Journal of Manufacturing Processes最新文献

{"title":"Wrinkling behavior and stress analysis in perforated metal sheets considering cutout geometry and material heterogeneity","authors":"Haoxing Tang ,&nbsp;Ling Jiang ,&nbsp;Tongwei Liu ,&nbsp;Mingxuan Li ,&nbsp;Wenhao Zheng ,&nbsp;Gang Fang","doi":"10.1016/j.jmapro.2025.06.070","DOIUrl":"10.1016/j.jmapro.2025.06.070","url":null,"abstract":"<div><div>Cutouts are primarily designed for assembly and weight reduction in sheet metal components; existing research predominantly focuses on structural stiffness and ultimate loading capacity, though several studies address plastic deformation characteristics and wrinkling analysis due to the complex stress states introduced by cutouts. This study employs rectangular strips and Yoshida buckling tests (YBTs) featuring seven cutout configurations with different rotation angles to analyze stress states and their effects on wrinkling. Simulations utilize a proposed initial imperfection implantation method based on material heterogeneity. Results indicate that cutouts increase sheet metal wrinkling sensitivity, causing wrinkling to occur prior to fracture. High stress concentrations around cutout corners dominate wrinkling behavior and increase fracture risk. A novel wrinkling prediction method combining Muskhelishvili's complex variable function with engineering plasticity theory is proposed, yielding an average error of approximately 7.62 % between theoretical and numerical results. However, errors in YBTs exceed those in strips due to greater deviations in effective forming regions and simplified boundary conditions. Although a state of non-uniform compression develops around cutouts regardless of shape, the magnitude and distribution of transverse compressive stress change with cutout shape and rotation angle. Under the combined influence of transverse compressive stress and shear stress near side edges, secondary wrinkling occurs, transforming initially linear edges into S-shaped profiles after post-buckling deformation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 700-713"},"PeriodicalIF":6.1,"publicationDate":"2025-06-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144517476","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 novel vision-based approach for high-speed jetting status monitoring of a multi-nozzle inkjet head","authors":"Sanghyun Park,&nbsp;Je Hoon Oh","doi":"10.1016/j.jmapro.2025.06.081","DOIUrl":"10.1016/j.jmapro.2025.06.081","url":null,"abstract":"<div><div>Multi-nozzle inkjet printing technology has attracted extensive attention in the manufacturing processes of various industrial fields due to its high throughput capability for mass production. However, a high defect rate caused by some abnormal nozzles is a major challenge in the application of this technology. Hence, monitoring the jetting status of all nozzles in multi-nozzle inkjet heads and detecting abnormal nozzles have become an important issue in most inkjet-based manufacturing processes. In this study, we proposed a novel vision-based approach for efficient and fast jetting status monitoring of a multi-nozzle inkjet head. The proposed approach utilizes a continuous scanning mechanism based on a variable pulse width triggering technique, enabling seamless and uninterrupted monitoring. Experimental results demonstrated that our proposed approach could monitor an industrial multi-nozzle inkjet head with 1024 nozzles in just 9.2 s while maintaining measurement accuracy of 99 %. Compared with the conventional method, the proposed approach could improve monitoring speed by 44.8 times and shorten the monitoring time by 97.8 %. To demonstrate the practicality of the proposed approach, in-house jetting status monitoring software was also developed, which can monitor and evaluate the jetting status of the whole nozzle in real-time. Overall, this study provides strong technical support for quality control of multi-nozzle inkjet printing technology and would help expedite the entire manufacturing process, improve manufacturing yield, and reduce production costs in the inkjet-based manufacturing process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 670-681"},"PeriodicalIF":6.1,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144501981","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 mechanical properties of Al-Cu alloy fabricated by inter-layer hammering hybrid wire arc directed energy deposition: Experiments and crystal plasticity finite element method","authors":"Shuo Wang ,&nbsp;Siyu Zhou ,&nbsp;Yili Zhao ,&nbsp;Zhonggang Sun ,&nbsp;Fei Xing ,&nbsp;Guang Yang","doi":"10.1016/j.jmapro.2025.06.080","DOIUrl":"10.1016/j.jmapro.2025.06.080","url":null,"abstract":"<div><div>Inter-layer deformation serves as an effective strategy to refine the micro-structure of wire arc-directed energy deposition (WA-DED), enabling the formation of periodic heterogeneous structures with alternating coarse grains (CG) and fine grains (FG) region. However, the mechanical behavior of such periodic micro-structures remains inadequately explored. This work provides a novel methodology for studying the deformation behavior of materials fabricated via IH hybrid WA-DED processes. The crystal plasticity finite element method (CPFEM) was first used in this study to investigate the evolution of mechanical properties of layered heterogeneous structures produced during the Inter-layer hammering (IH) WA-DED process under tensile simulation, establishing the relationship between microstructure and properties. The IH process yielded a Cube texture dominated micro-structure, with CG displaying a marginally higher Schmid factor (0.478) than FG (0.465). Notably, CG region exhibited elevated geometric compatibility factors (m′) at grain boundaries compared to FG region, promoting preferential dislocation slip activation and enhanced strain accommodation in CG region. CPFEM results demonstrated that slip systems in CG region were initially activated during the early plastic deformation stage. As deformation progressed, the distinct strain accommodation capacities between CG and FG region induced transverse cracks along the FG/CG interfaces to the tensile direction. Combined analysis of Schmid factors and m′ revealed that slip systems were predominantly activated perpendicular to the tensile direction, driving the nucleation and propagation of ductile cracks along this orientation. The interplay between single-slip system activation and dislocation motion emerged as the dominant deformation mechanism in the IH specimen, resulting in complex stress-strain distributions. These findings highlight the critical role of heterogeneous micro-structural features in governing deformation mechanisms and damage evolution in WA-DED processed alloys.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 682-699"},"PeriodicalIF":6.1,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144511041","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":"Martensitic to stainless steel gradient by laser-based directed energy deposition: Effect of thermal history on microstructure and hardness","authors":"Cole Britt ,&nbsp;Zi-Kui Liu ,&nbsp;Allison M. Beese ,&nbsp;Jayme Keist","doi":"10.1016/j.jmapro.2025.06.030","DOIUrl":"10.1016/j.jmapro.2025.06.030","url":null,"abstract":"<div><div>This study presents the effects of laser-based directed energy deposition additive manufacturing processing conditions on local variations in microstructure and hardness across a sample graded from high-strength martensitic steel AF9628 to stainless steel 316L. Hardness was shown to decrease with increasing height in regions of constant composition. As the sample graded from AF9628 to stainless steel 316L, the phases changed gradually from martensite to austenite as expected, with austenite forming preferentially at solidification cell walls due to elemental segregation. Varying amounts of tempering were observed from varying heat accumulation along the height of the part and from processing pauses during fabrication. This study demonstrates how spatial variations in thermal history during functionally graded material (FGM) fabrication can affect intrinsic tempering of previous layers leading to significant variations in properties throughout a part and highlights the importance and complexity of path planning for FGM component fabrication.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 662-669"},"PeriodicalIF":6.1,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144501980","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":"Mechanism investigation of ductility improvement in heat-assisted nanocutting of single crystal silicon","authors":"Xiaonan Pu,&nbsp;Jianghai Xu,&nbsp;Peng Huang,&nbsp;Zhiwei Zhu","doi":"10.1016/j.jmapro.2025.06.012","DOIUrl":"10.1016/j.jmapro.2025.06.012","url":null,"abstract":"<div><div>Single crystal silicon, which is widely used in multiple fields, is a typical difficult-to-machine material due to its hardness and brittleness. It has been demonstrated that elevated temperatures improve the ductility of single crystal silicon. However, the underlying mechanism of ductility improvement remains unclear, thereby constraining the advancement of ultra-precision cutting technology for single crystal silicon. In this study, a heat-assisted device with a heated tool is developed and utilized in the nanocutting of single crystal silicon. The scratch morphology indicates that the application of heat assistance up to 200 °C can enhance the brittle-to-ductile transition depth in single crystal silicon. Raman spectroscopy and transmission electron microscopy (TEM) were employed to examine the subsurface damage in the scratch. Furthermore, molecular dynamics (MD) simulations were conducted to elucidate the formation of chips and subsurface damage during heat-assisted nanocutting of single crystal silicon. By integrating the experimental and simulation results, it is evident that elevated temperatures enhance the ductile cutting of single crystal silicon by reducing the shearing resistance of amorphous silicon and promoting dislocations and slips in the single crystal substrate.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 599-609"},"PeriodicalIF":6.1,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144489904","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":"Multi-scale modeling of metallurgical phenomena in metal laser powder bed fusion additive manufacturing: A comprehensive review","authors":"Seyedeh Fatemeh Nabavi,&nbsp;Hamid Garmestani","doi":"10.1016/j.jmapro.2025.06.078","DOIUrl":"10.1016/j.jmapro.2025.06.078","url":null,"abstract":"<div><div>Laser Powder Bed Fusion (LPBF) has transformed additive manufacturing, enabling the production of intricate, high-performance components across aerospace, automotive, and biomedical industries. This review provides a novel analysis of the multi-scale metallurgical phenomena governing LPBF, addressing critical gaps in heat transfer dynamics, microstructural evolution, and residual stress formation. It highlights underexplored factors, including the interplay of laser-material interactions, thermal conductivity, and specific heat capacity, and their combined effects on rapid cooling rates and phase transformations. Advanced microstructure implementation strategies are explored, emphasizing the relationships between laser scanning speed, melt pool geometry, cooling rates, and grain morphology. Predictive models, such as phase field simulations, austenitization, and martensite transformations, are reviewed, with a focus on nucleation mechanisms and grain refinement to mitigate defects and optimize performance. The review evaluates advanced modeling approaches that integrate thermal, mechanical, and metallurgical aspects, such as phase-field and finite element models, for defect prediction and process optimization. The transformative potential of in-situ monitoring techniques, including thermal imaging and melt pool analysis, is emphasized for their ability to correlate process parameters with metallurgical outcomes. Emerging trends like machine learning and multi-physics simulations are identified as pivotal for addressing challenges in parameter tuning and adaptive process control. By proposing a roadmap for comprehensive multi-scale modeling, real-time monitoring integration, and material development tailored for LPBF, this review advances the understanding and scalability of LPBF technology, ensuring its impactful application in high-demand manufacturing sectors.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 610-644"},"PeriodicalIF":6.1,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144489905","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 multi-type riveting defect detection and classification method based on the enhancement of force-displacement curve timing features","authors":"Zhipu Tan ,&nbsp;Yonggang Kang ,&nbsp;Siren Song ,&nbsp;Shuaijia Kou ,&nbsp;Bin Li","doi":"10.1016/j.jmapro.2025.06.093","DOIUrl":"10.1016/j.jmapro.2025.06.093","url":null,"abstract":"<div><div>Aiming at the key requirements of riveting quality inspection for aircraft thin-walled structures, this study proposes an intelligent detection method for multi-type defects based on riveting timing feature enhancement. Addressing the issues of low efficiency and high subjectivity in traditional manual detection, the research achieves technical breakthroughs through three stages: First, based on the size measurement of the high-precision driven head, a classification system for riveting defects is constructed, and the visual mapping relationship between geometric parameters and quality standards is established. Second, the force-displacement dynamic characteristics and their change rates of the riveting process are incorporated into the analysis framework. The correlation mechanism between specific defects and mechanical responses is revealed by decoupling the characteristics of the process stages, and the relationship between the process characteristics and quality indicators is identified. Finally, an intelligent recognition model based on BiLSTM is constructed, and its superior performance in multi-type defect classification is validated through comparative experiments. The experimental results show that the four evaluation indexes of this method exceed 98 %, providing a quality monitoring solution for the field of aviation manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 645-661"},"PeriodicalIF":6.1,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144501979","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 sustainable milling performance of aluminum alloys with application of blended plant oil-based composite electrostatic spray lubrication","authors":"Yu Su,&nbsp;Chunhua Rui,&nbsp;Jingjie Zou,&nbsp;Zhicheng Pan","doi":"10.1016/j.jmapro.2025.06.072","DOIUrl":"10.1016/j.jmapro.2025.06.072","url":null,"abstract":"<div><div>The formidable challenges arise from castor oil's elevated viscosity and inadequate electrical conductivity, hampering the attainment of superior atomization, lubrication, and processing efficacy in composite electrostatic spray lubrication (CESL) applications. Adopting the blend of plant oils presents an effective solution to this issue. The type and ratio of plant oil blends and external/internal flow rate considerably affect the effectiveness of this solution. The appropriate above parameters can be expected to produce better performance than the optimal single plant oil. This work prepared the blends of castor oil with canola, soybean, palm, and sunflower oils in different volume ratios. The influence of CESL with blended plant oils on the milling performances of aluminum alloys was investigated at different external/internal flow rates. With both external and internal flow rates set to 6 ml/h, the blend of castor and palm oil with a volume ratio of 1:2 demonstrated the most significant decrease in milling forces and temperatures. When contrasting with pure LB2000 (the optimal single plant oil) and pure castor oil, the milling force, temperature, mean and maximum flank wear, and surface roughness under this condition were reduced by 1.40 %, 13.83 %, 23.83 %, 53.29 %, and 40.33 %, as well as 10.33 %, 20.71 %, 30.12 %, 57.75 %, and 47.99 %, respectively.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 582-598"},"PeriodicalIF":6.1,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144489903","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":"On-machine measurement and quantitative evaluation of belt wear in robotic grinding using line structured light scanning","authors":"Zhijian Tao ,&nbsp;Zenghuan Hou ,&nbsp;Yanan Wang ,&nbsp;Yu Sun ,&nbsp;Junde Qi ,&nbsp;Dinghua Zhang","doi":"10.1016/j.jmapro.2025.06.082","DOIUrl":"10.1016/j.jmapro.2025.06.082","url":null,"abstract":"<div><div>Due to the favorable characteristics of flexible contact and low grinding temperature, belt grinding has been widely used for the precision machining of difficult-to-machine materials such as superalloys and titanium alloys. However, belt wear is inevitable during the machining process, posing significant challenges to grinding process planning and quality control. Currently, there is still a lack of an efficient, accurate, and widely applicable method for monitoring belt wear. To address this shortcoming, this study proposes an on-machine measurement and quantitative evaluation method of belt wear in robotic grinding using line structured light scanning. Firstly, a line laser scanning module with integrated dust-removal and dust-proof functions is designed to mitigate the impact of dust contamination on measurement accuracy. Then, this study defines a wear coefficient based on the geometric characteristics and volume variations of agglomerate. Based on this, an evaluation method for belt wear using point cloud processing is proposed, and a wear matrix is employed to better characterize the wear distribution across different regions of the belt. Finally, the full-lifecycle wear experiment of the belt is conducted on a robotic grinding platform. The experimental results demonstrate that, within a 95 % confidence interval, the measurement deviation between the proposed method and the optical profilometer-based measurement method is within 10 %. Additionally, this study investigates the temporal evolution and spatial distribution patterns of belt wear and further explores its effect on grinding performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 555-569"},"PeriodicalIF":6.1,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144482460","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 influence of load inertia ratio on speed planning strategy of feed drive system","authors":"Xuesong Wang ,&nbsp;Zhengfa Li ,&nbsp;Dongsheng Zhang","doi":"10.1016/j.jmapro.2025.06.076","DOIUrl":"10.1016/j.jmapro.2025.06.076","url":null,"abstract":"<div><div>The speed planning of the feed system is an important factor affecting the machining accuracy and efficiency of high-speed and high-precision machine tools. Existing research on speed planning for CNC machine tools primarily focuses on reducing speed fluctuations and avoiding sudden changes in acceleration and jerk to improve machining accuracy and surface quality. They do not explicitly consider the comprehensive action of each subsystem. The load inertia ratio is one of the key parameters to study the comprehensive effect of subsystems. This paper fills this gap by elucidating the evolution of feed system performance under the combined effects of load inertia ratio and speed planning, starting from the dynamic fundamental mechanisms. By eliminating the influence of servo control, the influence of speed planning on the dynamic performance of the feed system under different load inertia ratios is studied. To further improve the dynamic performance of the feed system, the speed planning strategy should be adjusted according to the load inertia ratio. This paper provides a theoretical basis for speed planning considering the influence of the load inertia ratio.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 570-581"},"PeriodicalIF":6.1,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144489940","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}