Journal of Manufacturing Processes最新文献

{"title":"Inverse modeling of process parameters from data to predict the cooling behavior in injection molding","authors":"Manuel Wenzel ,&nbsp;Sven Robert Raisch ,&nbsp;Christian Hopmann ,&nbsp;Mauritius Schmitz","doi":"10.1016/j.jmapro.2025.02.057","DOIUrl":"10.1016/j.jmapro.2025.02.057","url":null,"abstract":"<div><div>AI methods, especially Deep Learning Methods (DLMs), present an excellent opportunity for the surrogate modeling of complex processes, like the injection molding process, based on simulation or measurement data. To overcome the need for large data sets DLMs usually require, the integration of domain knowledge into the learning process e.g., in the form of Partial Differential Equations (PDEs), is rising in popularity. In this study, an inverse approach based on Physics Informed Neural Networks (PINNs) is explored for parameterizing the influence of material and process parameters on the cooling behavior of an injection molded part. With the proposed method, the PDE, Initial Condition (IC), and Boundary Condition (BC) of the underlying physical process can be automatically parameterized based on data. To reduce modeling effort, a simplified generic representation of the physical process description is used. The effectiveness of the method is demonstrated by utilizing the inversely learned physical process model to regularize the surrogate model. When predicting the spatiotemporal temperature evolution dependent on different materials and process settings, a 25% lower Root-Mean-Squared-Error (RMSE) was achieved by the hybrid approach in comparison to a purely data-driven model. The use of the simplified process physics highlights the generalizability of the approach to other data types and processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 760-772"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592621","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":"Microstructure evolution and plastic deformation behavior of DR-B2/ID-FCC phase lightweight high entropy alloy during improving thermal processing properties","authors":"Xueyu Jiang ,&nbsp;Xin Che ,&nbsp;Haoyu Zhang ,&nbsp;Siqian Zhang ,&nbsp;Xuelong Wen ,&nbsp;Ge Zhou ,&nbsp;Lijia Chen ,&nbsp;Peter K. Liaw","doi":"10.1016/j.jmapro.2025.03.041","DOIUrl":"10.1016/j.jmapro.2025.03.041","url":null,"abstract":"<div><div>This paper comprehensively benchmarks the aero-engine hot-end component material GH4169/Inconel718. A nickel-based lightweight high entropy alloy (HEA) with a nearly equimolar distribution of DR-B2 + ID-FCC was prepared using a multi-element non-equimolar design. And carry out hot compression experiments using XRD, TEM, and EBSD detection methods to study energy dissipation and redistribution (<em>η</em> value) as the starting point. The results indicate that heterostructure is beneficial for expanding the thermal processing window, and a machinable zone (900 °C/0.32 s⁻¹) also appears in the low <em>η</em> value interval. In the medium/high <em>η</em> value interval, the alloy has more machinable ranges due to the contribution of the dynamic response behavior of heterostructure and the evolution behavior of dislocations. The ID-FCC phase exhibits discontinuous dynamic recrystallization (DDRX), mainly forming {001} &lt; 0<span><math><mover><mn>1</mn><mo>¯</mo></mover></math></span>0 &gt; Cube texture. The DR-B2 phase is continuous dynamic recrystallization (CDRX) with no apparent preference for texture orientation. The volume fraction of FCC phase recrystallization (<em>X</em>_<em>rec</em>) is higher than that of the B2 phase (<em>X</em>_{<em>rec-FCC</em>}: <em>X</em>_{<em>rec-B2</em>} = 1.05–2.3), making it more prone to recrystallization. Meanwhile, the FCC/B2 phase deformation mechanism is mainly a dislocation climb creep mechanism (<em>n</em>₁ = 4.96). These research results guide designing lightweight heterostructure HEA with good thermal processing performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 725-745"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143577755","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-physical process simulation of resistance spot welding available for synthetic data generation","authors":"Tian-Le Lv ,&nbsp;Yu-Jun Xia ,&nbsp;Siva Prasad Murugan ,&nbsp;Fernando Okigami ,&nbsp;Hassan Ghassemi-Armaki ,&nbsp;Blair E. Carlson ,&nbsp;Yongbing Li","doi":"10.1016/j.jmapro.2025.03.024","DOIUrl":"10.1016/j.jmapro.2025.03.024","url":null,"abstract":"<div><div>Resistance spot welding (RSW) faces challenges when realizing online quality evaluation because of insufficient labeled data. Finite element (FE) models can generate synthetic databases, but their application is limited due to the reliability and generalization ability problem. This paper establishes an FE model that can digitally twin the welding gun characteristics, contact behavior, nugget growth process, and key process signals simultaneously. A multi-spring structure was designed to simulate the loading feature of a servo gun, and certain modifications in material properties were applied to the model. The simulation errors can be restricted to 2 % for the weld profile and 5 % for all process signals. A quick generalization method is also proposed to apply the FE model on different stack-ups, only needing modification in electrical contact resistance (ECR) parameters. The modeling and generalization methods were validated on 6 stack-ups consisting of three steels with different mechanical strengths, sheet thickness, and various chemical compositions, and also validated under different currents. The reliability and generalization ability of the proposed model are superior to traditional models, maintaining &lt;5 % and &lt;10 % errors in simulated nuggets and signals, respectively. ECR analysis shows that contact film resistivity is strength-related, and all stack-ups have similar electrical contact resistances at electrode/sheet interfaces. A preliminary synthetic database was generated, including 10 stack-ups and about 1500 data. This study can help provide labeled data for machine/deep learning algorithm training and for interpreting the physical process of RSW.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 709-724"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143577754","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":"Temperature-sensitivity points selection for positioning error modeling of CNC machine tools based on analytic hierarchy process","authors":"Yang Li ,&nbsp;Jiaqi Wang ,&nbsp;Yue Yang ,&nbsp;Xu Zhao ,&nbsp;Hexuan Shi ,&nbsp;Fusheng Liang","doi":"10.1016/j.jmapro.2025.03.011","DOIUrl":"10.1016/j.jmapro.2025.03.011","url":null,"abstract":"<div><div>Selecting the appropriate temperature-sensitivity points (TSPS) is the key to robustly predict the thermal error, which is an important part of the thermal error data-driven model (DDM). At present, grouping search is a comprehensive and scientific method to select the TSPS. However, the temperature measurement points with relatively low correlation to thermal error will be selected as the TSPS by this method, which can affect the performance and the stability of the error model's long-term prediction. Therefore, analytic hierarchy process (AHP) is introduced to alleviate this problem. In this paper, AHP is firstly applied to reassign the weights of the TSPS, and then the TSPS are reselected again according to the result. To prove the effectiveness of AHP, extreme learning machine with AHP (ELM-AHP) and other three classic models are taken as examples to construct the thermal error model. The results show that ELM-AHP model has high predictive accuracy and strong robustness. It is proved that AHP can solve the problem of TSPS with low correlation to a certain extent, which can reduce the number of TSPS, and simplify the error model.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 667-678"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578257","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":"Weldability study of alloys 625 and 718 fabricated by laser-based additive manufacturing","authors":"Jhoan Guzman ,&nbsp;Kaue C. Riffel ,&nbsp;William Evans ,&nbsp;Eric Brizes ,&nbsp;Nicholas Avedissian ,&nbsp;Francisco Werley Cipriano Farias ,&nbsp;Antonio J. Ramirez","doi":"10.1016/j.jmapro.2025.02.051","DOIUrl":"10.1016/j.jmapro.2025.02.051","url":null,"abstract":"<div><div>Nickel-based alloys, Alloys 625 and 718, are widely used in the aerospace industry due to their excellent corrosion resistance and high strength at elevated temperatures. Recently, these alloys have been utilized to manufacture rocket engine components using additive manufacturing (AM) technologies such as laser powder bed fusion (LPBF) and powder-blown laser-based directed energy deposition (DED). These technologies offer faster and more cost-effective production while enabling the fabrication of near-net-shape parts that are subsequently joined by welding. However, solidification cracking susceptibility varies significantly between AM and conventionally processed materials, and limited weldability characterization has been conducted on AM-fabricated materials. This study assesses the weld solidification cracking susceptibility of Alloys 625 and 718 produced by wrought (mill-rolled), LPBF, and DED using transverse varestraint testing, Scheil-Gulliver simulations, the Crack Susceptibility Index (CSI), and the Flow Resistance Index (FRI). Transverse varestraint testing revealed that AM parts exhibited higher susceptibility due to the presence of larger and elongated grains in the fusion zone, affecting the weld solidification cracking response. In Alloy 625, the LPBF condition exhibited the highest maximum crack distance (MCD) of 2.35 ± 0.16 mm, compared to 1.56 ± 0.06 mm for wrought and 1.72 ± 0.10 mm for DED. Similarly, in Alloy 718, the DED condition showed the highest MCD of 2.93 ± 0.41 mm, while the wrought condition had an MCD of 2.01 ± 0.12 mm, and the LPBF condition reached 3.01 ± 0.33 mm at 5 % strain, without a clearly defined saturation strain. Although wrought materials demonstrated greater resistance to solidification cracking, solidification simulations did not correlate with the experimental testing, as they do not account for microstructural and mechanical factors, relying solely on chemistry.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 556-569"},"PeriodicalIF":6.1,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578251","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":"Enhanced droplet volume of material jetting based on bipolar waveform optimization","authors":"Xiaopei Wang ,&nbsp;Hongzhi Guo ,&nbsp;Hongmiao Tian ,&nbsp;Chao Yan ,&nbsp;Chunhui Wang ,&nbsp;Xiangming Li ,&nbsp;Xiaoliang Chen ,&nbsp;Jinyou Shao","doi":"10.1016/j.jmapro.2025.03.032","DOIUrl":"10.1016/j.jmapro.2025.03.032","url":null,"abstract":"<div><div>Fiercer requirements are put forward for the droplet jetting efficiency with the increasing application demand of piezoelectric inkjet technique in additive manufacturing. However, the progress of existing studies on promoting droplet jetting efficiency is restricted by their difficulty in achieving large scale droplet volume increase, with the maximum droplet volume limited to about 8 times the native droplet volume. Herein, a new droplet volume enhancing method was proposed based on bipolar waveform optimization, in which a bottom-up modular optimization method was applied according to the superposition characteristics of flow field oscillation inside the piezoelectric printhead system. More importantly, this method focused on the multi-droplet merging characteristics driven by multi-pulse waveforms, with the aim of realizing significant increase in droplet volume. The experimental results have shown that the newly designed waveform achieves stable droplets with the maximum-to-native volume ratio above 50, i.e., nearly six times above current levels. Hence, this work contributes a new perspective to droplet jetting efficiency.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 580-594"},"PeriodicalIF":6.1,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578250","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":"Preparation of NiTi shape memory alloy with enhanced mechanical properties using selective laser melting","authors":"Junwei Wang ,&nbsp;Dingyong He ,&nbsp;Xu Wu ,&nbsp;Xingye Guo ,&nbsp;Zheng Zhou ,&nbsp;Zhen Tan","doi":"10.1016/j.jmapro.2025.02.077","DOIUrl":"10.1016/j.jmapro.2025.02.077","url":null,"abstract":"<div><div>In this work, NiTi parts were prepared using selective laser melting (SLM) to investigate the effect of laser process parameters on the relative density and forming defects of the parts. The results showed that the SLM-built NiTi parts with high relative density (&gt;99 %) can be produced when the volume energy density (VED) was in the range of 57.2 to 83.6 J/mm³, and the relative density was below 99 % with the VED lower than 57.2 J/mm³ or &gt;83.6 J/mm³. In addition, when the VED was lower than 57.2 J/mm³, the main defects of the alloy were voids, while a large number of pores occurred with the VED higher than 83.6 J/mm³. The heat transfer mode was identified as conduction mode through the characterization of the molten pool and the calculation of normalized enthalpy, and further the defect formation mechanism was clarified. The tensile strength and elongation of the printed samples prepared using optimized process parameters can reach 780 ± 5 MPa and 14.2 ± 0.2 %, the enhancement of which is due to the formation of dynamic recrystallization during the SLM process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 570-579"},"PeriodicalIF":6.1,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578252","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":"Proposal of tilted helical grinding for grooving ZrO2 ceramics – Investigation of groove profile formation and machining performance","authors":"Chen Deng ,&nbsp;Qiang Wang ,&nbsp;Hui Zeng ,&nbsp;Xiaoliang Jin ,&nbsp;Yongbo Wu","doi":"10.1016/j.jmapro.2025.02.070","DOIUrl":"10.1016/j.jmapro.2025.02.070","url":null,"abstract":"<div><div>Zirconia dioxide (ZrO₂) ceramic is widely employed in industry due to its exceptional mechanical and physical properties. There are lots of grooving demands for ceramic parts in aviation, 3C, and biomedical industries. However, conventional grinding (CG) always struggles to achieve high machining efficiency and low grinding wheel wear. Therefore, this study proposed a novel method, which is sourced from helical grinding (HG), in which the grinding wheel moves forward along a helical path while rotating at high speed. Meanwhile, it is also tilted toward the revolution axis at a certain angle, thus called tilted helical grinding (THG). As a step toward the establishment of this new process, in this study, the kinematical analysis of single abrasive grain motion was compared with that of HG and CG. Then, the formation of grooved profile considering a generalized grinding wheel shape was modelled, followed by investigating the effect of several crucial parameters. Then, experiments were performed to confirm the machining performance of THG and theoretical analysis. The experimental results indicate that, under the same material removal rate, THG and HG had lower average grinding force than that of CG. The surface roughness after THG was similar to that of HG and CG, but the surface morphology of THG showed more plastic removal. The grinding wheel after THG processing showed the smallest area of wheel loading and the lowest weight percent of Zr element adhesion. The predicted cross-section profiles from the model were validated from the experimental results.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 536-555"},"PeriodicalIF":6.1,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578249","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":"Defect analysis and quality evaluation system for additive manufactured continuous fiber-reinforced polymer composites","authors":"Yawen Zhang ,&nbsp;Junxian Zhou ,&nbsp;Ruixian Qin ,&nbsp;Shanshan Shi ,&nbsp;Yunzhuo Lu ,&nbsp;Xu Zhang ,&nbsp;Jianxin Xu ,&nbsp;Bingzhi Chen","doi":"10.1016/j.jmapro.2025.03.023","DOIUrl":"10.1016/j.jmapro.2025.03.023","url":null,"abstract":"<div><div>The combination of continuous fiber-reinforced polymer composites (CFRPCs) and additive manufacturing (AM) offers a solution for the integrated manufacturing of high-performance, complex structures, but due to current process limitations, various defects exist within the parts. Most research has focused on internal pores defects and mechanical properties but lacks in-depth studies on the mechanisms of other defect forms and comprehensive quality evaluation systems. To address these gaps, this paper applied comprehensive parameter analysis, visualization techniques, rheological experiments, and mechanical experiments to systematically explore the effects of defects on the printing quality of AM-CFRPCs, focusing on shape fidelity, surface accuracy, structural integrity, and mechanical performance. Targeted improvement measures were proposed for various defects, effectively eliminating shape-related issues such as fiber slippage, fillet, first layer accumulation, and warpage, leading to a high-quality deposited surface with low roughness and waviness, as well as an internal structure with low porosity. Furthermore, a comprehensive molding quality evaluation system was established, offering a reliable framework for part quality assessment. Additionally, the variation patterns of the key-like profile cross-sections of the single path under different layer heights were summarized, and precise calculation models for path width and overlap ratio were presented. Consequently, this paper delivers detailed guidelines for enhancing molding quality to facilitate the production and evaluation of high-quality AM-CFRPCs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 595-612"},"PeriodicalIF":6.1,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578253","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 ultrasonic transverse vibration assisted micro electrochemical machining of high aspect-ratio groove with controllable cross section","authors":"Jianzhou Cai,&nbsp;Jing Li,&nbsp;Guixian Liu,&nbsp;Hongping Luo,&nbsp;Yongjun Zhang","doi":"10.1016/j.jmapro.2025.03.020","DOIUrl":"10.1016/j.jmapro.2025.03.020","url":null,"abstract":"<div><div>Micro-electrochemical machining (ECM) is an ideal machining method for micro-structure parts, but there is a problem that the electrolytic products cannot be discharged in time when machining micro-groove structures with high aspect ratio. In this paper, a novel ultrasonic transverse vibration assisted micro- electrochemical machining method (UTVA-ECM) is proposed, which combines Bernoulli-Euler beam theory and ultrasonic vibration technology. The transverse vibration of the micro-rode electrode can disperse electrolytic products effectively. However, under ultrasonic transverse vibration, the distribution of bubble layer on the micro-rode electrode is uneven, which affects the cross section of grooves in UTVA-ECM. In order to explore the influence of bubble layer distribution in UTVA-ECM. Firstly, in order to explore the influence of bubble layer distribution in UTVA-ECM, the theoretical model of transverse vibration of the micro-rode electrode was established. Through simulation and observation experiments, it is found that an uneven bubble layer affected by amplitude is formed on the electrode surface. The bubbles are dispersed in the wave loop area with strong amplitude, and the bubbles are difficult to disperse in the wave node area with weak amplitude. The uneven bubble layer leads to different conductivity at different positions in the axial direction of the electrode, and finally irregular cross section grooves are processed. Secondly, the influence of different processing parameters on groove machining by UTVA-ECM was studied. With the increase of ultrasonic voltage, the decrease of pulsed voltage and the increase of feed rate, the difference of groove width between wave node and wave loop area is greater. Finally, the machining of regular cross section grooves with an aspect ratio of 8.03 and the irregular cross section grooves with aspect ratio of 9.70 were realized by UTVA-ECM.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 613-626"},"PeriodicalIF":6.1,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578254","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}