"10.1016/j.jmapro.2025.04.003","url":null,"abstract":"<div><div>This study investigates the crystal plane-dependent material removal mechanisms in single crystal aluminum nitride (AlN) using molecular dynamics (MD) simulation. The results reveal that the deformation and removal behaviors in AIN vary significantly with crystal orientation and scratch depth, as evidenced by analyses of scratch force, contact area, and pressure. Material removal, dominated by plastic deformation, is highly dependent on crystal orientation. Critical scratch depths for atomic removal initiation were identified as 4 Å on the <em>a</em>-plane, 6 Å on the <em>m</em>-plane, and 12 Å on the <em>c</em>-plane. The minimum removal depths corresponded to a monolayer of atoms for the <em>a</em>-plane (1.6 Å) and bilayers for the <em>m</em>-plane (5.4 Å) and <em>c</em>-plane (5.1 Å). The simulation demonstrated that tangential forces play a dominant role in material removal within the plastic regime. A removal model that incorporates the influence of crystal plane was developed to predict the elastic-plastic transition. This model was validated across multiple scales. The findings emphasize the critical influence of crystal plane on the thresholds and mechanisms of material removal, providing valuable insights for advancing ultra-precision machining of single crystal AlN.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 114-131"},"PeriodicalIF":6.1,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143808437","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 unique insight into the atomic-scale removal on 6H-SiC","authors":"Shengyao Yang","doi":"10.1016/j.jmapro.2025.04.009","DOIUrl":"10.1016/j.jmapro.2025.04.009","url":null,"abstract":"<div><div>As one of the most promising and powerful next-generation semiconductor materials, single crystal silicon carbide (SiC) must possess exceptionally high surface and subsurface quality. Chemical mechanical polishing (CMP) is usually used as the final finishing step. In this letter, a novel removal mode on the C-face of 6H-SiC that was different from that on the Si-face is identified. For the first time, the underlying mechanism responsible for the difference in processing efficiency between the Si- and C-faces of 6H-SiC is thoroughly elucidated. The powerful capabilities of molecular dynamics simulations are once again demonstrated, and its potential in the field of material processing is further explored.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 79-85"},"PeriodicalIF":6.1,"publicationDate":"2025-04-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800181","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multi-degree-of-freedom thermal error modeling of rotary worktable based on three-dimensional spatiotemporal temperature information","authors":"Zheyu Li ,&nbsp;Guolong Li ,&nbsp;Kai Xu ,&nbsp;Yang Xiao ,&nbsp;Long Wang","doi":"10.1016/j.jmapro.2025.04.010","DOIUrl":"10.1016/j.jmapro.2025.04.010","url":null,"abstract":"<div><div>The machining accuracy of machine tools is seriously impacted by the thermal error of rotary worktables. Accurate compensation relies on thermal error prediction and monitoring. However, existing thermal error models are limited in accuracy and robustness due to the loss of temperature information and variations in temperature-sensitive points. Moreover, the thermal error of the rotary worktable has a coupled relationship between position and temperature, posing challenges in thermal error modeling. To tackle the issues, a multi-degree-of-freedom (MDOF) thermal error model with three-dimensional spatiotemporal temperature information (3DSTI) is developed for the gear grinding machine rotary worktable. Firstly, the temperature field mechanism model is established by Galerkin-based Green's function method after proposed structural simplification and thermal parameter equivalence. Combining the temperature field mechanism model, parallel Aquila optimizer, and measured data, a temperature field dynamic adjustment method is proposed. Secondly, the MDOF thermal error measurement method is proposed using the double ball bar. The MDOF thermal error is decomposed into multiple temperature-dependent amplitudes, thereby simplifying the thermal error modeling process. Thirdly, a series of continuous-time 3DSTIs are constructed by integrating the temperature field mechanism model with the measured temperature. The convolutional block attention module-gate recurrent unit extracts spatiotemporal temperature features from 3DSTI to establish the thermal error model. Finally, the experiments and simulations are conducted to validate the proposed method. The results indicate that the proposed method is proficient in accurately predicting thermal errors. Compared with the existing method, it exhibits superior prediction accuracy and robustness.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 56-78"},"PeriodicalIF":6.1,"publicationDate":"2025-04-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800180","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":"Application of unsupervised learning methods based on video data for real-time anomaly detection in wire arc additive manufacturing","authors":"Runsheng Li ,&nbsp;Hui Ma ,&nbsp;Rui Wang ,&nbsp;Hao Song ,&nbsp;Xiangman Zhou ,&nbsp;Lu Wang ,&nbsp;Haiou Zhang ,&nbsp;Kui Zeng ,&nbsp;Chunyang Xia","doi":"10.1016/j.jmapro.2025.03.113","DOIUrl":"10.1016/j.jmapro.2025.03.113","url":null,"abstract":"<div><div>In the Wire Arc Additive Manufacturing (WAAM) process, ensuring the quality of components is of paramount importance. However, existing defect detection research is predominantly confined to laboratory environments, rendering it inadequate for addressing the practical demands of industrial production. Furthermore, these studies primarily depend on supervised learning, which requires extensive labeled data, while anomalous data are scarce in industrial settings. This scarcity further limits the applicability of supervised learning methodologies. To mitigate this issue, this paper introduces an unsupervised anomaly detection framework based on manufacturing videos captured by industrial cameras. This framework integrates a Vector Quantization Variational Convolutional Autoencoder (VQ-VCAE) with the Isolation Forest algorithm, leveraging the temporal characteristics of anomalies inherent in the additive manufacturing process to significantly enhance detection accuracy. In this study, the defects predominantly detected include spatter and holes. However, the framework is capable of detecting various types of shape deviations and geometric defects in real-world industrial applications. Compared to baseline methods, the proposed approach substantially improves both precision and recall, achieving an F1 score of 0.9307 on the test dataset. Additionally, this framework employs video datasets derived from actual industrial production processes, thereby ensuring its feasibility and effectiveness in real-world scenarios.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 37-55"},"PeriodicalIF":6.1,"publicationDate":"2025-04-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785078","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 burr formation in Ti-6Al-4V drilling","authors":"B. DEBARD,&nbsp;P.A. REY,&nbsp;M. CHERIF","doi":"10.1016/j.jmapro.2025.03.108","DOIUrl":"10.1016/j.jmapro.2025.03.108","url":null,"abstract":"<div><div>To enhance the efficiency of aircraft structural assemblies, aircraft manufacturers are striving to implement a one-way assembly drilling strategy. This strategy negates the necessity for structures to be disassembled for cleaning and deburring interfaces subsequent to drilling. The implementation of this innovative strategy presents a significant industrial challenge, as it must address several technical issues, including the management of burrs at stack interfaces. It is imperative that these burrs be monitored, as they have the potential to negatively impact the fatigue strength of assemblies. Despite the extensive research conducted on burrs, the underlying mechanisms of their formation remain poorly understood, particularly with regard to the thermal phenomena that occur during the cutting process. The present study employs an interrupted experimental design, complemented by thermal measurements, to investigate the burr formation during the drilling process of Ti-6Al-4V alloy. Additionally, metallographic analyses are conducted to examine the alteration in microstructure in the vicinity of the hole surface. The results obtained facilitate a more in-depth comprehension of the processes that occur during burr formation, which may potentially impact the assembly performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"142 ","pages":"Pages 482-493"},"PeriodicalIF":6.1,"publicationDate":"2025-04-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143783448","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of a novel automated surface treatment method within accumulative roll bonding of AA6016 sheets","authors":"Bastian Zettl,&nbsp;Marion Merklein","doi":"10.1016/j.jmapro.2025.03.119","DOIUrl":"10.1016/j.jmapro.2025.03.119","url":null,"abstract":"<div><div>In order to minimize resource utilization and fuel consumption in the transportation and construction sector, possibilities to further enhance the mechanical properties of structural metal alloys are very lucrative. Especially in times of increasing energy costs as well as prices for certain elements, conventional heat treatments as well as alloying routes can be problematic. In this context, purely mechanical methods are capable of providing significant strengthening of already established alloys. Belonging to these methods and especially suitable for sheet metals, is the so-called Accumulative Roll Bonding (ARB) process. It enables the cumulation of the forming degree within the material and can lead to the evolution of an ultrafine grain sized microstructure. However, it severely lacks in its reproducibility and efficiency due to many influencing factors in the process chain. For this, the introduced work focuses on the least investigated step in the process chain, the surface treatment. For this, a novel and automated brushing method is analyzed in terms of its reproducibility as well as feasibility within ARB. Through roughness and topography measurements, it is shown that the force as well as the dwell time of the active brushing contact has a high influence on the resulting surface condition. Additionally, the run-in behavior and the deflection of the brush must be taken into account in order to generate a homogeneous surface finish. By selecting a suitable combination of parameters within the novel surface treatment method, a significant improvement regarding the scattering of the bonding strength is proven. Whereas the conventional manual surface treatment leads to fluctuations of the bonding strength of around 35 %, the newly introduced method displays a clearly reduced deviation of only 1.6 %. This enables to derivate cause-effect relationships between the input parameters regarding brushing, the resulting surface condition and the resulting bonding properties of ARB sheets.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 30-36"},"PeriodicalIF":6.1,"publicationDate":"2025-04-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143783566","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Electric-field-assisted direct ink writing (eDIW) process modeling","authors":"Yinong Chen,&nbsp;Xinnian Wang,&nbsp;Anupam Ajit Deshpande,&nbsp;Yayue Pan","doi":"10.1016/j.jmapro.2025.03.099","DOIUrl":"10.1016/j.jmapro.2025.03.099","url":null,"abstract":"<div><div>Direct ink writing (DIW) is an extrusion-based additive manufacturing technology. Recently, researchers found that by introducing an electric field into the system, the ink extrusion can be manipulated with a larger flexibility, and hence enhancing the printing success rate, resolution, and enabling higher printing speeds for targeted trace widths, offering advantages over the conventional DIW method including higher printing speed, higher resolution, and a wider range of ink choices. Yet due to the introduction of the additional electric field, the eDIW process becomes more complicated and therefore more challenging to control. This paper introduces a modeling system designed to enhance the eDIW process control over its printing quality and accuracy. In this modeling system, automated image processing techniques are employed to gather training data and machine learning algorithms are explored to predict the printing width. After training, the system takes process parameter settings as direct input and provides result prediction maps as the output. The prediction effectiveness is compared and discussed. Test cases are conducted to evaluate the performance of the proposed methods. This machine-learning-based modeling system shows significant promise and potential in eDIW process planning.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 17-29"},"PeriodicalIF":6.1,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143776630","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":"Influences of impact loading rate on the protective effect of shims on breakage of inserts in intermittent cutting","authors":"Yonglong Liu,&nbsp;Guosheng Su,&nbsp;Yan Xia,&nbsp;Hongxia Zhang,&nbsp;Gaofeng Wei,&nbsp;Yujing Sun,&nbsp;Binxun Li,&nbsp;Peirong Zhang,&nbsp;Jin Du,&nbsp;Bin Fang","doi":"10.1016/j.jmapro.2025.03.096","DOIUrl":"10.1016/j.jmapro.2025.03.096","url":null,"abstract":"<div><div>In high-speed cutting, the shim-insert system is subjected to high-speed impact loads, and different stiffness of the shim-insert system exhibit varying impact responses at different load rates, which in turn affect the wear and damage of the inserts. This paper investigates the effect of load impact rate on the protective performance of weak stiffness shims. A mass-spring vibration model for the shim-insert system is established to analyze the effect of load rate on the inertial forces within the system. Finite element analysis is conducted to explore the influence of impact load rate on the stress distribution at the tool tip for four different shim stiffness levels. Additionally, intermittent cutting experiments using four different stiffness shims are performed to study the impact of load rate on cutting forces, vibration acceleration, and insert fracture under different cutting speeds (load rates). The results show that as the impact load rate increases, the protective effect of weak stiffness shims on the inserts gradually weakens. At low impact load rates, the shim reaction force dominates, and the inertial force of the insert can be neglected. As the load rate increases, the inertial force of the insert increases and becomes dominant, while the shim reaction force gradually diminishes. As the cutting speed increases (from 500 r/min to 900 r/min), the weak stiffness shim's ability to reduce cutting force weakens (from 13.44 % to 4.17 %), the inhibition of vibration acceleration amplitude decreases (from 40.47 % to 9.57 %), and the reduction in rake face damage diminishes (from 75 % to 11 %). Therefore, under high-speed impact, the protective effect of weak stiffness shims weakens, leading to a reduction in tool protection performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 1-16"},"PeriodicalIF":6.1,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143769195","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":"Single-step precision manufacturing of ZnSe lenses for FLIR thermal imaging: From atomic insights to lab-scale fabrication and integration","authors":"Neha Khatri ,&nbsp;Sonam Berwal ,&nbsp;Bharpoor Singh ,&nbsp;Suman Tewary ,&nbsp;K. Manjunath ,&nbsp;Saurav Goel","doi":"10.1016/j.jmapro.2025.03.082","DOIUrl":"10.1016/j.jmapro.2025.03.082","url":null,"abstract":"<div><div>Zinc selenide (ZnSe) is widely used in optical components, including lenses, mirrors and thermal imaging systems, owing to its medium refractive index and broad infrared transmission range (0.6 to 21 μm). However, its soft-brittle nature presents challenges in achieving the nanometric smooth finishes required for precision manufacturing. This study introduces a single-step precision manufacturing process for ZnSe and demonstrates its application in a plano-convex lens integrated into FLIR thermal imaging systems for heat detection in integrated circuits.</div><div>To explore ZnSe's ductile plasticity, we developed a molecular dynamics (MD) model. Generalized Stacking Fault Energy (GSFE) calculations revealed that ZnSe favours slip on the Shuffle set ⟨110⟩ (111), unlike harder, brittle materials like silicon and silicon carbide, which favour the Glide set ⟨11–2⟩ (111) explaining the soft and brittle nature of ZnSe. The model predicted that a Peierls stress of approximately 0.027 GPa initiates the motion of ½ ⟨110⟩ perfect dislocations along the (111) slip planes, leading to plasticity and dislocation dissociation into 1/6 ⟨112⟩ (Shockley) partial dislocations. Analysis of the cutting region revealed phase transformation from zinc-blende to a hexagonal structure and defects, including intrinsic stacking faults and ∑3 coherent twin boundaries. Additionally, simulations indicated that the (100) orientation requires the least stress for plastic deformation, while the (110) orientation requires the most.</div><div>By shedding light on these mechanisms, this research aims to enhance our understanding of the precision machining of ZnSe, guiding the development of optimised cutting strategies to minimise defects and improve manufacturing outcomes. In sum, it introduces a “Design-to-Manufacture” approach, linking atomic-level insights with the practical integration of ZnSe lenses into thermal imaging applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"142 ","pages":"Pages 468-481"},"PeriodicalIF":6.1,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143768657","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}