Procedia CIRP最新文献_第2页

A Multi-Physics Simulation Model for Universal Cutting Process based on an Enhanced CWE Extraction Method

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.032

Chenghan Wang , Ting Yue , Dongdong Xu , Zhirong Liao , Jun Wu , Bin Shen

{"title":"A Multi-Physics Simulation Model for Universal Cutting Process based on an Enhanced CWE Extraction Method","authors":"Chenghan Wang , Ting Yue , Dongdong Xu , Zhirong Liao , Jun Wu , Bin Shen","doi":"10.1016/j.procir.2025.02.032","DOIUrl":"10.1016/j.procir.2025.02.032","url":null,"abstract":"<div><div>Cutting processes involve complex interactions among various physical factors that collectively influence machining performance, including cutting force, tool wear, deformation, and chatter. Accurately simulating these factors is essential for enhancing the efficiency of process development and optimization, yet it remains a significant challenge in the field. One of the main obstacles is the lack of a comprehensive simulation framework that integrates multiple physical models. To address this challenge, this paper presents a novel multi-physics simulation model that combines material removal, cutting force and temperature predictions, and tool wear distribution assessment. A key feature of our approach is the enhanced point-based Cutter-Workpiece Engagement (CWE) extraction algorithm, which accurately models cutting tools with arbitrary cutting-edge shapes and discretizes the cutting process into explicit orthogonal cutting elements. By breaking down complex time-varying processes into a series of standard problems, we can effectively integrate various physical factors. We utilize neural networks trained on physical datasets to derive cutting forces and temperatures for each element, facilitating precise predictions of tool wear evolution along the cutting edge throughout the machining process. The effectiveness of our method has been validated through ball-end milling experiments and an application of aeroengine blade milling process. This innovative, machine learning-integrated framework for multi-physics modeling establishes a solid foundation for a reliable and comprehensive virtual machining system.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 179-184"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759552","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

Exit delamination failure modelling during drilling of CFRP laminates

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.033

Iker Urresti Espilla , Iñigo Llanos , Luis Norberto López de Lacalle

{"title":"Exit delamination failure modelling during drilling of CFRP laminates","authors":"Iker Urresti Espilla , Iñigo Llanos , Luis Norberto López de Lacalle","doi":"10.1016/j.procir.2025.02.033","DOIUrl":"10.1016/j.procir.2025.02.033","url":null,"abstract":"<div><div>Drilling of CFRP components is a key manufacturing process in the aircraft manufacturing industry. Airframe structures and fuselage skins are often assembled using riveted joints, which require pre-drilling of composite parts. However, drilling CFRP can be challenging due to the inhomogeneous and anisotropic nature of the material, which can lead to major defects such as delamination, fiber pull-out and uncut fibers. In particular, push-out delamination at the hole exit is considered critical, as it can compromise the structural health of the components and even lead to their rejection. Therefore, the development of monitoring and modeling techniques to predict push-out delamination is of great importance to the industry. In this regard, the present work introduces a theoretical model for the prediction of exit delamination and thrust force evolution during CFRP drilling. The results are evaluated in comparison to part delamination and thrust force data obtained from experimental drilling tests. The results indicate that the proposed model can provide valuable insight into the CFRP drilling for process optimization, enabling the aerospace industry to improve current drilling practices towards delamination free drilling of CFRP components.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 185-190"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759553","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

Simulative approach to investigate the influence of tool deviations on the effective cutting conditions in gear skiving

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.010

Emma Punsmann , Tassilo Arndt , Volker Schulze

{"title":"Simulative approach to investigate the influence of tool deviations on the effective cutting conditions in gear skiving","authors":"Emma Punsmann , Tassilo Arndt , Volker Schulze","doi":"10.1016/j.procir.2025.02.010","DOIUrl":"10.1016/j.procir.2025.02.010","url":null,"abstract":"<div><div>In the course of electromobility the demand for resistant and high-precision internal gears is increasing. Gear skiving is a complex manufacturing process offering a good compromise of productivity and flexibility for this application. The process is characterized by a strong variation of the effective cutting conditions across the tool profile and the engagement. Therefore numerical models are required for profound process design. However, common methods for calculating the effective cutting conditions do not take deviations of tool teeth into account.</div><div>This work presents a simulative approach to investigate the influence of tool deviations on the effective cutting conditions in gear skiving. An existing penetration calculation is extended to include radial and axial runout and pitch deviation of the tool teeth. An exemplary simulation study is conducted to analyze their influence on the effective cutting parameters with a focus on the detection of extreme values. It is shown that pitch deviations have a significant effect on the uncut chip thickness and the effective rake angle. This effect can be further amplified or mitigated by radial runout deviations.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 49-54"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759644","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

Three-dimensional cellular magnetorheological elastomer absorber for suppressing time-varying chatter in robotic milling

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.028

Rui Fu , Xiaowei Tang , Jiawei Wu , Fangyu Peng , Rong Yan , Shihao Xin

{"title":"Three-dimensional cellular magnetorheological elastomer absorber for suppressing time-varying chatter in robotic milling","authors":"Rui Fu , Xiaowei Tang , Jiawei Wu , Fangyu Peng , Rong Yan , Shihao Xin","doi":"10.1016/j.procir.2025.02.028","DOIUrl":"10.1016/j.procir.2025.02.028","url":null,"abstract":"<div><div>Robotic machining technology plays a crucial role in the manufacturing of large components. However, the time-varying chatter phenomenon is a major obstacle to improving machining efficiency. Effective vibration suppression devices for robots must cope with chatter that changes in both direction and frequency, as well as maintain reliability during large variations in robot poses. This paper introduces a novel three-dimensional cellular magnetorheological elastomer (C-MRE) absorber. The absorber consists of meshed magnetorheological elastomers (MREs) and magnetically conductive spheres embedded therein in the form of a cellular distribution, allowing it to operate in any direction within three-dimensional space, and maintaining its ability during any rotation. A dynamics model of the C-MRE absorber is established, and its natural frequencies are simulated for various parameter combinations, revealing design principles or guidelines for selecting absorber parameters. The operating frequency band of the C-MRE absorber can be adjusted by controlling the current, to match the time-varying frequency of chatter. Experiments show that the developed C-MRE absorber prototype can achieve a maximum suppression effect of 87% for various robot modes. Additionally, it continues to function normally after rotation, with an operational bandwidth of approximately 10-30 Hz.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 155-160"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759656","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

Copyright Page

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/S2212-8271(25)00220-3

引用次数: 0

Integrating Hybrid Physics-Data Approaches for Enhanced Cutting Force Modeling in Digital Twins of Helical End Mills

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.062

Yuan Jing , Guanchen Gong , Albrecht Hänel , Steffen Ihlenfeldt

{"title":"Integrating Hybrid Physics-Data Approaches for Enhanced Cutting Force Modeling in Digital Twins of Helical End Mills","authors":"Yuan Jing , Guanchen Gong , Albrecht Hänel , Steffen Ihlenfeldt","doi":"10.1016/j.procir.2025.02.062","DOIUrl":"10.1016/j.procir.2025.02.062","url":null,"abstract":"<div><div>Industry 4.0 has significantly improved data efficiency by leveraging key technologies such as the Internet of Things and Machine Learning. Among these key technologies, digital twins stand out by offering a promising approach to intelligently utilize this data. In the virtual representation of a physical asset, data reflects the conditions of the physical entity, while models simulate and predict its behavior. In this paper, a hybrid cutting force model is proposed for digital twins of helical end mills, focusing on cutting force analysis during the utilization phase of the machining process. This model combines a fairly mature physical process modelling approach with a data-driven method, specifically a neural network trained on real process data, to address the limitations inherent in their respective applications. The physics-based model provides meaningful constraints on the neural network’s training, ensuring reliable cutting force prediction, particularly in scenarios with limited process data availability. The cutter’s profile, generated by the geometric model, and the cutter-workpiece engagement maps, derived from the virtual machining model, together serve as inputs for the hybrid cutting force model.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 358-363"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759269","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

Using plunging-type testing to investigate process mechanics at micro scale machining

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.096

Syed Ahsan Adeeb , Yigit Karpat

{"title":"Using plunging-type testing to investigate process mechanics at micro scale machining","authors":"Syed Ahsan Adeeb , Yigit Karpat","doi":"10.1016/j.procir.2025.02.096","DOIUrl":"10.1016/j.procir.2025.02.096","url":null,"abstract":"<div><div>In plunging-type tests, a cutting tool is given a sinusoidal movement as the work material with a web on its surface is rotated at a constant speed. If the amplitude and feed rate of the cutting tool and rotational speed of the work material are correctly set, the plunging test can be completed within a full rotation. As a result, a detailed investigation of different episodes of micro-scale machining, such as rubbing, plowing, and shearing, can be conducted with a single test. Combined with force measurements and cut chip morphology, the process mechanics can be investigated in detail. This study conducted plunging tests on an ultra-precision CNC with a diamond cutting tool on commercially pure titanium alloy. The differences in tangential and normal forces observed during plunge-in and pull-out periods corresponding to the same amplitude were analyzed using an analytical model. Resultant forces during the pull-out phase are larger than those observed in the plunge-in phase, attributed to an increase in cut chip thickness. A computational model of the plunging-type experiment has also been developed based on the findings of the analytical model. The proposed hybrid approach may be useful to improve identification of material constitutive model parameters based on micro scale machining experiments.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 561-566"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759278","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

New Geometric Stability Maps for Predicting Unstable Lobe Regeneration During Shoe-Type Centerless Grinding with Tilting Shoes

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.044

U. Guerricagoitia , J. Álvarez , D. Barrenetxea , M. García , U. Alonso

{"title":"New Geometric Stability Maps for Predicting Unstable Lobe Regeneration During Shoe-Type Centerless Grinding with Tilting Shoes","authors":"U. Guerricagoitia , J. Álvarez , D. Barrenetxea , M. García , U. Alonso","doi":"10.1016/j.procir.2025.02.044","DOIUrl":"10.1016/j.procir.2025.02.044","url":null,"abstract":"<div><div>The shoe-type centerless grinding (STCG) process stands out for its high productivity and geometric precision in grinding bearing rings. The roundness error of these parts is critical, as it affects on the generation of unwanted noise during operation, dynamic performance and service life of the components among other problems. Recently, the industry has required that the Fast Fourier Transform (FFT) of the peripherical surface of the part remains below a specific acceptance curve to avoid problems arising from this roundness error. Geometric regeneration, which is mainly affected by the geometry and angular positioning of the support shoes is a crucial aspect, as it can produce components with high amplitude that exceed the acceptance curve. Previous studies have investigated this phenomenon with fixed single contact shoes; however, the industry has started using double and tilting support shoes. In this paper, the geometric stability of double shoes has been characterized and experimentally validated. This has enabled the development of stability maps that predict the components produced under different shoe angle combinations, allowing the selection of the optimal combination and reducing set-up times.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 250-255"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759358","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

Εvaluating Carbon Emissions of Hybrid Manufacturing Process: A Case Study on Additive and Subtractive Manufacturing

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.045

Vasiliki C. Panagiotopoulou , Evangelia Xydea , Panagiotis Stavropoulos

{"title":"Εvaluating Carbon Emissions of Hybrid Manufacturing Process: A Case Study on Additive and Subtractive Manufacturing","authors":"Vasiliki C. Panagiotopoulou , Evangelia Xydea , Panagiotis Stavropoulos","doi":"10.1016/j.procir.2025.02.045","DOIUrl":"10.1016/j.procir.2025.02.045","url":null,"abstract":"<div><div>All environmental issues, and particularly climate change, have irreversible environmental, social, and financial impacts. Significantly reducing carbon emissions by 2030, as the highest contributor to climate change, is a vital for EU as expressed in the European Green Deal. In this direction, sustainable manufacturing intends to reduce negative impacts by minimizing energy consumption, lowering carbon emissions, and optimizing resource efficiency. Hybrid Manufacturing (HM), combining additive (AM) and subtractive manufacturing (SM) processes, is a very promising process in sustainable manufacturing, in addition of being a novel approach. The aim of this paper is to identify the carbon intensive parts of a HM cell, perform carbon footprint calculations through mathematical modelling and Life Cycle Assessment (LCA) and classify them as either energy or material related carbon emissions. This methodology is implemented in an HM including Direct Energy Deposition (DED) and CNC milling, successively alternating between the two to complete the part. Results indicate that at machine tool level, the material related emissions (4.64 kg CO<sub>2</sub>-eq), slightly dominate over the energy related emissions (4.51 kg CO<sub>2</sub>-eq). Powder consumption is almost solely responsible for material related emissions. Among energy related emissions, the AM cell’s chiller was the largest contributor (accounting for 28.3% of the total emissions), followed by the AM head motion system (10.9%), and laser machine (9.6%), while the subtractive process emitting considerably less in this case. Future work will aim to optimize process parameters to reduce HM emissions while ensuring high product quality.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 256-261"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759359","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

Optimal modelling of Colding parameters for round inserts with respect to tool use-time criteria

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.050

Juan Manuel Bello Bermejo , Berk Saatçi , Daniel Johansson , Sören Hägglund , Jan-Eric Ståhl , Christina Windmark

{"title":"Optimal modelling of Colding parameters for round inserts with respect to tool use-time criteria","authors":"Juan Manuel Bello Bermejo , Berk Saatçi , Daniel Johansson , Sören Hägglund , Jan-Eric Ståhl , Christina Windmark","doi":"10.1016/j.procir.2025.02.050","DOIUrl":"10.1016/j.procir.2025.02.050","url":null,"abstract":"<div><div>Optimization of machining processes, such as milling, is essential for industrial efficiency and product quality. To achieve greater efficiency, it is necessary to understand how tools wear down in different conditions in order to anticipate possible undesirable events like sudden breakage or unpredictable degradation. This study focuses on understanding tool wear in dry milling of compacted graphite iron (CGI) EN-GJV-450 using PVD-coated cemented carbide and cBN tools to predict tool life effectively. The research builds on the Colding model, an empirical framework for tool life estimation, by incorporating and comparing two chip thickness concepts in order to optimize the Colding model’s performance, maximum chip thickness (h<sub>max</sub>) and equivalent chip thickness (h<sub>e</sub>). Through systematic experimentation and modelling, this work has identified optimal conditions for tool life prediction, with h<sub>max</sub> offering a potentially resource-efficient cross-validation alternative aligned with sustainability goals. The results demonstrate that the optimized Colding model effectively predicts tool life for both coated cemented carbide and cBN cutting tools with round geometry in dry milling of CGI. The insights gained further enhance our understanding of the milling process and provide a solid foundation for selecting appropriate machining parameters to extend tool life and improve process efficiency.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 286-291"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759364","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