Journal of Manufacturing and Materials Processing最新文献

{"title":"Process Chains for Micro-Manufacturing: Modeling and Case Studies","authors":"V. Basile, F. Modica, Lara Rebaioli, R. Surace, I. Fassi","doi":"10.3390/jmmp7060215","DOIUrl":"https://doi.org/10.3390/jmmp7060215","url":null,"abstract":"As the complexity of micro-products increases, the micro-manufacturing processes, tool setups, and measurement processes have to be more precise and efficient. Combining them in a multi-stage process chain can effectively improve production accuracy and performance and reduce limitations and production costs. This paper focuses on the process chains for the manufacturing of micro-products and presents the state of the art, highlighting the specific characteristics of the existing models of process chains for micro-manufacturing. Based on the critical review of these characteristics, an evolution of the process chain model for micro-manufacturing is proposed, considering machining, measurement/characterization, referencing processes, and their combination into a suitable sequence. The proposed model accounts for relevant aspects of micro-manufacturing, such as size effects and technological fingerprints at the microscale. This paper also discusses the hierarchical properties of multiple micro-manufacturing process chains and some specific techniques to address the critical issue of referencing processes. Furthermore, some relevant case studies involving micro-electrical discharge machining, micro-injection molding, additive manufacturing, and micro-milling are presented to demonstrate how the micro-manufacturing potentiality can be increased using process chains.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":" 63","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138612062","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design","authors":"Hui Huang, Y. Lim, Yiyu Wang, Yuan Li, Zhili Feng","doi":"10.3390/jmmp7060216","DOIUrl":"https://doi.org/10.3390/jmmp7060216","url":null,"abstract":"Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"71 s298","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138621991","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics","authors":"E. Uhlmann, M. Polte, S. Yabroudi, Nicklas Gerhard, Ekaterina Sakharova, Kai Thißen, Wilhelm Penske","doi":"10.3390/jmmp7060217","DOIUrl":"https://doi.org/10.3390/jmmp7060217","url":null,"abstract":"The electro-discharge (ED) drilling of precision boreholes in difficult-to-machine materials, particularly with respect to the cost-effectiveness of the overall process, is still a challenge. Flushing is one key factor for the precise machining of boreholes, especially with high aspect ratios. Therefore, the influence of internal and external flushing geometries for six types of brass tool electrodes with a diameter of 3 mm with and without a helical groove was analyzed experimentally and numerically. Using this helical external flushing channel, drilling experiments in X170CrVMo18-3-1 (Elmax Superclean) with an aspect ratio of five revealed a material removal rate (MRR) that was increased by 112% compared with a rod electrode, increased by 28% for a single-channel tool electrode and decreased by 8% for a multi-channel tool electrode. Signal analyses complemented these findings and highlighted correlations between classified discharge event types and the experimental target parameters. Amongst others, it was verified that the arcing frequency ratio drove the electrode wear rate and the beneficial frequency ratio correlated with the MRR and the surface roughness Ra. Sophisticated 3D computational fluid dynamics (CFD) models of the liquid phase were introduced and evaluated in great detail to demonstrate the validity and further elucidate the effect of the external flushing channel on the evacuation capability of debris and gas bubbles. The presented methods and models were found to be suitable for obtaining in-depth knowledge about the flushing conditions in the ED drilling working gap.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"214 4","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138621385","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Powder-Mixed Micro-Electro-Discharge Machining-Induced Surface Modification of Titanium Alloy for Antibacterial Properties","authors":"Nurlan Nauryz, Salikh Omarov, Ainur Kenessova, Tri T. Pham, D. Talamona, Asma Perveen","doi":"10.3390/jmmp7060214","DOIUrl":"https://doi.org/10.3390/jmmp7060214","url":null,"abstract":"The powder-mixed electro-discharge machining (PM-EDM) technique has shown its advantages in forming surfaces and depositing elements on the machined surface. Moreover, using hydroxyapatite (HA) powder in PM-EDM enhances the biocompatibility of the implant’s surfaces. Ti-6Al-4V alloy has tremendous advantages in biocompatibility over other metallic biomaterials in bone replacement surgeries. However, the increasing demand for orthopedical implants is leading to a more significant number of implant surgeries, increasing the number of patients with failed implants. A significant portion of implant failures are due to bacterial inflammation. Despite that, there is a lack of current research investigating the antibacterial properties of Ti-6Al-4V alloys. This paper focuses on studying the performance of HA PMEDM on Ti-6Al-4V alloy and its effects on antibacterial properties. By changing the capacitance (1 nF, 10 nF and 100 nF), gap voltage (90 V, 100 V and 110 V) and HA powder concentration (0 g/L, 5 g/L and 10 g/L), machining performance metrics such as material removal rate (MRR), overcut, crater size and hardness were examined through the HA PM micro-EDM (PM-μ-EDM) technique. Furthermore, the surface roughness, contact angle, and antibacterial properties of HA PM micro-wire EDM (PM-μ-WEDM)-treated surfaces were evaluated. The antibacterial tests were conducted for Staphylococcus aureus, Pseudomonas aeruginosa, Escherichia coli, and Bacillus subtilis bacteria. The key results showed a correlation between the discharge energy and powder concentration with the antibacterial properties of the modified surfaces. The modified surfaces exhibited reduced biofilm formation under low discharge energy and a 0 g/L powder concentration, resulting in a 0.273 μm roughness. This pattern persisted with high discharge energy and a 10 g/L powder concentration, where the roughness measured 1.832 μm. Therefore, it is possible to optimize the antibacterial properties of the surface through its roughness.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"20 1","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139214602","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Forging Treatment Realized the Isotropic Microstructure and Properties of Selective Laser Melting GH3536","authors":"Shuai Huang, Tianyuan Wang, Kai Li, Biao Zhou, Bingqing Chen, Xuejun Zhang","doi":"10.3390/jmmp7060213","DOIUrl":"https://doi.org/10.3390/jmmp7060213","url":null,"abstract":"The anisotropy of mechanical properties in SLMed alloy is very important. In order to realize the homogeneity of the microstructure and mechanical properties of GH3536 alloy prepared by selective laser melting (SLM), the as-deposited samples were treated by hot isostatic pressing and then forged at different temperatures. The microstructure, grain size, room- and high- temperature tensile properties, and endurance properties of the samples were studied. The results showed that the microstructure of the sample was mainly equiaxed austenite phase, and granular carbides were precipitated inside the grains after forging treatment, resulting in the anisotropy of the sample almost disappearing. The grain boundary phase difference distribution was most concentrated at 60°. The grain size was less than 10 μm, and a large number of twins were formed. With the increase in forging temperature, the yield strength, tensile strength, and contraction of area of the samples changed little, and the properties parallel to the z-axis (parallel samples) and vertical to the z-axis (vertical samples) were almost the same. In particular, the yield strength, tensile strength, and contraction of area in the transverse and vertical samples were almost at the same level. Judging from the elongation after fracture and the contraction of area, the properties of the samples showed characteristics of anisotropy after a high temperature endurance test.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"47 1","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139215062","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mechanical Investigation of Recyclability for Sustainable Use of Laser-Based Metal–Polymer Joints","authors":"Christoph Wortmann, Maximilian Brosda, Constantin Häfner","doi":"10.3390/jmmp7060210","DOIUrl":"https://doi.org/10.3390/jmmp7060210","url":null,"abstract":"Metal–plastic hybrid components combine the strength of metal with the low density of plastic. Due to weight reduction, these components are becoming increasingly important. To reduce the need for raw materials, processes for the recyclability of hybrid compounds are being investigated to reuse the metal part. The aim of this research is to characterize the mechanical bond strength after laser-based cleaning and reuse of the metal component. For this purpose, laser radiation is used to introduce microstructures into the metal surface. Afterwards, the polymer is joined to the metal component with laser radiation. As a reference of the initial mechanical bond strength, the joined samples are examined in a tensile testing machine. The polymer residues remaining in the structured metal surface are removed with different laser-based cleaning strategies. The metal is used again to generate another hybrid joined sample with a new polymer component. The results of the subsequent tests in the tensile testing machine are used for a detailed analysis of the reusability. As a result of this investigation, the laser-cleaned specimens showed significant improvements in bond strength compared to the uncleaned specimens. The process of laser-based cleaning for the reuse of the metallic part of hybrid joined components provides a fundamental procedure for improving the circular economy. In the future, this study should be validated in subsequent investigations on realistic components with complex geometries.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"45 1","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-11-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139215252","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of Temperature on the Forming Limits of High-Strength Low Alloy, and Dual-Phase Steels","authors":"N. Woellner, M. L. Gipiela, S. F. Lajarin, C. J. Rebeyka, C. Nikhare, Paulo V. P. Marcondes","doi":"10.3390/jmmp7060211","DOIUrl":"https://doi.org/10.3390/jmmp7060211","url":null,"abstract":"High-strength steels (HSS) appear as a good alternative to common steels to reduce vehicle weight, thus reducing fuel consumption. Despite the excellent mechanical behavior towards its lower weight, its application in industry is still limited, as manufacturing such materials suffers from limitations, especially regarding formability. The literature shows springback to be the most common problem. Among the parameters that can be studied to minimize this problem, the temperature appears, according to the literature, to be one of the most influential parameters in minimizing springback. However, the consequence of the temperature increase on the forming limits of materials is not completely understood. This study proposes to determine the consequences of the use of the temperature rise technique in the forming limits of high-strength steels. Two different steels were studied (HSLA 350/440 and DP 350/600). To evaluate the formability, the Nakazima method was used (practical). Finite element models were made which describe the material as well as Nakazima experimental behavior. To predict the forming limit strains via the numerical method, the thickness gradient criterion was applied. The practical and computational results were compared to validate the finite element model. Four different temperature ranges were analyzed. In general, it was found that 400 °C has a negative impact on the forming limits of both steels. This negative effect was found to be due to the alloying elements, such as silicon and manganese, present in the alloy. These alloying elements take part in the increase and decrease in resistance coefficient at the elevated temperature. For HSLA 350/440 steel, the forming limit strain decreased with an increase in temperature up to 600 °C and then increased at 800 °C; whereas for DP 350/600 steel, the forming limit strain decreased till 400 °C and then increased for 600 °C and 800 °C. Another factor which might have contributed to the behavior of the DP steel is the interaction of hard martensite with soft ferrite phase.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"344 1","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-11-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139224307","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Surface Characteristics and Residual Stress Variation in Semi-Deep Hole Machining of Ti6Al4V ELI with Low-Frequency Vibration-Assisted Drilling","authors":"Joon-Hyeok Choe, Ju Hyung Ha, Jisoo Kim, Dong Min Kim","doi":"10.3390/jmmp7060209","DOIUrl":"https://doi.org/10.3390/jmmp7060209","url":null,"abstract":"This study examined the impact of vibration-assisted drilling (VAD) on hole quality and residual stress in Ti-6Al-4V ELI (Extra Low Interstitials) material. Ti-6Al-4V ELI possesses excellent mechanical properties but presents challenges in machining, including chip evacuation, burr formation, and elevated cutting temperatures. VAD, particularly low-frequency vibration-assisted drilling (LF-VAD), has been explored as a potential solution to address these issues. The research compares LF-VAD with conventional drilling (CD) under various cutting and cooling conditions. LF-VAD exhibits higher maximum thrust forces under specific conditions, which result in accelerated tool wear. However, it also demonstrates lower RMS (root mean square) forces compared to CD, offering better control over chip formation, reduced burr formation, and improved surface roughness within the hole. Furthermore, LF-VAD generates greater compressive residual stresses on the hole’s inner surface compared to CD, suggesting enhanced fatigue performance. These findings indicate that LF-VAD holds promise for improving the hole’s surface characteristics, fatigue life, and overall component durability in Ti-6Al-4V machining applications.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"12 1","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-11-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139230363","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Towards a Simulation-Assisted Prediction of Residual Stress-Induced Failure during Powder Bed Fusion of Metals Using a Laser Beam: Suitable Fracture Mechanics Models and Calibration Methods","authors":"Hannes Panzer, Daniel Wolf, Andreas Bachmann, M. F. Zaeh","doi":"10.3390/jmmp7060208","DOIUrl":"https://doi.org/10.3390/jmmp7060208","url":null,"abstract":"In recent years, Additive Manufacturing (AM) has emerged as a transformative technology, with the process of Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) gaining substantial attention for its precision and versatility in fabricating metal components. A major challenge in PBF-LB/M is the failure of the component or the support structure during the production process. In order to locate a possible residual stress-induced failure prior to the fabrication of the component, a suitable failure criterion has to be identified and implemented in process simulation software. In the work leading to this paper, failure criteria based on the Rice-Tracey (RT) and Johnson-Cook (JC) fracture models were identified as potential models to reach this goal. The models were calibrated for the nickel-based superalloy Inconel 718. For the calibration process, a conventional experimental, a combined experimental and simulative, and an AM-adapted approach were applied and compared. The latter was devised to account for the particular phenomena that occur during PBF-LB/M. It was found that the JC model was able to capture the calibration data points more precisely than the RT model due to its higher number of calibration parameters. Only the JC model calibrated by the experimental and AM-adapted approach showed an increased equivalent plastic failure strain at high triaxialities, predicting a higher cracking resistance. The presented results can be integrated into a simulation tool with which the potential fracture location as well as the cracking susceptibility during the manufacturing process of PBF-LB/M parts can be predicted.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"39 1","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-11-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139232878","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Comprehensive Investigation of Hastelloy C-22 Powder Weld Overlay on SA 240 Type 316L Using Laser Beam Welding for Enhanced Performance","authors":"Manish V. Mehta, Mrunalkumar D. Chaudhari, R. Chaudhari, Sakshum Khanna, Jay Vora","doi":"10.3390/jmmp7060207","DOIUrl":"https://doi.org/10.3390/jmmp7060207","url":null,"abstract":"This article presents a comprehensive study on the application of Hastelloy C-22 powder weld overlay on SA 240 Type 316L austenitic stainless steel using the laser beam welding process. This novel combination of materials and processes was investigated for the first time, focusing on its potential utility for various industrial applications. Various testing techniques, including visual testing, hardness testing, bend testing, chemical composition analysis using optical spectroscopy, corrosion resistance assessment through the potentiodynamic polarization technique, and macro- and microstructural observation, were employed to evaluate the performance of the weld overlay. The research findings had several significant outcomes. Notably, precise control and minimal alloy mixing were achieved, as evidenced by the dilution at a remarkable height of 0.5 mm from the base metal. The laser welding process resulted in a minimal heat-affected zone and a fine columnar interdendritic microstructure, with average primary and secondary arm spacing values of 3.981 µm and 2.289 µm, respectively. Rigorous visual and bend testing confirmed the integrity of the sound welds in the overlay. Moreover, the high-quality finish of the weld overlay eliminated the need for extensive machining and finishing processes, resulting in cost reductions. This study also demonstrated primary and secondary inter-laminar spacing, leading to improved overall structural integrity. Additionally, the weld overlay exhibited excellent hardness characteristics. The current work contributes to the advancement of welding processes and provides practical solutions to enhance efficiency, cost-effectiveness, and structural performance in relevant industrial applications.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":"2017 8","pages":""},"PeriodicalIF":3.2,"publicationDate":"2023-11-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139239550","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}