Procedia CIRP最新文献

{"title":"Forward design of temperature field in laser-assisted milling of Ti6Al4V alloy through numerical simulation","authors":"Xin Liu,&nbsp;Hongguang Liu,&nbsp;Shijia Shi,&nbsp;Binbin Xu,&nbsp;Jun Zhang","doi":"10.1016/j.procir.2025.02.053","DOIUrl":"10.1016/j.procir.2025.02.053","url":null,"abstract":"<div><div>Laser-assisted machining (LAM) is an advanced technique, which can significantly reduce cutting forces and improve machining efficiency of difficult-to-cut materials by preheating the local area. A crucial step for obtaining ideal machinability is to control the temperature field by modulating process parameters. In this paper, by quantitative characterization of the output laser beam quality, an analytical model is adopted to characterize the temperature field induced by the moving laser source. Following, a temperature-controlling strategy is proposed for adapting the moving path of the laser source to obtain a uniform temperature distribution within the cutting area. Then, based on the classical oblique cutting model, an analytical force model of LAM is developed sequentially coupled with the optimized laser moving path to predict the milling forces. The proposed forces model takes into account the effects of laser heating and material softening. Thus, the controlling strategy of the temperature field was established. Furthermore, the proposed strategy is verified by the variation of cutting forces during the face-milling of Ti6Al4V. The results show that the proposed strategy can significantly reduce the milling forces by over 10%. The developed force model can provide acceptable predicted accuracy, which reflects the impacts of temperature field distribution on cutting forces. In summary, the proposed strategy can effectively regulate the preheating temperature, providing a theoretical way for the forward design of laser-heating parameters.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 304-309"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759367","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":"Modelling the energy consumption of an industrial robot with different types of trajectory for machining tasks","authors":"Florian Delooz ,&nbsp;Valentin Dambly ,&nbsp;François Ducobu ,&nbsp;Édouard Rivière-Lorphèvre ,&nbsp;Bryan Olivier","doi":"10.1016/j.procir.2025.02.054","DOIUrl":"10.1016/j.procir.2025.02.054","url":null,"abstract":"<div><div>Industrial robots are being used more and more for machining operations, in particular due to their agility in the case of products with complex geometries, as well as their adaptability across various applications. For some years, as industries become more ecologically conscious, energy consumption (EC) during operations becomes an important consideration. This growing awareness motivates the need for models that monitor the EC of a robot during machining operations. Firstly, the robot multibody model used in the simulations will be completely described. The computational methodology used to calculate EC during these machining tasks will also be outlined, including a discussion of the motors model applied in the simulations. Then, to validate the established model, an initial simulation will be carried out using a simple general case, depicting a straight line trajectory, to demonstrate the effectiveness of the model used. Finally, other relevant simulation tests will be presented for distinct cases: a smooth and continuous machining trajectory with variations in the curve parameter and the followed axes. The results of these numerical tests provide insights into how different machining strategies impact EC, providing guidelines for optimizing robot operation in an environmentally conscious industrial context.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 310-315"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759368","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":"An Apparatus Design for Multiaxial Ductile Fracture: Application to AISI1045","authors":"Afonso V.L. Gregorio ,&nbsp;Tiago E.F. Silva ,&nbsp;José C. Outeiro ,&nbsp;Carlos E.H. Ventura ,&nbsp;Pedro Areias ,&nbsp;Abílio M.P. de Jesus ,&nbsp;Pedro Rosa","doi":"10.1016/j.procir.2025.02.035","DOIUrl":"10.1016/j.procir.2025.02.035","url":null,"abstract":"<div><div>Metal cutting involves extensive plastic deformation as the workpiece material flows through the shear plane, promoting mechanisms of initiation, coalescence, and propagation of cracks. This the largest plastic deformation that it can withstand, above those of tensile and compression tests. Such condition ultimately leads to the onset of an ever-present crack just ahead of the cutting edge that provides the separation mechanism necessary to form the chip. However, it is neither easy nor simple to measure the fraction of the total energy involved in the material separation mechanism and its correlation with operating conditions.</div><div>In this research, a new design of a multiaxial tool for determining mode II ductile fracture toughness is proposed. This testing tool is composed of several hydraulic and pneumatic actuators that allow a shearing punch to act against double-notched prismatic specimens with superimposed orthogonal load, yielding a wide range of stress triaxialities. This load can vary from the compressive to tensile yield stress of the material. Thus, allowing the influence analysis of the stress state on the mechanical response of ductile materials, like that experienced on the shear plane of metal cutting due to rake face angle variation. Experiments performed in AISI 1045 give support to the presentation and allow a better understanding of the influence of the superimposed pressure on fracture toughness of ductile metals.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 197-202"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759555","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":"DEM Simulation of Abrasive Brushing Processes on Additively Manufactured Workpieces","authors":"Anton Hoyer ,&nbsp;Eckart Uhlmann","doi":"10.1016/j.procir.2025.02.036","DOIUrl":"10.1016/j.procir.2025.02.036","url":null,"abstract":"<div><div>Brushing with bonded abrasives is a finishing process mainly used for deburring, edge rounding, and surface roughness reduction. The brushing tools consist of flexible polymer filaments embedded with abrasive grains, allowing them to adapt to complex workpiece shapes. However, interactions between filaments lead to complex motion, chipping, and wear behaviors, making it difficult to predict work results. The discrete element method (DEM) has been shown to be effective in simulating process forces, contact areas, and filament interactions on flat workpieces. Consequently, this article focuses on processing geometrically complex workpieces, particularly additively manufactured turbine fan blades (Ni-Cr-Co), using round brushes with bonded silicon carbide. First, a vectorized iterative method is introduced to generate artificial filament patterns, enhancing DEM simulation accuracy compared to state-of-the-art filament pattern models. Subsequently, dry brushing experiments are carried out on a fan blade feature demonstrator, aiming to achieve homogeneous roughness reduction. The qualitative analysis of the contact surface suggests that results from DEM simulations can reduce the need for costly technological investigations and prototypes.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 203-208"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759556","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":"Sensitivity analysis for considering the process dynamics during the calibration of process force models","authors":"Melina Wenzel ,&nbsp;Daniel Welling ,&nbsp;Dirk Biermann ,&nbsp;Petra Wiederkehr","doi":"10.1016/j.procir.2025.02.072","DOIUrl":"10.1016/j.procir.2025.02.072","url":null,"abstract":"<div><div>When analyzing milling processes, various characteristics such as process forces and tool deflections can be investigated using process simulations. The analysis of cutting forces is subject to the dynamic effects of the tool and workpiece, whereby the force measurement technology used has a further influence due to its own modal properties and its specific force transfer behavior. Particularly during finishing with spherical milling tools, the variation of radius and helix angle along the cutting edge leads to variations of the engagement situation and effective cutting speed. These different geometric properties and orientations of the tools infuence the process forces and dynamics and their interactions. Due to various influences on force measurements and dynamic superimposition, a higher model quality can be achieved through a sophisticated calibration methodology.</div><div>In this paper, a methodology is presented in which the effects of tool dynamics are included in the calibration of force model coefficients to improve the accuracy of the resulting model. To this end, the inclusion of non-stationary tooth engagements during run-in and run-outs are considered, where process dynamics are more prevalent. For this analysis the cutting edge of spherical tools was divided into sections using confocal microscopy, which were replicated as analogous tools using cylindrical end mills. Peripheral milling tests with different process scenarios were conducted with these analogy tools, which had different geometric properties, in order to generate an experimental database. Based on this data, a sensitivity analysis was carried out for process force calibration taking process dynamics into account.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 418-423"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759210","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":"Improved coolant channel flow efficiency for grooving tools through simulation and additive manufacturing","authors":"Patrick Fischmann,&nbsp;Sebastian Galland,&nbsp;Frederik Zanger","doi":"10.1016/j.procir.2025.02.060","DOIUrl":"10.1016/j.procir.2025.02.060","url":null,"abstract":"<div><div>Laser-based powder bed fusion for metals (PBF-LB/M) enables the production of complex external and internal shapes. This enables tool production with targeted supply of cooling lubricant. The simulative channel design and the resulting increase in coolant flow after production are the focus of this work. The optimization process is illustrated using a commercially available grooving tool with three channels and four outlets. Accordingly, a simulation was conducted to investigate and ultimately reduce the pressure loss between the inlet and outlet of the channel. This approach resulted in a calculated reduction in pressure loss of up to 97 % in the channels, as well as increased uniformity of the stream at the coolant outlet. After production of the optimized tool using PBF-LB/M, a volume flow measurement was conducted under varying coolant pressure. Fluctuations between the different tool holders were observed, which can be attributed to the additive manufacturing process and resulting spatter. In relation to all cooling channels in the grooving tool, an increase in the flow rate of up to 6% was determined.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 346-351"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759267","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":"Investigation of biological tissue cutting for minimal tissue damage using finite element simulation","authors":"Urara Satake ,&nbsp;Ryusei Senda ,&nbsp;Ryutaro Sambe ,&nbsp;Toshiyuki Enomoto","doi":"10.1016/j.procir.2025.02.085","DOIUrl":"10.1016/j.procir.2025.02.085","url":null,"abstract":"<div><div>In surgical cutting procedures for biological soft tissues, it is crucial to minimize tissue damage. However, before cut initiation, tissues undergo significant deformation due to their elastomeric properties. This deformation can cause tissue damage and increase the risk of complications, particularly in neurosurgery and ophthalmic surgery. The cut-initiation ability of a process must be improved to reduce the depth of the blade indentation required for cut initiation. Adding a slicing motion to the blade indentation has been found to enhance the cut initiation; however, the specific advantages of this method over pure indentation are not fully understood. This study aims to analyze the effects of cutting parameters, including blade motion, on the initiation of cuts in elastomeric solids, such as biological soft tissues, by examining the strain states beneath the blade that trigger cut initiation. During cutting, deep indentation by a sharp blade causes significant geometric nonlinearity, displacing the workpiece surface along the blade surface. These blade–workpiece interfacial interactions likely affect the strain states beneath the blade. Therefore, this study uses finite element simulations to examine the blade–workpiece interfacial interactions and their relation to the strain states, focusing on the influence of interfacial friction. The results indicate that the distribution of in-plane stretch along the blade surface of the workpiece is crucial for determining the strain states and the resulting cut-initiation ability. The improved cut initiation achieved by introducing a slicing motion to blade indentation can be attributed to the enhanced distribution of in-plane surface stretch.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 495-500"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759179","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":"Modeling of temperature fields in milling of unidirectionally reinforced CFRP depending on the fibre orientation angle and the effective width of cut","authors":"Wolfgang Hintze ,&nbsp;Ganna Shchegel ,&nbsp;Jan Mehnen ,&nbsp;Carsten Möller ,&nbsp;Jan Dege","doi":"10.1016/j.procir.2024.09.006","DOIUrl":"10.1016/j.procir.2024.09.006","url":null,"abstract":"<div><div>CFRP parts are conventionally used within various industries; however, during machining these components, the generated heat is a very relevant limiting factor. Exceeding the glass transition temperature can lead to workpiece degradation, reduced strength, and shorter lifetime. During up-cut milling of unidirectional (UD) CFRP with PCD cutters, the temperature was measured using thermocouples and a thermographic camera, while the cutting torque was measured with a rotating dynamometer. The maximum temperature increase at the machined surface, the heat flow from the machining zone into the material, and the ratio of heat flow to spindle power were simulated. An analytical model developed earlier for the temperature field in machining orthotropic composites with arbitrary fibre orientation was used. The results indicate that cutting power, heat flow, and the ratio of heat flow to cutting power exhibit approximate symmetry relative to the fibre orientation angle Φ = 90°. Introducing the concept of the fibre orientation symmetry angle is useful. Unexpected fractures of larger segments of remaining UD CFRP material occur at all feeds at higher fibre orientation and engagement angles within a small range of fibre cutting angles near 45°, significantly reducing the nominal width of cut and impairing results. The effective width of cut was evaluated based on the drop in cutting torque, measured at various fibre orientation angles, cutting speeds, feeds, and nominal widths of cut. The highest maximum temperature increase consistently occurs at Φ = 135°. As an overall effect, higher cutting speeds lead to increased cutting power, heat flow, and maximum temperature at the machined surface, but result in a smaller depth of the heat-affected zone. The simulations conclude that a higher fibre orientation symmetry angle leads to a higher equivalent heat flux, shorter thermal contact length, and reduced heat flow, and vice versa. In the future, the influence of different tools and composite materials needs to be investigated.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"131 ","pages":"Pages 19-25"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143509370","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Advanced Ply Shape Generation in Composite Material Layup Using FEA-derived Fiber Information","authors":"Raphael Höfer ,&nbsp;Henrik Eschen ,&nbsp;Felix Gehlhoff ,&nbsp;Alexander Fay","doi":"10.1016/j.procir.2024.09.007","DOIUrl":"10.1016/j.procir.2024.09.007","url":null,"abstract":"<div><div>The current manufacturing process of commercial aerospace components using Automated Fiber Placement (AFP) fails to fully utilize the potential of composites, producing quasi-isotropic laminates. The design, computation, and path generation steps are isolated, requiring extensive design cycles and manual effort. To harness potential weight and cycle time reductions, new automated path planning processes are needed to optimize parameters like load path-compliant path planning and tape width variation. This paper presents a novel approach for the automatic and integrated generation of ply shapes based on stress results from Finite Element Analysis (FEA) for variable angle laminates manufactured using AFP. The proposed method aims to reduce manual effort, components weight and production time. The focus is on extracting FEA data to automatically identify regions of high stress and similar fiber properties. A segmentation technique is proposed, dividing the component into segments to generate tailored ply shapes that conform to complex geometries and curvature requirements. This method allows for flexible load path-compatible planning and high deposition rates without introducing defects due to limited fiber tape steering. Segmentation forms the basis for load path-optimized path planning, emphasizing the interplay between FEA data extraction and segmentation. The benefits in terms of cost and production time are demonstrated by applying the method to components in both simulation and real tests.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"131 ","pages":"Pages 26-31"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143509371","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effects of Metal Surface Treatment on the Interfacial Strength in Magnesium Alloy-Based Fiber Metal Laminates","authors":"Rachele Bertolini ,&nbsp;Enrico Simonetto ,&nbsp;Andrea Ghiotti ,&nbsp;Stefania Bruschi","doi":"10.1016/j.procir.2024.09.008","DOIUrl":"10.1016/j.procir.2024.09.008","url":null,"abstract":"<div><div>Magnesium alloy-based fiber metal laminates (FMLs) represent a novel composite type, increasingly recognized for their potential in high-performance engineering applications, particularly in the aerospace and automotive industries. A strong bonding interface is a key factor in improving the durability of these laminates; to achieve this, appropriate surface treatments of the magnesium alloy sheets need to be applied.</div><div>The study aims to compare different metal surface treatments, specifically phosphating and sandblasting, to enhance the interfacial strength between the metal skins and the composite core of the fiber metal laminates. The morphology, composition, and surface energy of the differently treated metal surfaces were analyzed using scanning electron microscopy, chemical analysis, and measurements of wettability and roughness. Subsequently, the resistance of the interfacial strength was evaluated through lap shear tests under mode II loading conditions. After mechanical testing, the characteristics of the fractured surfaces were analyzed.</div><div>Although the FML samples with phosphatized metal surfaces exhibit a less defective interface than those with sandblasted metal surfaces, they are characterized by a lower mechanical strength. This behavior is attributed to the premature peeling off of the phosphating layer from the magnesium alloy sheets. With the gained insights, further research avenues open up towards optimized interfaces for FML components.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"131 ","pages":"Pages 32-36"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143509372","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}