Journal of Manufacturing and Materials Processing最新文献_第5页

Selection of Welding Conditions for Achieving Both a High Efficiency and Low Heat Input for Hot-Wire Gas Metal Arc Welding 为热丝气体金属弧焊选择既高效又低热输入的焊接条件

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-18 DOI: 10.3390/jmmp8020082

Keita Marumoto, A. Fujinaga, Takeshi Takahashi, Hikaru Yamamoto, Motomichi Yamamoto

{"title":"Selection of Welding Conditions for Achieving Both a High Efficiency and Low Heat Input for Hot-Wire Gas Metal Arc Welding","authors":"Keita Marumoto, A. Fujinaga, Takeshi Takahashi, Hikaru Yamamoto, Motomichi Yamamoto","doi":"10.3390/jmmp8020082","DOIUrl":"https://doi.org/10.3390/jmmp8020082","url":null,"abstract":"This study presents a new gas metal arc welding (GMAW) technique that achieves both high efficiency and low heat input using a hybridization of the hot-wire method. The optimal combination of welding speed and welding current conditions was investigated using a fixed hot-wire feeding speed of 10 m/min on a butt joint with a V-shaped groove using 19 mm thick steel plates. Molten pool stability and defect formation were observed using high-speed imaging and cross-sectional observations. The power consumption and heat input were predicted prior to welding and measured in the experiments. The results indicate that a combination of a welding current of 350–500 A and welding speed of 0.3–0.7 m/min is optimal to avoid defect formation and molten metal precedence using three or four passes. The higher efficiency and lower heat input achieved by hot-wire GMAW results in a weld metal of adequate hardness, narrower heat-affected zone, smaller grain size at the fusion boundary, and lower power consumption than those obtained using tandem GMAW and high-current GMAW. Based on the experimental results, a single bevel groove, which is widely used in construction machinery welding joints, was welded using hot-wire GMAW, and we confirmed that the welding part could be welded in six passes, whereas eight passes were required with GMAW only.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.2,"publicationDate":"2024-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140689312","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}

引用次数: 0

Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power 脉冲和恒定发电机功率下感应线材熔化过程中的液滴形成和能量输入

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-18 DOI: 10.3390/jmmp8020080

J. Kimme, Jonas Gruner, A. Hälsig, Jonas Hensel

{"title":"Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power","authors":"J. Kimme, Jonas Gruner, A. Hälsig, Jonas Hensel","doi":"10.3390/jmmp8020080","DOIUrl":"https://doi.org/10.3390/jmmp8020080","url":null,"abstract":"Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study investigates a novel approach to AM based on inductive heating, where a steel wire is melted and droplets are detached periodically using a two-winding induction coil. The process parameters and energy input into the droplets are characterized. The induction generator exhibits a sluggish response to the excitation voltage, resulting in a lag in the coil current. The process is captured using a high-speed camera, revealing a regular droplet formation of 14 Hz and uniform shapes and sizes between 2.11 and 2.65 mm in diameter when operated within an appropriate process window. Larger drops and increased spatter formation occur outside this window. The proposed method allows for the production of droplets with almost spherical shapes. Further analysis and characterization of droplet formation and energy input provide insights into process optimization and indicate an overall efficiency of approximately 10%.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.2,"publicationDate":"2024-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140686596","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}

引用次数: 0

Soft Robot Design, Manufacturing, and Operation Challenges: A Review 软机器人的设计、制造和运行挑战：综述

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-16 DOI: 10.3390/jmmp8020079

Getachew A. Ambaye, Enkhsaikhan Boldsaikhan, Krishna Krishnan

{"title":"Soft Robot Design, Manufacturing, and Operation Challenges: A Review","authors":"Getachew A. Ambaye, Enkhsaikhan Boldsaikhan, Krishna Krishnan","doi":"10.3390/jmmp8020079","DOIUrl":"https://doi.org/10.3390/jmmp8020079","url":null,"abstract":"Advancements in smart manufacturing have embraced the adoption of soft robots for improved productivity, flexibility, and automation as well as safety in smart factories. Hence, soft robotics is seeing a significant surge in popularity by garnering considerable attention from researchers and practitioners. Bionic soft robots, which are composed of compliant materials like silicones, offer compelling solutions to manipulating delicate objects, operating in unstructured environments, and facilitating safe human–robot interactions. However, despite their numerous advantages, there are some fundamental challenges to overcome, which particularly concern motion precision and stiffness compliance in performing physical tasks that involve external forces. In this regard, enhancing the operation performance of soft robots necessitates intricate, complex structural designs, compliant multifunctional materials, and proper manufacturing methods. The objective of this literature review is to chronicle a comprehensive overview of soft robot design, manufacturing, and operation challenges in conjunction with recent advancements and future research directions for addressing these technical challenges.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.2,"publicationDate":"2024-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140697194","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}

引用次数: 0

Comprehensive Distortion Analysis of a Laser Direct Metal Deposition (DMD)-Manufactured Large Prototype Made of Soft Martensitic Steel 1.4313 激光直接金属沉积 (DMD) 制造的 1.4313 软马氏体钢大型原型的综合变形分析

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-16 DOI: 10.3390/jmmp8020078

I. Dey, Raphael Floeder, Rick Solcà, T. Schudeleit, Konrad Wegener

{"title":"Comprehensive Distortion Analysis of a Laser Direct Metal Deposition (DMD)-Manufactured Large Prototype Made of Soft Martensitic Steel 1.4313","authors":"I. Dey, Raphael Floeder, Rick Solcà, T. Schudeleit, Konrad Wegener","doi":"10.3390/jmmp8020078","DOIUrl":"https://doi.org/10.3390/jmmp8020078","url":null,"abstract":"Additive manufacturing (AM) by using direct metal deposition (DMD) often causes erratic distortion patterns, especially on large parts. This study presents a systematic distortion analysis by employing numerical approaches using transient–thermal and structural simulations, experimental approaches using tomography, X-ray diffraction (XRD), and an analytical approach calculating the buckling distortion of a piston. The most essential geometrical features are thin walls situated between massive rings. An eigenvalue buckling analysis, a DMD process, and heat treatment simulation are presented. The eigenvalue buckling simulation shows that it is highly dependent on the mesh size. The computational effort of the DMD and heat treatment simulation was reduced through simplifications. Moreover, artificial imperfections were imposed in the heat treatment simulation, which moved the part into the buckling state inspired by the experiment. Although the numerical results of both simulations are successful, the eigenvalue and DMD simulation cannot be validated through tomography and XRD. This is because tomography is unable to measure small elastic strain fields, the simulated residual stresses were overestimated, and the part removal disturbed the residual stress equilibrium. Nevertheless, the heat treatment simulation can predict the distortion pattern caused by an inhomogeneous temperature field during ambient cooling in an oven. The massive piston skirt cools down and shrinks faster than the massive core. The reduced yield strength at elevated temperatures and critical buckling load leads to plastic deformation of the thin walls.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.2,"publicationDate":"2024-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140696970","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}

引用次数: 0

Computer-Aided Optimisation in Additive Manufacturing Processes: A State of the Art Survey 计算机辅助优化增材制造工艺：技术现状调查

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-15 DOI: 10.3390/jmmp8020076

Tanja Emilie Henriksen, T. Brustad, Rune Dalmo, Aleksander Pedersen

引用次数: 0

Interrelations between Printing Patterns and Residual Stress in Fused Deposition Modelling for the 4D Printing of Acrylonitrile Butadiene Styrene and Wood–Plastic Composites 用于丙烯腈-丁二烯-苯乙烯和木塑复合材料 4D 印刷的熔融沉积模型中印刷图案与残余应力之间的相互关系

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-15 DOI: 10.3390/jmmp8020077

Yerong Huang, S. Löschke, Yixiang Gan, G. Proust

{"title":"Interrelations between Printing Patterns and Residual Stress in Fused Deposition Modelling for the 4D Printing of Acrylonitrile Butadiene Styrene and Wood–Plastic Composites","authors":"Yerong Huang, S. Löschke, Yixiang Gan, G. Proust","doi":"10.3390/jmmp8020077","DOIUrl":"https://doi.org/10.3390/jmmp8020077","url":null,"abstract":"Four dimensional printing enables the advanced manufacturing of smart objects that can morph and adapt shape over time in response to stimuli such as heat. This study presents a single-material 4D printing workflow which explores the residual stress and anisotropy arising from the fused deposition modelling (FDM) printing process to create heat-triggered self-morphing objects. In particular, the study first investigates the effect of printing patterns on the residual stress of FDM-printed acrylonitrile butadiene styrene (ABS) products. Through finite element analysis, the raster angle of printing patterns was identified as the key parameter influencing the distribution of residual stresses. Experimental investigations further reveal that the non-uniform distribution of residual stress results in the anisotropic thermal deformation of printed materials. Thus, through the design of printing patterns, FDM-printed materials can be programmed with desired built-in residual stresses and anisotropic behaviours for initiating and controlling the transformation of 4D-printed objects. Using the proposed approach, any desktop FDM printers can be turned into 4D printers to create smart objects that can self-morph into target geometries. A series of 4D printing prototypes manufactured from conventional ABS 3D printing feedstock are tested to illustrate the use and reliability of this new workflow. Additionally, the custom-made wood–plastic composite (WPC) feedstocks are explored in this study to demonstrate the transposability of the 4D printing approach.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.2,"publicationDate":"2024-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140702754","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}

引用次数: 0

Rolling Eccentric Steel Rings on an Industrial Radial–Axial Ring Rolling Mill 在工业径向轴向环形轧机上轧制偏心钢环

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-12 DOI: 10.3390/jmmp8020075

M. Gröper, Marten Quadfasel, D. Bailly, G. Hirt

{"title":"Rolling Eccentric Steel Rings on an Industrial Radial–Axial Ring Rolling Mill","authors":"M. Gröper, Marten Quadfasel, D. Bailly, G. Hirt","doi":"10.3390/jmmp8020075","DOIUrl":"https://doi.org/10.3390/jmmp8020075","url":null,"abstract":"Various industries, including mechanical engineering, utilize steel rings featuring variable cross-sectional profiles, such as eccentric rings. Presently employed methods for producing eccentric rings possess drawbacks like restricted geometries, significant material wastage or uneven microstructures. The radial–axial ring rolling process serves to create seamless rolled steel rings with near-net-shaped cross-sections. A novel technique involves achieving eccentricity by dynamically adjusting the mandrel’s position during the ring rolling process. This method’s fundamental feasibility has previously been showcased using a blend of oil clay and a labor test bench. Transferring the possibility of manufacturing eccentric rings on industrial radial–axial ring rolling mills would expand the product range of ring manufacturers without encountering drawbacks associated with existing manufacturing processes. The objective of this paper is to demonstrate the basic feasibility of the concept of an industrial radial–axial ring rolling mill. In the first step, FEA simulation studies were carried out to develop the rolling strategy and estimate the achievable eccentricity on the institute’s radial–axial ring mill. Subsequently, the rolling strategy was implemented on an industrial ring rolling mill with the help of a unique technology module programmed in C++. Finally, an eccentric ring was ring rolled and compared with the FEA simulation, and the reproducibility was demonstrated to be successful.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.2,"publicationDate":"2024-04-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140711187","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}

引用次数: 0

Influence of the Hot-Top Thermal Regime on the Severity and Extent of Macrosegregation in Large-Size Steel Ingots 炉顶热制度对大型钢锭宏观偏析严重程度和范围的影响

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-11 DOI: 10.3390/jmmp8020074

Neda Ghodrati, Henri Champliaud, J. Morin, Mohammad Jahazi

{"title":"Influence of the Hot-Top Thermal Regime on the Severity and Extent of Macrosegregation in Large-Size Steel Ingots","authors":"Neda Ghodrati, Henri Champliaud, J. Morin, Mohammad Jahazi","doi":"10.3390/jmmp8020074","DOIUrl":"https://doi.org/10.3390/jmmp8020074","url":null,"abstract":"The influence of hot-top designs with different heat capacities on the distribution of positive and negative macrosegregation was investigated on a 12 metric tonne (MT) cast ingot made using Cr-Mo low-alloy steel. The three-dimensional finite element modeling code THERCAST® was used to simulate the thermo-mechanical phenomena associated with the solidification process, running from filling the mold until complete solidification. The model was validated on an industrial-scale ingot and then utilized to evaluate the influence of the thermal history of the hot-top, a crucial component in the cast ingot setup. This assessment aimed to comprehend changes in solidification time, temperature, and heat flux—all of which contribute to the determination of macrosegregation severity. The results showed that preheating the hot-top had a minor effect on solidification time, while modifications of thermal conductivity in the hot-top region increased the solidification time by 31%, thereby significantly affecting the macrosegregation patterns. The results are discussed and interpreted in terms of the fundamental mechanisms governing the kinetics of solidification and macrosegregation phenomena.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.2,"publicationDate":"2024-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140714171","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}

引用次数: 0

Theoretical-Numerical Investigation of a New Approach to Reconstruct the Temperature Field in PBF-LB/M Using Multispectral Process Monitoring 利用多光谱过程监测重建 PBF-LB/M 中温度场的新方法的理论和数值研究

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-10 DOI: 10.3390/jmmp8020073

Lisa May, M. Werz

{"title":"Theoretical-Numerical Investigation of a New Approach to Reconstruct the Temperature Field in PBF-LB/M Using Multispectral Process Monitoring","authors":"Lisa May, M. Werz","doi":"10.3390/jmmp8020073","DOIUrl":"https://doi.org/10.3390/jmmp8020073","url":null,"abstract":"The monitoring of additive manufacturing processes such as powder bed fusion enables the detection of several process quantities important to the quality of the built part. In this context, radiation-based monitoring techniques have been used to obtain information about the melt pool and the general temperature distribution on the surface of the powder bed. High temporal and spatial resolution have been achieved at the cost of large storage requirements. This contribution aims to offer an alternative strategy of gaining information about the powder bed’s temperature field with sufficient resolution but with an economical amount of data. The investigated measurement setup uses a spectrometer to detect the spectral radiation intensities emitted by an area enclosing the melt pool and part of its surroundings. An analytical description of this process is presented, which shows that the measured spectral entities can be reconstructed by the Ritz method. It is also shown that the corresponding weighting factors can be physically interpreted as subdomains of constant temperature within the measurement area. Two different test cases are numerically analyzed, showing that the methodology allows for an approximation of the melt pool size while further assumptions remain necessary to reconstruct the actual temperature distribution.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.2,"publicationDate":"2024-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140716665","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}

引用次数: 0

Investigation of Deposition Parameters for Near-Beta Alloy Ti-55511 Fabricated by Directed Energy Deposition 定向能沉积法制造的近贝塔合金 Ti-55511 沉积参数研究

IF 3.2

Journal of Manufacturing and Materials Processing Pub Date : 2024-04-10 DOI: 10.3390/jmmp8020072

Addison J. Rayner, Greg A. W. Sweet, Owen Craig, Mahdi Habibnejad-Korayem, Paul Bishop

引用次数: 0