Journal of Manufacturing Processes最新文献

{"title":"Particle-on-demand electrohydrodynamic printing from a reciprocating tip","authors":"Ji-hun Jeong ,&nbsp;Seong Jae Kim ,&nbsp;Sanha Kim ,&nbsp;A. John Hart","doi":"10.1016/j.jmapro.2025.04.011","DOIUrl":"10.1016/j.jmapro.2025.04.011","url":null,"abstract":"<div><div>While inkjet printing has revolutionized manufacturing of graphics and decorations, flexible electronics, and has enabled new additive manufacturing (AM) technologies, direct micro-scale deposition of metals remains challenging. Here, we present a particle-on-demand electrohydrodynamic printing approach, using a reciprocating tip mechanism that enables particles to be fed and ejected individually from an oil-coated membrane, and then printed to a target substrate. We examine the mechanism of printing using high-speed imaging and study the limiting mechanisms via controlled experiments with a range of particle sizes and materials, and then extract representative scaling laws for the ejection behavior. Based on this understanding, we demonstrate printing of two-dimensional patterns of stainless steel microparticles over a wide size range (50–700 μm particle diameter). With envisioned improvements to the tip geometry and particle-fluid interaction, and via parallelization, this particle-on-demand approach would be a versatile addition to high-resolution printing technologies for metals, including for manufacturing of intricate miniature components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 133-141"},"PeriodicalIF":6.1,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859750","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":"Efficient fabrication of low-damage, high-quality diamond microgrooves with high adhesion graphite-graphene layers on their surfaces using LIPAA technology","authors":"Zhuo Li ,&nbsp;Keyi Zhu ,&nbsp;Shajiu Le ,&nbsp;Ahmed Mohamed Mahmoud Ibrahim ,&nbsp;Baodong Wang ,&nbsp;Yangjian Chen ,&nbsp;Haoyu Su","doi":"10.1016/j.jmapro.2025.04.002","DOIUrl":"10.1016/j.jmapro.2025.04.002","url":null,"abstract":"<div><div>The fabrication of highly adhesive graphene layers on the surface of diamond microstructures can greatly promote the application of diamonds in high-performance sensors and ultra-precision manufacturing. However, this technology remains a significant challenge and is difficult to achieve efficient preparation. To overcome this challenge, the effect of target-substrate distance on microgroove morphology and material removal rate was investigated by ablating single crystal diamond using laser-induced plasma-assisted ablation (LIPAA) technology. Through precise target-substrate distance tuning, the efficient fabrication of low-damage, high-quality diamond microgrooves with high adhesion graphite-graphene layers on their surfaces has been achieved. The graphitization evolution on the surface of diamond microgrooves was detected using Raman and TEM, and the formation mechanism of graphite layer and graphene structure on the microgroove surface was analyzed by combining molecular dynamics (MD) simulation. An optimal target-substrate distance range was established for the efficient processing of diamond microgrooves with graphene attached to the surface through process optimization. These results offer valuable insights for advancing the application of single-crystal diamonds in sensor and semiconductor technologies.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 71-84"},"PeriodicalIF":6.1,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143854510","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":"Hybrid manufacturing of a 3D-shaped fiber metal laminate","authors":"Matthias Merzkirch ,&nbsp;Erwan Juin ,&nbsp;Jesper Eman ,&nbsp;Jocke Pettersson ,&nbsp;Magdalena Juntikka ,&nbsp;Fredrik Ahlqvist ,&nbsp;Olof Säfvenberg","doi":"10.1016/j.jmapro.2025.04.031","DOIUrl":"10.1016/j.jmapro.2025.04.031","url":null,"abstract":"<div><div>This contribution presents a methodology for designing, manufacturing, and testing of a multi-material solution demonstrator of a lower control arm for electric vehicle (EV) chassis made of a three-dimensional Fiber reinforced polymer-Metal Laminate (FML). The Integrated Computational Materials Engineering (ICME) approach includes simulation methodology for process modeling, i.e. forming and draping, and part performance with the aim to reduce the developing time and related trial and errors.</div><div>The challenges, besides a limited availability of resources and material input data for numerical models, include the combination of different forming methods for Glass Fiber Reinforced Polymers (GFRP) and sheet metals (aluminum alloy) with the aim of simultaneous forming of both materials. Especially the sheet metal forming needed several improvement steps regarding heat treatment state to increase the ductility and reduce crack propagation, as well as optimization of the shape of the blanks to be formed into an asymmetric, three-dimensional geometry. Assembly includes adhesive bonding of the flat FML to the curved structure, and adapters for the testing to be performed. The quasi-static misuse testing is in good agreement to the results obtained from the simulated structural performance, with the weakest location being the adhesive bond line. An outlook on potential improvements regarding process simulation for manufacturing Fiber Metal Laminates, including necessary input data, is provided.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 85-98"},"PeriodicalIF":6.1,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859947","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":"Advancing the machinability and tribological characteristics of AISI 9310 steel using a novel ultrasonic vibration-assisted MQL approach","authors":"Syed Hammad Ali ,&nbsp;Minxiu Zhang ,&nbsp;Guoliang Liu ,&nbsp;Biao Zhao ,&nbsp;Wenfeng Ding ,&nbsp;Muhammad Jamil ,&nbsp;Makesh Mohan ,&nbsp;Hussain Waris ,&nbsp;Ahmar Khan ,&nbsp;Sadam Hussain","doi":"10.1016/j.jmapro.2025.04.022","DOIUrl":"10.1016/j.jmapro.2025.04.022","url":null,"abstract":"<div><div>High production machining of low alloyed hardened steel AISI 9310 generates elevated cutting temperatures due to material's hardness and toughness causing dimensional deviations, premature failure of cutting tools, material softening, poor surface finish, rapid oxidation, and corrosion. This study proposes the implementation of an indigenously developed cooling and lubrication approach named ultrasonic atomization-based minimum quantity lubrication (UMQL) technique using eco-benign sunflower oil as a lubricant during finish milling, to control the cutting heat and to improve the machinability. To assess machinability of the AISI 9310 steel under UMQL, milling tests are carried out at varying machining parameters such as cutting speed, feed per tooth and radial depth of cut and each with three levels, and varied as a single-factor variable, and results were compared to dry and conventional MQL cutting. Subsequently, UMQL effectiveness is evaluated in terms of cutting forces, temperature, surface integrity (average surface roughness, 3D surface topography and surface texture) and chip morphology. The experimental results indicated that UMQL exhibited 18 %, 48 %, and 50 % reduction in milling forces, temperature and surface roughness compared to dry and MQL, respectively. Furthermore, in terms of topography and surface texture, UMQL produced relatively less peaks and valleys with more uniform surface features showcasing better heat and friction management at the machining zone due to its superior cooling, lubrication and chip flushing characteristics. Finally, the chip formation was studied in different environments, and UMQL showed the least number of friction tracks with uniform folds and minimal serration. Overall, the results indicated that UMQL provided the best performance regarding machinability, by forming a stable tribo-film with droplets effectively penetrating the cutting zone. Lastly from this study, the manufacturing industry will gain valuable insights into how certain cutting processing parameters and efficient lubrication will impact the mechanical behaviour in machining AISI 9310 parts and will offer a valuable resource for engineers and researchers to enhance machining processes while reducing environmental impact and operational expenses.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 99-115"},"PeriodicalIF":6.1,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859949","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 tool design for magnetic pulse welding of sheet metal using compression coil","authors":"Khushwant Singh Gavel ,&nbsp;Meraj Ahmed ,&nbsp;Ayisha Ali ,&nbsp;Hari Narayan Bhargaw ,&nbsp;Sanjay Kumar Panthi ,&nbsp;Amit Bhargav","doi":"10.1016/j.jmapro.2025.03.111","DOIUrl":"10.1016/j.jmapro.2025.03.111","url":null,"abstract":"<div><div>The Magnetic Pulse Welding (MPW) process is becoming more popular due to its advantages over conventional joining. Although sheet metal joining using MPW is reported, but not as extensively as circular geometry joining. Generally, a single or double-sided H-type coil is used for sheet metal joining using MPW. Relatively poor workability and low durability of such coils raise the need for further innovation in the design of tools. The present study proposes a novel concept of using a compression coil of bitter type with a conceptually designed field shaper to join sheet metal using MPW. Further, this study aims to demonstrate sheet metal joining using the proposed tooling and investigate the weld quality through mechanical pull-out tests and metallurgical analysis (SEM and fractography) of joint samples. The sheet metal samples are successfully joined, and an estimation of energy requirements for the joining is evaluated. Finite element analysis has also been carried out to analyze the variation of process parameters like magnetic field, Lorentz force, stress, velocity, etc., on tools and workpieces. The findings of the same are correlated with experimental results.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 261-277"},"PeriodicalIF":6.1,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143855959","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 review on modeling strategies in understanding the process mechanism of 3D printed continuous fiber-reinforced thermoplastic composites","authors":"Shenru Wang ,&nbsp;Xin Yan ,&nbsp;Baoning Chang ,&nbsp;Jiae Zhang ,&nbsp;Siqin Liu ,&nbsp;Fei Liu ,&nbsp;Junfan Shang ,&nbsp;Li-Hua Shao ,&nbsp;Sha Yin ,&nbsp;Wuxiang Zhang ,&nbsp;Yingdan Zhu ,&nbsp;Xilun Ding","doi":"10.1016/j.jmapro.2025.04.014","DOIUrl":"10.1016/j.jmapro.2025.04.014","url":null,"abstract":"<div><div>Continuous fiber 3D printing (CF3DP) has emerged as a promising technique that deposits continuous fiber alongside resin, offering numerous functional and intelligent applications. CF3DP involves rapid heating and cooling of materials, characterized by multiscale and multiphase nature, which complicates the understanding of the underlying process mechanisms. This difficulty hinders the prediction and control of the manufacturing defects and may lead to the compromise of mechanical properties. Although significant efforts have been made in process modeling to establish the relationship between process parameters and manufacturing performance, a systematic review of these studies remains absent. In this work, we attempted to provide an overview of the modeling strategies in understanding the process mechanism of CF3DP. The various physical phenomena involved in the CF3DP process are systematically analyzed and the corresponding modeling studies are summarized. Then, special attention is devoted to exploring how multiscale modeling approaches can establish a relational framework between the CF3DP process and the prediction of mechanical properties. This article also discusses the modeling strategies of failure behaviors considering the manufacturing defects. Finally, this paper discusses emerging applications of CF3DP and highlights the critical role of process modeling in driving future advancements. With the discussion of the process modeling strategies in CF3DP, researchers can identify appropriate methods tailored to their specific interests while gaining deeper insights into the underlying process mechanism.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 46-70"},"PeriodicalIF":6.1,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143854364","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":"Creep performance and microstructure of grade 91 steel weldments with integrated welding and thermal processing","authors":"Daniel Codd ,&nbsp;Joseph McCrink ,&nbsp;Timothy Lach ,&nbsp;Xiang (Frank) Chen","doi":"10.1016/j.jmapro.2025.04.049","DOIUrl":"10.1016/j.jmapro.2025.04.049","url":null,"abstract":"<div><div>Ferritic-Martensitic steel welds typically require post weld heat treatment (PWHT) to restore toughness and high temperature performance. This off-line thermal process reduces disparities between weld and base metal, but can cause distortion, cracking, or simply be impractical due to assembly size and joint non-uniformity. Here we show integrated welding and thermal processing applied to modified 9Cr-1Mo (Grade 91) steel, favored for advanced power generation applications, performed in real time through the addition of a secondary heat source near the primary weld head. Optimal integrated processing reduces weld fusion and heat affected zone hardness by 125 HV, approaching performance of conventional 730 °C, 60 min PWHT processing. Microstructures and mechanical performance are compared for mechanized GTAW welds, with equivalent lifetimes noted in cross-weld creep rupture tests up to 234 MPa at 550 °C, and up to 104 MPa at 650 °C. The integrated process was validated on a Grade 91 pressure vessel with multipass cold wire feed GTAW. After 550 °C, 71.4 bar thermomechanical cyclic testing, the maximum weld hardness is &lt;350 HV.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 34-45"},"PeriodicalIF":6.1,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143852302","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 flat bottom drill for bone drilling without plunging","authors":"Yue Zhang ,&nbsp;Zhaokun Zhang ,&nbsp;Chengyong Wang ,&nbsp;Ruitao Su ,&nbsp;Albert J. Shih","doi":"10.1016/j.jmapro.2025.04.018","DOIUrl":"10.1016/j.jmapro.2025.04.018","url":null,"abstract":"<div><div>Drilling holes on the skull or spine bones using a twist drill with a pointed tip is a common procedure in neurosurgery to gain access to the brain or spine. The point tip of the twist drill penetrates beyond the bone before neurosurgeons can rely on their haptic senses to detect the drop in thrust force and retract the drill. The tip of an over-penetrated twist drill may damage the brain or spinal nerve underneath the bone. The bone drilling devices with automatic retraction have the same issue of sharp twist drill over-penetration due to the small force drop at the point of penetration. This research designs a flat bottom drill capable of creating a flat bottom hole in bone drilling to overcome the over-penetration issue. This flat bottom drill has a sudden thrust force drop as a signal to stop and retract the drill without penetrating the bone. The flat bottom drill may also use the color change on the bottom surface of the drilled hole for visual feedback for retraction. The design and geometric features of the flat bottom drill are first introduced. A mathematical model is developed to calculate the rake and inclination angles on cutting edges. Four flat bottom drills are designed, manufactured, and evaluated in drilling the ex-vivo bovine bone. Results of the drilling thrust force and torque as well as the chip formation are compared with those of the twist drill. The flat bottom drill has demonstrated to be much more sensitive than the twist drill in penetration detection by sensing the sudden drop in thrust force at the end of bone drilling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 326-338"},"PeriodicalIF":6.1,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143852183","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 plate forging process for manufacturing outer flanged cup parts with non-uniform thickness","authors":"Wenzheng Dong ,&nbsp;Aoyu Zhao ,&nbsp;Zhenzhu Wang ,&nbsp;Shunyuan Le ,&nbsp;Qiquan Lin","doi":"10.1016/j.jmapro.2025.04.046","DOIUrl":"10.1016/j.jmapro.2025.04.046","url":null,"abstract":"<div><div>Plate forging process makes it possible to produce complex parts with non-uniform thickness while reducing manufacturing costs and extending mold life, without compromising mechanical properties or functional performance of components. Aiming at address the issues of folding and buckling commonly encountered in traditional manufacturing methods, this work proposed a novel plate forging process for manufacturing outer flanged cup parts with non-uniform thickness. Firstly, the deformation characteristics of the new plate forging process in the production of flange cup parts were analyzed. Secondly, the influence of different punch boss heights, cup wall thicknesses and initial plate thicknesses on the forming quality of flanged cup parts was explored through finite element simulations and plate forging experiments. As a result, a cup part with an outer flange was successfully manufactured, thereby verifying the feasibility of the new process. Finally, to address the local thinning and fracture defects encountered during the stretching of thick plates to form cup bottoms, an enhanced method using a multi-step punch was proposed. The improvement mechanism was analyzed, and both experimental and simulation results demonstrated its significant effectiveness in improving local thinning defects.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 22-33"},"PeriodicalIF":6.1,"publicationDate":"2025-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143850202","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":"In-situ melt pool characterization via thermal imaging for defect detection in Directed Energy Deposition using Vision Transformers","authors":"Israt Zarin Era ,&nbsp;Fan Zhou ,&nbsp;Ahmed Shoyeb Raihan ,&nbsp;Imtiaz Ahmed ,&nbsp;Alan Abul-Haj ,&nbsp;James Craig ,&nbsp;Srinjoy Das ,&nbsp;Zhichao Liu","doi":"10.1016/j.jmapro.2025.03.123","DOIUrl":"10.1016/j.jmapro.2025.03.123","url":null,"abstract":"<div><div>Directed Energy Deposition (DED) has significant potential for rapidly manufacturing complex and multi-material parts. However, it is prone to internal defects, such as lack of fusion porosity and cracks, that may compromise the mechanical and microstructural properties, thereby, impacting the overall performance and reliability of manufactured components. This study focuses on in-situ monitoring and characterization of melt pools closely associated with internal defects like porosity, aiming to enhance defect detection and quality control in DED-printed parts. Traditional machine learning (ML) approaches for defect identification require extensive labeled datasets. However, in real-life manufacturing settings, labeling such large datasets accurately is often challenging and expensive, leading to a scarcity of labeled datasets. To overcome this challenge, our framework utilizes self-supervised learning using large amounts of unlabeled melt pool data on a state-of-the-art Vision Transformer-based Masked Autoencoder (MAE), yielding highly representative embeddings. The fine-tuned model is subsequently leveraged through transfer learning to train classifiers on a limited labeled dataset, effectively identifying melt pool anomalies associated with porosity. In this study, we employ two different classifiers to comprehensively compare and evaluate the effectiveness of our combined framework with the self-supervised model in melt pool characterization. The first classifier model is a Vision Transformer (ViT) classifier using the fine-tuned MAE Encoder’s parameters, while the second model utilizes the fine-tuned MAE Encoder to leverage its learned spatial features, combined with an MLP classifier head to perform the classification task. Our approach achieves overall accuracy ranging from 95.44% to 99.17% and an average F1 score exceeding 80%, with the ViT Classifier outperforming the MAE Encoder Classifier only by a small margin. This demonstrates the potential of our framework as a scalable and cost-effective solution for automated quality control in DED, effectively utilizing minimal labeled data to achieve accurate defect detection.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 11-21"},"PeriodicalIF":6.1,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143847442","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}