Procedia CIRP最新文献_第7页

Reference geometries and indicators for the process window development of wire Directed Energy Deposition

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.01.016

Konstantinos Tzimanis , Nikolas Porevopoulos , Nikolas Bourlesas , Panagiotis Stavropoulos

引用次数: 0

Long-pulse fibre laser micro-hole drilling of nickel superalloy

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.01.007

Mitchell Leering , Chris Ellis , Annie Kerwin , Sundar Marimuthu

{"title":"Long-pulse fibre laser micro-hole drilling of nickel superalloy","authors":"Mitchell Leering , Chris Ellis , Annie Kerwin , Sundar Marimuthu","doi":"10.1016/j.procir.2025.01.007","DOIUrl":"10.1016/j.procir.2025.01.007","url":null,"abstract":"<div><div>The laser drilling process represents state-of-the-art technology for producing components with micro-holes across various engineering sectors, from hybrid laminar flow control in aerospace to electrodes in hydrogen systems. Various types of lasers are used to create micro-holes, ranging from long-pulse fibre lasers (multi-mode or single-mode) to short and ultra-short pulse lasers. This research focuses on understanding the characteristics of micro-hole (<100 µm) drilling in 1 mm thick nickel superalloy using a long pulse (millisecond) multi-mode quasi-continuous-wave fibre laser with a fibre core diameter of 50 µm and a focus spot size of 35 µm. The effects of various process parameters on drilling performance have been evaluated, and a high-speed camera has been used to gain a detailed understanding of the process. The results of this study have been compared with our previous work on high-power multi-mode laser drilling (fibre diameter of 100 µm and focus spot size of 75 µm) and single-mode fibre laser drilling (fibre diameter of 15 µm and focus spot size of ~15 µm). Despite significant variations in focus spot beam sizes across different laser setups, the optimised minimum hole diameters for millisecond pulse laser drilling of 1-2 mm thick nickel alloy remained consistently in the range of ~70-80 µm, suggesting that heat conduction and melting phenomena play a critical role in determining hole size.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"132 ","pages":"Pages 37-42"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143511032","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}

引用次数: 0

Application of generative AI technologies to engineering design

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.01.025

Daniel Byrne , Vincent Hargaden , Nikolaos Papakostas

引用次数: 0

Thermal assessment and energy analysis in the machining of titanium alloys using SPRT. 使用 SPRT 加工钛合金时的热评估和能量分析。

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.092

El Hatimi Imane , Wagner Vincent , Dessein Gilles

{"title":"Thermal assessment and energy analysis in the machining of titanium alloys using SPRT.","authors":"El Hatimi Imane , Wagner Vincent , Dessein Gilles","doi":"10.1016/j.procir.2025.02.092","DOIUrl":"10.1016/j.procir.2025.02.092","url":null,"abstract":"<div><div>Understanding the interplay between tool dynamics and thermal behaviour is essential when machining challenging materials like titanium alloys. Ti54M, a titanium alloy with low thermal conductivity, poses significant machining challenges due to heat concentration in the secondary cutting zone (SCZ). Excessive heat in this zone accelerates tool wear, reducing efficiency and surface quality. Self-Propelled Rotary Tools (SPRTs) address these issues by introducing passive rotation of the cutting insert, redistributing heat and wear across the tool surface. This study investigates the relationships between tool rotation speed, chip flow velocity, and their indirect effects on thermal behaviour, addressing gaps noted in foundational studies. Using high-speed cameras, experiments analysed the kinematic interactions under various cutting conditions. Results demonstrate that higher chip flow velocities and tool rotation speeds enhance heat evacuation, mitigating localized thermal peaks. Unlike prior works, this study emphasizes indirect thermal indicators, contributing unique insights to SPRT technology. These findings provide a comprehensive understanding of the interplay between kinematics and thermal effects, offering practical guidelines for optimizing machining parameters. Future research will integrate advanced thermal imaging techniques to validate these findings and explore their broader implications for sustainable machining.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 537-542"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759096","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

Modeling of friction in the presence of cooling lubricants

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.009

B. Denkena , B. Bergmann , J. Schenzel

{"title":"Modeling of friction in the presence of cooling lubricants","authors":"B. Denkena , B. Bergmann , J. Schenzel","doi":"10.1016/j.procir.2025.02.009","DOIUrl":"10.1016/j.procir.2025.02.009","url":null,"abstract":"<div><div>High pressure cooling lubricant (CL) supply is associated with high electrical energy consumption. With a reduced CL-supply the energy efficiency of cutting processes can be increased while maintaining the material removal rate and surface quality of the workpiece. In order to design adapted CL strategies, basic knowledge of the fundamental mechanisms of CL is necessary. However, due to high normal stresses and small contact areas of the chip and the cutting wedge, the analysis of the mechanisms of CL is challenging. In this paper high-speed video recordings and force measurements are used for in-situ analysis to model the velocity-dependent effects of CL on friction at the tool-chip considering CL. Different rake angles γ = [-6 °, 0 °, +6 °] are being set in order to investigate a wide variety of relative velocities between the tool and the chip. Using local normal- and tangential stresses as well as local relative velocities, which are measured using Digital Particle Image Velocimetry (DPIV), the velocity depended effects are investigated. The interaction of the tool and chip on the rake face is modeled using local force coefficients µ* as the quotient of the local tangential and normal stresses in dependency of the relative velocity and the CL pressure p.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 43-48"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759643","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

The role of the layer thickness on the surface integrity of LPBF AlSi7Mg after turning

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.017

Edoardo Ghinatti , Rachele Bertolini , Andrea Ghiotti , Stefania Bruschi

{"title":"The role of the layer thickness on the surface integrity of LPBF AlSi7Mg after turning","authors":"Edoardo Ghinatti , Rachele Bertolini , Andrea Ghiotti , Stefania Bruschi","doi":"10.1016/j.procir.2025.02.017","DOIUrl":"10.1016/j.procir.2025.02.017","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) is an additive manufacturing process used to fabricate aluminum alloy complex structures for the aerospace and automotive industries. By optimizing the printing and subsequent heat treatment parameters, it is possible to achieve physical and mechanical properties comparable to those of cast and wrought aluminum alloys. The influence of the printing parameters on the aluminum alloy mechanical properties is well documented, but their effect on the machinability has not been extensively studied, yet.</div><div>In this regard, the paper aims to investigate the effect of the layer thickness adopted in LPBF on the machinability of the aluminum alloy AlSi<sub>7</sub>Mg. Three sets of cylindrical samples were printed with different layer thicknesses (20, 25, and 30 µm), followed by a T6 heat treatment. Then, the cylinders were machined at fixed cutting parameters while recording the cutting forces. Afterward, the machined surface roughness and defects were analyzed.</div><div>Results show that increasing layer thickness improves the overall machining performance, with a decrease of more than 70% of the surface roughness and forces when printing with the highest layer thickness. To explain such behavior, microstructural analyses, including melt pool and grain distribution, precipitate type, and morphology, were carried out, proving that an increased layer thickness promoted the formation of silicon precipitates, which, in turn, improved the alloy’s machinability.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 90-95"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759659","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

Experimental and Numerical Analysis of Grinding Burn and Surface Layer Modification Depth after Case Hardening and subsequent Surface Grinding

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.006

Gerrit Kuhlmann , Martin Hunkel , Lars Langenhorst , Carsten Heinzel

{"title":"Experimental and Numerical Analysis of Grinding Burn and Surface Layer Modification Depth after Case Hardening and subsequent Surface Grinding","authors":"Gerrit Kuhlmann , Martin Hunkel , Lars Langenhorst , Carsten Heinzel","doi":"10.1016/j.procir.2025.02.006","DOIUrl":"10.1016/j.procir.2025.02.006","url":null,"abstract":"<div><div>Heat treatment and machining processes are usually analyzed in two independent simulations. Instead, in this work, a process chain simulation of case hardening and subsequent surface grinding is performed with the aim of taking into account overall tempering effects such as hardness reduction, retained austenite transformation and precipitate formation induced by both processes. Hardness and microstructure distribution resulting from the case-hardening simulation are used in the grinding simulation. The thermal load applied to the material by surface grinding is simulated by a moving heat source using the measured contact area, specific grinding power and the contact length. The thermal process limits are deliberately exceeded by increasing the depth of cut in order to generate grinding burn in form of tempering zones. A comparison of experimental and simulated carbon depth profile and hardness depth profile validate the models. The formation of tempering zones and accompanying changes in hardness can be predicted regarding their modification depth by means of simulated cementite precipitation as well as tempering time. This allows to determine the thermal process limit in grinding without extensive and cost-intensive metallographic measurements.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","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":"143758995","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

Identification of Cutting Coefficients from Multiple Milling Tests

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.008

Edouard Rivière-Lorphèvre , Martin Van Hee , Thomas Beuscart , François Ducobu

{"title":"Identification of Cutting Coefficients from Multiple Milling Tests","authors":"Edouard Rivière-Lorphèvre , Martin Van Hee , Thomas Beuscart , François Ducobu","doi":"10.1016/j.procir.2025.02.008","DOIUrl":"10.1016/j.procir.2025.02.008","url":null,"abstract":"<div><div>The simulation of cutting forces in milling is a prerequisite for reliable process modeling. Among the different approaches used in the literature, the mechanistic models show good compromise between good precision and reasonable simulation time. The main challenge for these models is the identification of their parameters, such as the cutting coefficients, for a given tool/material couple.</div><div>This paper presents a method based on an inverse analysis to identify these parameters. At first, the preprocessing of the signal is made to automatically detect the time during which the cutter is actively engaged in the workpiece. The consistency of the input data is also checked to reject outliers. Then, to avoid the classical pitfalls of this approach such as the non-uniqueness of solution, the identification is made on a whole database of results using an iterative method. The use of optimization algorithm allows the identification of parameters having nonlinear effect on the results such as cutter runout.</div><div>A set of 57 milling tests in Ti6Al4V alloys have been used to demonstrate the effectiveness of this method. It allows a reduction of 5 to 20% of the root mean square error between the model and the measurements as compared to the use of coefficients identified on a single cutting test.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 37-42"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143758997","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

Prediction of crater induced failure of coated wires during wire EDM of Ti-6Al-4V alloy

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.089

Sanghamitra Das , Shrikrishna N. Joshi

{"title":"Prediction of crater induced failure of coated wires during wire EDM of Ti-6Al-4V alloy","authors":"Sanghamitra Das , Shrikrishna N. Joshi","doi":"10.1016/j.procir.2025.02.089","DOIUrl":"10.1016/j.procir.2025.02.089","url":null,"abstract":"<div><div>Coated wires are widely used in wire electric discharge machining (WEDM) due to their better performance in terms of material removal, cutting speed and excellent sparking abilities as compared to uncoated wires. Prediction and restriction of the wire breakage phenomenon are however crucial in order to achieve sustainable and efficient machining. In the present work, a three-dimensional thermo-mechanical finite element model (FEM) of spark generation on a coated wire tool has been developed by considering realistic assumptions like moving heat source characteristics of spark plasma, Gaussian heat source, current and discharge duration based spark radius equation. The numerical model was well validated with experimental results conducted in a High-speed wire EDM machine with reciprocating wire travel movement. The temperature and stresses generated in the wire at different sets of process conditions are computed. The craters generated due to a variety of combination of process parameters were thoroughly analysed and a methodology has been developed to predict the failure of coated wires. The wire strength is estimated based on the amount of material removed from the zinc coated brass wire tool. It was noted that the wire experiences failure when the crater volume exceeds a threshold value during the machining operation. This value of crater volume was considered as the threshold limit or the wire safety factor to avoid unwanted wire failure. In the end, parametric studies to investigate the effects of input parameters on the temperature, residual stresses and crater volume generated in the wire were carried out.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 519-524"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759118","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

Mechanistic modeling of cutting forces in milling of unidirectional Glass Fiber Reinforced Polymer (UD-GFRP)

Procedia CIRP Pub Date : 2025-01-01 DOI: 10.1016/j.procir.2025.02.073

Matthias Nutte , Edouard Rivière-Lorphèvre , Valentin Dambly , Pedro-José Arrazola , Ismail Lazoglu , Aurélie Granjon , François Ducobu

{"title":"Mechanistic modeling of cutting forces in milling of unidirectional Glass Fiber Reinforced Polymer (UD-GFRP)","authors":"Matthias Nutte , Edouard Rivière-Lorphèvre , Valentin Dambly , Pedro-José Arrazola , Ismail Lazoglu , Aurélie Granjon , François Ducobu","doi":"10.1016/j.procir.2025.02.073","DOIUrl":"10.1016/j.procir.2025.02.073","url":null,"abstract":"<div><div>Mechanistic models, established on experimental data, are recognized for their precision and simplicity in implementation. In this context of milling, the modeling of cutting forces, specifically radial and tangential components, has been extensively explored for unidirectional carbon fiber-reinforced polymer (UD-CFRP) parts. These models account for the anisotropic nature of fiber-reinforced polymers (FRPs), with cutting coefficients that vary based on the instantaneous cutting angle. However, due to the inherent flexibility of these materials, primarily attributed to their low thickness, axial cutting forces must also be incorporated to accurately represent the phenomena occurring during the machining process. This study develops a model for calculating cutting forces in three spatial directions for UD-GFRPs (unidirectional Glass Fiber-reinforced polymers). Building on an existing model from the literature for UD-CFRP, this new version introduces several modifications. First, the model validated for CFRPs must be extended to GFRPs. Secondly, the model must be extended from two dimensions to three dimensions. Finally, to ensure that the model includes only the actual contributions of the trimming operation, machining tests will be performed using only the rolling teeth. The cutting coefficients are modelled as a periodic function with a fundamental period of π. A first-order Fourier series was chosen for this purpose. Fourier series parameters are identified from the milling forces measured during a set of slotting operations at three feed rates and four fiber orientations. While the average levels of cutting forces are accurately modelled for both slotting and shoulder milling (with 50% immersion in up milling), the modeling of force amplitudes still requires improvement.</div></div>","PeriodicalId":20535,"journal":{"name":"Procedia CIRP","volume":"133 ","pages":"Pages 424-429"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759167","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