He Zhu, Yong Feng, Zhiyuan Zhou, Baofeng Lu, Lei Zheng, Weiwei Xu
{"title":"Simulation and experimental research on longitudinal-torsional ultrasonic vibration drilling of CFRP/Ti laminates","authors":"He Zhu, Yong Feng, Zhiyuan Zhou, Baofeng Lu, Lei Zheng, Weiwei Xu","doi":"10.1177/09544054241245475","DOIUrl":"https://doi.org/10.1177/09544054241245475","url":null,"abstract":"Carbon fiber reinforced polymer (CFRP) and titanium alloy (Ti) laminated materials are extensively employed as primary load-bearing structures in aerospace engineering due to their exceptional characteristics. During the drilling process of CFRP/Ti laminates, issues like delamination and burr formation significantly impede the overall performance of these laminates. The finite element simulation was carried out to address above challenges using longitudinal-torsional ultrasonic vibration drilling (LT-UVD) of CFRP/Ti laminates. A three-dimensional solid model of CFRP/Ti laminates was developed using the ABAQUS custom VUMAT subroutine interface. A cohesive element was skillfully incorporated into the model to simulate delamination defects in the CFRP material effectively and to elucidate the material damage trends and stress distribution throughout the drilling process of laminated materials. The results obtained from the finite element simulation are meticulously compared with experimental data, revealing a consistent trend in the axial force curve. The simulated axial force’s peak value is 14.45% lower than the peak value obtained from experimental observations. The findings of this research substantiate the efficacy of the developed finite element model for LT-UVD of CFRP/Ti. The model successfully predicted the changing trend of axial force and layered defects during the drilling process. Moreover, it provides a visually intuitive instantaneous cutting state and stress distribution, imparting valuable insights into the intricate drilling mechanisms involved in CFRP/Ti laminates.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140662543","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Xuefei Liu, Chuanzhen Huang, Hanlian Liu, Dun Liu, Peng Yao, Bin Zou, H. Zhu, Zhen Wang, Longhua Xu, Shuiquan Huang
{"title":"Modeling and optimizing of laser-assisted waterjet process parameters for near-damage-free micromachining of monocrystalline silicon","authors":"Xuefei Liu, Chuanzhen Huang, Hanlian Liu, Dun Liu, Peng Yao, Bin Zou, H. Zhu, Zhen Wang, Longhua Xu, Shuiquan Huang","doi":"10.1177/09544054241245763","DOIUrl":"https://doi.org/10.1177/09544054241245763","url":null,"abstract":"Monocrystalline silicon-based microstructure functional surfaces are widely used in the field of photoelectricity. However, the traditional process is prone to damage due to the hardness and brittleness of monocrystalline silicon. In this study, the depth, width, and depth-width ratio of the micro-V-groove on the surface of monocrystalline silicon were studied using laser-assisted waterjet technology. Firstly, the nanosecond laser pulse width was optimized to minimize processing damage. Then, the response surface method (RSM) was employed to optimize the V-groove’s depth-width ratio and show the process parameters’ interactive effects. The results show that the heated affected zone (HAZ) and lattice disorder at 10 ns are significantly smaller than those at other pulse widths, and there is almost no amorphous phase on the surface of V-grooves. Single process parameter usually has different effects on the size of the V-groove, and the process parameters have significant interactive effects, which are discussed in detail in the study. According to the prediction model, the highest depth-width ratio of a V-groove is 1.39. Near-damage-free V-groove with a high depth-width ratio helps to lower the reflectivity and increase the hydrophobicity of monocrystalline silicon.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140675324","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Fuzzy process capability evaluation model for asymmetric tolerance production","authors":"Chun-Min Yu, Kuen-Suan Chen","doi":"10.1177/09544054241245164","DOIUrl":"https://doi.org/10.1177/09544054241245164","url":null,"abstract":"Process capability indices (PCIs) are commonly applied assessment tools which enable the evaluation of process quality during production processes and also allow internal engineers to conveniently and effectively communicate with each other. Many studies have indicated that improving process capabilities not only increases product value but also reduces rates of scrap and rework and betters product availability. Furthermore, enhancing product quality also lengthens product lifespan and delays recovery. Clearly, quality is a crucial factor of corporate sustainability. The quality characteristics of many machine products have asymmetric tolerances, so PCIs with asymmetric tolerances are needed to evaluate these quality characteristics. Many researchers have stressed that sample sizes are not usually large due to cost and technical considerations as well as corporate demands for swift responses. Also, small sample sizes are associated with an increased risk of misjudgement. To address this, we developed a fuzzy evaluation method based on confidence intervals for PCIs with asymmetric tolerances. This approach incorporated expert experience and accumulated data to boost evaluation accuracy and diminish the likelihood of misjudgement resulting from sampling errors.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140675072","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"A novel pellet-based 3D printing of high stretchable elastomer","authors":"Jianxun Zhang, Shengyang Luo","doi":"10.1177/09544054241245468","DOIUrl":"https://doi.org/10.1177/09544054241245468","url":null,"abstract":"Elastomers, known for their high stretchability and flexibility, are widely used in high-tech applications. However, traditional manufacturing methods for elastomeric part production have limitations. 3D printing, particularly fused deposition modeling (FDM), offers a promising alternative by allowing the fabrication of customized elastomers with desired shapes and properties. Conventional filament-based FDM techniques struggle to print elastomers. This article presents a novel approach for 3D printing polyolefin elastomer (POE) using a direct pellet printing technique. A customized pellet printer with a pneumatic pressure feeding system was used that eliminates filament buckling issues commonly associated with conventional filament-based 3D printing methods. The mechanical properties and microstructure of the printed parts were analyzed to evaluate the suitability of the technique for producing high-quality elastomeric components. SEM images indicated a high-quality and accurate printing method; however, there are micro-holes between the raster due to the high shrinkage rate of POE and increasing the nozzle temperature improves the print quality. The mechanical properties of the printed samples exhibited remarkable formability, with elongation reaching up to 1965%. It is also found that as the nozzle temperature increased, the strength, elongation, and bonding between layers improved significantly. This innovative 3D printing technique has the potential for various applications such as soft robotics and wearable electronics.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140677650","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Study on automated guided vehicle navigation method with external computer vision","authors":"Yingbo Zhao, Xiu Shichao, Hong Yuan, Bu Xinyu","doi":"10.1177/09544054241245476","DOIUrl":"https://doi.org/10.1177/09544054241245476","url":null,"abstract":"Automated guided vehicle (AGV) navigation is extensively used in industrial manufacturing. Existing AGV navigation methods have high accuracy but usually require expensive positioning sensors. This paper proposes a novel method for AGV navigation based on external computer vision (NECV). No matter how many AGVs are in the workshop, the proposed NECV method uses only an external camera mounted on the top of the roof to detect and track AGVs, and all the AGVs don’t need to be equipped with any positioning sensors. Because there is no need to equip positioning sensors on AGVs, and also don’t need to arrange positioning signs, NECV significantly reduces the positioning cost of navigation. YOLOv8 was selected as the detector for NECV, and the training was completed using a prepared dataset. We improved the structure of the StrongSORT algorithm and used it as the tracker. The improved StrongSORT algorithm is the core of NECV. The imaging coordinates of the AGVs are detected by the detector, transformed into global coordinates through inverse perspective mapping, and passed to the master console. Experimental results indicated that the NECV detection deviation q of the AGV and the experimental accuracy metrics of the NECV after compensating q were considerably improved, close to those of the popular Quick Response (QR) code navigation method. Statistically, NECV can reduce the cost of AGV positioning detection by 90%.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140678933","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Guanyu Sun, Zhenchao Qi, W. Tian, Wenhe Liao, Yanxin Xu
{"title":"Assembly deviation analysis of satellite flexible parts integrating rigid and flexible properties: Modeling and experiment","authors":"Guanyu Sun, Zhenchao Qi, W. Tian, Wenhe Liao, Yanxin Xu","doi":"10.1177/09544054241245017","DOIUrl":"https://doi.org/10.1177/09544054241245017","url":null,"abstract":"With the advancement of space technology, satellites are assuming an increasingly pivotal role in various fields. Currently, satellite structures incorporate a growing number of thin-walled parts. During the assembly process, the movement and connection of these parts are prone to generating assembly deviations, which seriously affects the overall assembly quality of the satellites. In order to accurately predict assembly deviations before assembly, this paper introduced an assembly deviation analysis model which took rigid and flexible properties into account. Starting from the attitude adjustment of satellite assembly, the transmission law of manufacturing error was established. Then, the assembly deviation analysis model integrating rigid and flexible properties was established. Finally, the assembly experiment was carried out to verify the effectiveness of the proposed model. The results showed that the average absolute error between the measurement results and calculation results was only 0.032 mm and the maximum absolute error was 0.074 mm. The average solving accuracy of the assembly deviation was 94%. The result fully proved the effectiveness of the proposed model.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140696073","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yazui Liu, Haodong Shen, Gang Zhao, Xishuang Jing, Xiaoxiao Du
{"title":"Improved Jacobian-Torsor model for optimizing mechanical product quality","authors":"Yazui Liu, Haodong Shen, Gang Zhao, Xishuang Jing, Xiaoxiao Du","doi":"10.1177/09544054241244999","DOIUrl":"https://doi.org/10.1177/09544054241244999","url":null,"abstract":"The quality of an assembly largely depends on the predictive accuracy of the assembly deviation model in the selective assembly process. Presently, three-dimensional deviation analysis methods only offer tolerances that indicate the overall deviation of a part feature. This limitation fails to accurately represent the fit of the parts during the assembly process, resulting in initial inaccuracies in the selective assembly model. To address this issue, an improved Jacobian-Torsor model is proposed that incorporates measured data from part assembly features into the deviation analysis model. Initially, the actual contact state of the assembly is determined by measuring the contact surface of the plane fit and the shaft-hole fit. Next, the Jacobian matrix, representing the transmission path of assembly deviation, is constructed by analyzing the assembly connection diagram. Subsequently, by integrating the actual contact state characterized by small displacement torsor (SDT) into the unified Jacobian-Torsor model, the advantage of high credibility tolerance propagation is provided. Finally, the feasibility of the proposed improved Jacobian-Torsor model is verified using the double-joint manipulator.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140697717","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Van Thao Le, Thuy Duong Nguyen, Tien-Dat Hoang, Van-Canh Nguyen
{"title":"Optimization of single-track deposits in wire arc-based direct energy deposition of ER110S-G steel using MONS-MFO and TOPSIS algorithms","authors":"Van Thao Le, Thuy Duong Nguyen, Tien-Dat Hoang, Van-Canh Nguyen","doi":"10.1177/09544054241245472","DOIUrl":"https://doi.org/10.1177/09544054241245472","url":null,"abstract":"Wire and arc-based direct energy deposition (wire and arc DED) is a promising metallic additively manufacturing (MAM) technology to fabricate large-size metallic components. Among high-strength-low-alloy steels used in wire and arc DED processes, ER110S-G is a commonly used material. However, previous studies have often relied on process parameters recommended by suppliers for conventional welding methods. This study aims to predict the optimum processing parameters for the manufacture of ER110S-G steel by a wire and arc DED process based on experiment and multi-attribute optimization algorithms. The experiment was designed using the full factorial method with the input variables ( U– voltage, I– current, and v– traveling speed) while considering three attributes of single tracks ( STW– single track width, STH– single track height, and LMP– length of melting pool). To find the optimal processing variables, MONS-MFO (Multi-Objective Non-Sorted Moth Flame) was utilized. The outcomes reveal that the developed predictive models of attributes feature a high accurate level ( R2 = 98.11%, 98.38%, and 98.07% for STW, STH, and LMP, respectively). The optimal parameters obtained by MONS-MFO & TOPSIS were I = 159.4 A, v = 0.3 m/min, and U = 21.4 V allow fabricating single tracks with smooth and regular shape and a s-shaped thin-wall component with regular shape and height. Moreover, no spatters generated with the optimal parameters, demonstrating their suitability and efficiency for the printing process.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140713246","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zhiwei Yu, Guang-qiang Chen, Wentao Xuan, Hong Wei
{"title":"Machining performance of micro-pit and micro-groove composite textured tools in tungsten alloy turning","authors":"Zhiwei Yu, Guang-qiang Chen, Wentao Xuan, Hong Wei","doi":"10.1177/09544054241240172","DOIUrl":"https://doi.org/10.1177/09544054241240172","url":null,"abstract":"Tungsten alloys are widely used in aerospace because of their high-temperature resistance, corrosion resistance, high strength, and other excellent comprehensive properties. But tungsten alloys are typical hard-to-machining materials. Surface micro-textures can improve friction properties, such as preparing micro-textures on the surface of cutting tools for tungsten alloys, which is expected to enhance the cutting performance of tungsten alloys. Still, the relevant cutting laws need to be further studied. A combination texture of micro-pit and micro-groove was designed, and the micro-textured tool surface was prepared by laser machining. Compared with non-textured tools, micro-pit and micro-groove composite textured tools can effectively improve the processing quality of tungsten alloys. It happened because textures on the tool’s surfaces enhance machining performance by reducing the actual contact area between the tool and the chip and storing lubrication medium. At the same time, comparative experiments of micro-textured tools and non-textured tools were carried out. The results showed that when cutting W93NiFe alloys with textured and non-textured tools, the maximum reduction in resultant cutting forces with textured tools was 9%. The maximum reduction in surface roughness was 39.3%, the surface burr height of the tungsten alloy workpiece was lower, the number of surface grooves was lesser, and the surface was more flat. The research results are significant in achieving the efficient processing and high-quality manufacturing of tungsten alloys.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140728007","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Muhammad Tajuddin Reduan, P. Mativenga, Lin Li, J. Ouyang, N. Mirhosseini, Zhu Liu
{"title":"A generic mathematical model for gate-to-gate carbon emissions in laser materials processing","authors":"Muhammad Tajuddin Reduan, P. Mativenga, Lin Li, J. Ouyang, N. Mirhosseini, Zhu Liu","doi":"10.1177/09544054241234095","DOIUrl":"https://doi.org/10.1177/09544054241234095","url":null,"abstract":"The manufacturing industry needs to reduce carbon emissions in support of the net-zero agenda. Carbon emissions are classified into three operational groups based on the framework of the Greenhouse Gas (GHG) Protocol. Although extensive research has been undertaken, this has focused on energy consumption, which contributes to Scope 2 emissions only. In order to address a knowledge gap relating to the total environmental burden of laser material processing, the paper develops a generic mathematical model covering all three operational groups of emissions in relation to the gate-to-gate scope of life cycle assessment. The model was applied to selective laser removal of coating to evaluate the environmental burden and to understand which impact factor contributes the highest emissions. Scope 2 emissions had the highest contribution to the environmental burden in the laser removal of coatings from substrates compared to Scope 1 and 3. The mathematical model provides a simple, accessible and less complex tool for evaluating carbon emissions in laser processing. This supports the net-zero emission agenda.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":null,"pages":null},"PeriodicalIF":2.6,"publicationDate":"2024-03-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140360289","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}