Journal of Manufacturing Processes最新文献_第9页

Optimizing porous Ti-6Al-4V alloys: Gradients disordered cell enhance mechanical properties and energy absorption

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-07 DOI: 10.1016/j.jmapro.2025.02.008

Shiyue Guo , Rusheng Zhao , Zhifeng Huang , Donggen Yang , Xuezheng Yue , Xiangyu Guo , Huiling Tang , Lei Yang , Fan Zhang

{"title":"Optimizing porous Ti-6Al-4V alloys: Gradients disordered cell enhance mechanical properties and energy absorption","authors":"Shiyue Guo , Rusheng Zhao , Zhifeng Huang , Donggen Yang , Xuezheng Yue , Xiangyu Guo , Huiling Tang , Lei Yang , Fan Zhang","doi":"10.1016/j.jmapro.2025.02.008","DOIUrl":"10.1016/j.jmapro.2025.02.008","url":null,"abstract":"<div><div>Porous Ti-6Al-4V alloys produced via laser powder bed fusion (PBF-L) are highly valued for their tunable mechanical properties and excellent energy absorption, which are critical for aerospace, biomedical, and automotive applications. Achieving an optimal balance between compressive strength and energy absorption in these materials is challenging due to shear deformation in regular structured porous systems and localized stress concentrations in irregular ones. This study introduces gradient-disordered cells within an ordered matrix, enhancing both energy absorption and compressive strength while reducing shear band formation, which is typically observed in uniformly ordered structures. Through quasi-static compression testing and finite element analysis (FEA), we demonstrate that a configuration with a regularity (<em>R</em>) of 0.8 and two disordered layers offers the best compromise between structural integrity and energy absorption. A single disordered layer increases energy absorption by as much as 156.3 % without compromising compressive strength, highlighting the potential of gradient-disordered cellular structures to precisely tailor the mechanical properties of porous metals. When compared to uniformly ordered or fully disordered structures, these gradients deliver superior mechanical performance, offering significant advantages in structural design. However, variations in structural regularity continue to present challenges, guiding future research toward understanding the role of cell geometry and regularity in material performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 342-362"},"PeriodicalIF":6.1,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143348635","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

A study on eco-friendly organic antimicrobial agents to inhibit microbial growth in copper chemical mechanical polishing slurry

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-07 DOI: 10.1016/j.jmapro.2025.01.075

Jaewon Lee , Gyuyoung Lee , Seunghwan Lee , Hyeongseok Choi , Kihong Park , Eungchul Kim , Seokjun Hong , Taesung Kim

{"title":"A study on eco-friendly organic antimicrobial agents to inhibit microbial growth in copper chemical mechanical polishing slurry","authors":"Jaewon Lee , Gyuyoung Lee , Seunghwan Lee , Hyeongseok Choi , Kihong Park , Eungchul Kim , Seokjun Hong , Taesung Kim","doi":"10.1016/j.jmapro.2025.01.075","DOIUrl":"10.1016/j.jmapro.2025.01.075","url":null,"abstract":"<div><div>Metal CMP slurry contains various chemical additives, and some organic compounds can cause microbial growth as nutrients. Microbial growth due to slurry aging can cause various problems during CMP process, and specific research on this topic is lacking. This study evaluates the impact of microbial growth on CMP process and proposes antimicrobial agents to inhibit it. Microbial growth changes the basic properties of slurry, such as pH value and viscosity, and directly affects CMP performance. As a result of identification evaluation, various types of microbes (Gram-positive, Gram-negative bacteria and mold) were confirmed in the aged slurry. To suppress these microbes, <span><math><mi>ε</mi></math></span>-poly-<span>l</span>-lysine (EPL) and nisin were proposed as environmentally friendly antimicrobial agents to replace existing biocides. The antimicrobial activities of EPL and nisin were compared by the type of microbe, and their insufficient performances were improved through optimization by combined addition. The optimized condition based on combined addition performed inhibition rate of at least 92.8 % for bacteria and mold. Furthermore, the optimized slurry was evaluated to inhibit microbial growth for >8 weeks, and it achieved maintenance of copper removal rate and surface roughness (R<sub>a</sub>) improvement from 0.373 nm to 0.324 nm compared with the original slurry.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 363-375"},"PeriodicalIF":6.1,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143348634","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

A novel welding schedule for expanding the expulsion-free process window in resistance spot welding of dissimilar joints with ultra-high strength steel

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-07 DOI: 10.1016/j.jmapro.2025.02.009

Keke Yang , Zhuoqun Wang , Viktor Haak , Viktoria Olfert , Bassel El-Sari , David Hein , Max Biegler , Michael Rethmeier , Gerson Meschut

{"title":"A novel welding schedule for expanding the expulsion-free process window in resistance spot welding of dissimilar joints with ultra-high strength steel","authors":"Keke Yang , Zhuoqun Wang , Viktor Haak , Viktoria Olfert , Bassel El-Sari , David Hein , Max Biegler , Michael Rethmeier , Gerson Meschut","doi":"10.1016/j.jmapro.2025.02.009","DOIUrl":"10.1016/j.jmapro.2025.02.009","url":null,"abstract":"<div><div>This study introduces a novel approach to expanding the maximum expulsion-free process window in resistance spot welding (RSW) of dissimilar joints between ultra-high strength steel (UHSS) and mild steel. Quantitative analysis revealed that expulsion is driven by the interaction between nugget growth rate and plastic shell thickness. Based on this finding, the welding schedule was optimized by applying a preheating current to form an initial plastic shell, followed by a ramp-up current profile during the main welding phase. Welding simulations indicated that the ramp-up current slowed nugget growth, improved plastic shell formation, and prevented nugget breakthrough, thereby reducing the risk of expulsion. Experimental validation showed a 19 % increase in maximum expulsion-free heat input, with the nugget diameter increasing by 7.6 % to 8.94 mm compared to the reference welding schedule. Furthermore, even when expulsion occurred beyond the process window, this optimization delayed its occurrence, minimizing its impact on spot weld quality. Finally, the optimized welding schedule also exhibited significant robustness. Despite a 2 mm initial gap disturbance, the maximum expulsion-free heat input increased by 57 %, while the nugget diameter grew by 30 % to 8.92 mm. These results confirm that the proposed approach effectively extends the process window by preventing expulsion and enhances process stability.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 306-319"},"PeriodicalIF":6.1,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143321629","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}

引用次数: 0

Parameter optimization of ultrasonic impact for deformation control based on Dual Information Neural Network

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-06 DOI: 10.1016/j.jmapro.2025.01.063

Ningkun Wang , Yingguang Li , Changqing Liu , Zhiwei Zhao , Dong He , Kai Tang

{"title":"Parameter optimization of ultrasonic impact for deformation control based on Dual Information Neural Network","authors":"Ningkun Wang , Yingguang Li , Changqing Liu , Zhiwei Zhao , Dong He , Kai Tang","doi":"10.1016/j.jmapro.2025.01.063","DOIUrl":"10.1016/j.jmapro.2025.01.063","url":null,"abstract":"<div><div>Thin-walled structural parts are prone to complex deformations during machining process, primarily due to the residual stress fields within material. Ultrasonic impact treatment is an effective mean for machining deformation control by introducing beneficial compressive stress to counter/cancel the residual tensile stress of the part. However, the effectiveness of residual stress by ultrasonic impact treatment is influenced by various parameters, and a simple treatment of them cannot effectively reduce the deformation of structural parts. Moreover, the initial residual stress field of a part will also influence its overall deformation. In this paper, the influence of different ultrasonic impact size parameters on residual stress was analyzed firstly. A Dual Information Neural Network (DINN) surrogate model was built for rapid deformation prediction by both considering the impact of ultrasonic impact parameters and residual stress within the workpiece, which is further utilized to optimize the ultrasound impact parameters (e.g., impact velocity) through genetic algorithms such that the deformation is minimized. The validation results demonstrate that the proposed DINN can significantly reduce the training time and improve the model prediction accuracy, and the ultrasonic impact parameters selected by the proposed method can effectively reduce the part deformation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 113-124"},"PeriodicalIF":6.1,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143321261","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

3D printing of microwave materials, components and their applications – A review

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-06 DOI: 10.1016/j.jmapro.2025.02.006

Ravina R. Holkar, Govind G. Umarji, Manish D. Shinde, Sunit B. Rane

{"title":"3D printing of microwave materials, components and their applications – A review","authors":"Ravina R. Holkar, Govind G. Umarji, Manish D. Shinde, Sunit B. Rane","doi":"10.1016/j.jmapro.2025.02.006","DOIUrl":"10.1016/j.jmapro.2025.02.006","url":null,"abstract":"<div><div>Additive manufacturing (AM) or 3D printing is gaining a lot of ground as an alternative manufacturing technology to conventional methods owing to its easy customization, less wastage and more economical aspects. However, it is still in infancy as far as the development of microwave materials and strategies of their printing is concerned. Though the work in this direction has started a decade ago, significant developments have taken place over the last five years. However, there is still a dearth of an extensive review related to the contemporary developments in this field which can assist the researchers to accordingly align their research acumen for converging their expertise with AM technology. The developments pertaining to microwave materials, 3D printing processes of such materials and their applications as various microwave components and devices are presented in this review. Additionally, the reported results on microwave dielectric properties of 3D printed components and their applications are discussed. The challenges associated with 3D printing of microwave materials and components are also elaborated. Finally, the future scope of 3D printing technology in this area is presented.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 280-305"},"PeriodicalIF":6.1,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143321631","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Enhancement of machining performance for electrochemical arc machining (ECAM) of SiCP/Al with arc discharge energy control

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-06 DOI: 10.1016/j.jmapro.2025.01.095

Yuehong Ma, Xiaolong Fang, Ningsong Qu

{"title":"Enhancement of machining performance for electrochemical arc machining (ECAM) of SiCP/Al with arc discharge energy control","authors":"Yuehong Ma, Xiaolong Fang, Ningsong Qu","doi":"10.1016/j.jmapro.2025.01.095","DOIUrl":"10.1016/j.jmapro.2025.01.095","url":null,"abstract":"<div><div>Electrochemical arc machining (ECAM) can be efficiently utilized for difficult-to-cut materials regardless of their mechanical properties. In ECAM using a non-pulse direct-current supply, arc discharges with varying energy levels are generated, among which high-energy arc discharges cause severe electrode wear and reduce machining performance. Herein, arc discharge behavior was manipulated by changing tool electrode materials and through the introduction of a regulating resistor to improve machining performance. Through the analysis of electrical signals, an equivalent circuit model was established for the electrochemical and arc discharge stages of ECAM. Based on this model, the arc discharge behavior was quantitatively characterized from three dimensions: arc discharge frequency, average arc discharge peak current, and average arc discharge sustaining time. Further, the effects of tool electrode materials and voltage on arc discharge behavior were investigated. The results indicated that the WCe electrode converted more electrical energy into arc discharge energy than W and graphite electrodes. Moreover, arc discharges generated by the WCe electrode exhibited good consistency, with approximately 93.4 % of arc discharges being within 1000–1200 A at 40 V. To limit the excessive arc discharge peak current, a 0.1 Ω regulating resistor connected in series was added into the machining circuit, thereby reducing the arc discharge peak current from 1125.75 to 210.40 A. The corresponding arc discharge transitioned from a low–frequency (<10 Hz) high-energy status to a medium–frequency (10–100 Hz) low-energy status. Owing to the decrease in the peak current of a single arc discharge, the relative electrode wear rate decreased from 2.23 % to 1.12 %, which is the lowest value reported thus far for the machining of SiC<sub>P</sub>/Al. In addition, the machining accuracy was improved, with the machined groove width being reduced from 7.100 to 6.861 mm.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 263-279"},"PeriodicalIF":6.1,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143321632","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Estimation of cutting temperature using machine learning based on signal information received from power analyzer in vortex machining conditions

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-06 DOI: 10.1016/j.jmapro.2025.02.004

Yusuf Siyambaş , Aslan Akdulum , Ramazan Çakıroğlu , Gültekin Uzun

{"title":"Estimation of cutting temperature using machine learning based on signal information received from power analyzer in vortex machining conditions","authors":"Yusuf Siyambaş , Aslan Akdulum , Ramazan Çakıroğlu , Gültekin Uzun","doi":"10.1016/j.jmapro.2025.02.004","DOIUrl":"10.1016/j.jmapro.2025.02.004","url":null,"abstract":"<div><div>Cutting temperature directly determines power consumption by influencing tool wear and workpiece quality. Especially for workpieces that cause high heat generation due to low thermal conductivity coefficients, such as Ti6Al4V, it is a challenge to control and determine the cooling method and cutting parameters accordingly. Pre-process modeling and estimation of the cutting temperature due to the cutting variables is necessary for effective process planning and machining efficiency. In this study, it is aimed to use various signal information received from the power analyzer as input features to effectively model and estimate by using the machine learning method the cutting temperature occurring in the turning using various cooling environments of Ti6Al4V workpieces. The features extracted from the four signal information were used both individually and by obtaining hybrid signal features where all the features are combined. While individual signals were used directly in establishing the models, hybrid signals were ranked using the feature ranking method according to six different importance levels. As a result of the study, it was determined that the cutting temperature could be predicted with high success by modeling it according to the features extracted from the signal information obtained from the power analyzer.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 100-112"},"PeriodicalIF":6.1,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143321262","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Influencing of microparticle on surface morphology during broaching FGH 4097 with quasi-two-dimensional simulation model

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-05 DOI: 10.1016/j.jmapro.2025.01.091

Zhongyue Su , Zhen Meng , Jing Ni , Baotao Wang , Zefei Zhu , Weiguang Liu , Xinghua Wu , Shaorong Lin

{"title":"Influencing of microparticle on surface morphology during broaching FGH 4097 with quasi-two-dimensional simulation model","authors":"Zhongyue Su , Zhen Meng , Jing Ni , Baotao Wang , Zefei Zhu , Weiguang Liu , Xinghua Wu , Shaorong Lin","doi":"10.1016/j.jmapro.2025.01.091","DOIUrl":"10.1016/j.jmapro.2025.01.091","url":null,"abstract":"<div><div>Nickel-based alloys are widely used in aerospace and other fields due to their excellent mechanical properties. However, nickel-based superalloys typically contain hard phases that impact their machinability and the integrity of the machined surface. To accurately predict the processing state of nickel-based superalloy components and optimize the processing technology, the accurate modeling of heterogeneous materials is very important. This study innovatively proposed an accurate multi-scale material model that incorporates microscopic hard phase particles into a macroscopic material model and applies this material model to the cutting dynamics simulation analysis of FGH 4097. Through comparison, it is found that the model established in this paper can greatly improve the accuracy of simulation prediction. Compared to conventional simulation models, the model proposed in this paper effectively illustrates the impact of microscopic particles in materials on the cutting process. The experimental results show that the accuracy of this model in predicting cutting force and temperature is 85.6 % and 91.7 % respectively. This model effectively enhances the prediction accuracy of surface roughness and delves into the potential mechanism of hard phases during the work-hardening process, offering new insights into the understanding and control of the machining process. In summary, the multi-scale material model developed in this study has great potential for analyzing the impact of material micro-particles on macro-cutting performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 196-206"},"PeriodicalIF":6.1,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143322135","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Prediction of the powder catchment efficiency and melt track height in laser directed energy deposition

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-05 DOI: 10.1016/j.jmapro.2025.01.039

Colin Ancalmo, Sneha Prabha Narra

{"title":"Prediction of the powder catchment efficiency and melt track height in laser directed energy deposition","authors":"Colin Ancalmo, Sneha Prabha Narra","doi":"10.1016/j.jmapro.2025.01.039","DOIUrl":"10.1016/j.jmapro.2025.01.039","url":null,"abstract":"<div><div>Powder catchment and melt track height are foundational for build planning in powder blown laser beam directed energy deposition. However, the interconnected relationships of the catchment efficiency with laser parameters, powder size distribution, and carrier gas flow rate make build planning across machines and feedstock challenging without trial-and-error verification. The primary geometry-based catchment model from laser cladding assumes that this relationship is captured through knowledge of the particle stream and laser spot diameter. First, this work evaluated the applicability of the geometry-based catchment model across a range of AISI 316L powder sizes, carrier gas flow rates, and laser spot diameters. By measuring particle stream diameters from high-speed imaging, the geometry-based catchment model predicted catchment with a root mean squared error of 11.5% for single melt tracks. Second, recognizing the burden of deploying high-speed imaging, this work utilized Stokes number for rapid catchment prediction in place of the particle stream diameter. This approach predicted the catchment with a root mean squared error of 11.8%. Finally, the predicted catchment and laser spot diameter was used to predict the average melt track height with a root mean squared error below 75 <span><math><mi>μ</mi></math></span>m. Thus, end-users can apply this Stokes number-based approach to accelerate build planning when using AISI 316L feedstock.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 207-220"},"PeriodicalIF":6.1,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143322136","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}

引用次数: 0

The role of tool edge geometry on material removal and surface integrity in cutting metal matrix composites

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-02-05 DOI: 10.1016/j.jmapro.2025.01.096

Chengjin Tian , Jian Weng , Kejia Zhuang , Dongdong Xu , Jinming Zhou , Rachid M'Saoubi

{"title":"The role of tool edge geometry on material removal and surface integrity in cutting metal matrix composites","authors":"Chengjin Tian , Jian Weng , Kejia Zhuang , Dongdong Xu , Jinming Zhou , Rachid M'Saoubi","doi":"10.1016/j.jmapro.2025.01.096","DOIUrl":"10.1016/j.jmapro.2025.01.096","url":null,"abstract":"<div><div>Metal matrix composites (MMCs) possess excellent material properties due to the combination of metals and reinforcing phases, yet this reduces their machinability. Numerous studies have shown that, due to the ploughing effect of the cutting tool, the edge effect can directly impact the material removal mechanism and the generation of surface integrity. However, the influence of different cutting-edge geometries on the cutting phenomena of MMCs has not been comprehensively investigated. This study explored the effects of three cutting-edge geometries (sharp, rounded, asymmetric) on the mechanisms of material removal and surface integrity under different uncut chip thicknesses (UCT) in orthogonal cutting of Al/SiCp. The results indicated that the altered cutting edge caused by dead metal zone (DMZ) played a dominant role in the material removal mechanisms of MMC. While cutting force was primarily affected by edge geometry, it showed minimal variation. Chip morphology varied with UCT, transitioning from long and continuous chips to more fragmented chips as UCT increased. Surface and subsurface defects worsened at higher UCT, with limited differences due to edge geometries. The DMZ formation transformed the blunt edge into a relatively sharp one, eliminating the effect of edge geometries. This effect became more pronounced as UCT increased and persisted even under small UCT and sharp edge conditions. Besides eliminating the edge effect, the DMZ introduced a lateral fish-scale-like surface defect, significantly compromising post-cutting surface integrity.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 135-149"},"PeriodicalIF":6.1,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143321259","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0