Advances in Industrial and Manufacturing Engineering最新文献

{"title":"Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304","authors":"Elizabeth M. Mamros ,&nbsp;Fabian Maaß ,&nbsp;Thomas H. Gnäupel-Herold ,&nbsp;A. Erman Tekkaya ,&nbsp;Brad L. Kinsey ,&nbsp;Jinjin Ha","doi":"10.1016/j.aime.2025.100161","DOIUrl":"10.1016/j.aime.2025.100161","url":null,"abstract":"<div><div>Stress superposition is one of the strategies used in metal deformation processes to increase the material formability, decrease the required forming forces, and create highly customized components. To investigate the effects of tensile and compressive stresses superposed to the single point incremental forming (SPIF) process, experiments and numerical simulations were conducted for a stainless steel 304 (SS304) truncated square pyramid geometry. Tensile stresses were superposed in-plane on the specimen blank by a custom hydraulic frame, and compressive stresses were incorporated via a polyurethane die. Identified parameters for a martensitic transformation kinetics model for SS304 were used in a two-step finite element approach to predict the <span><math><mrow><mi>α</mi></mrow></math></span>’-martensite volume fraction. These results were compared to experimental results measured by a Feritscope at four locations along each pyramid wall and validated by electron backscatter diffraction. The residual stresses were measured using x-ray diffraction. The parts from each incremental forming process revealed differences in the residual stresses, which impacted the final geometries, and the <span><math><mrow><mi>α</mi></mrow></math></span>’-martensite volume fraction at the four measurement locations. The evolution of the stress state, defined by the stress triaxiality and Lode angle parameter, for each process contributed to the phase transformation variance. It was found that superposing both tensile and compressive stresses to SPIF resulted in the greatest phase transformation and lowest magnitude of residual stresses near the base and the greatest overall geometrical accuracy. Stress-superposed incremental forming can be implemented to manipulate final part properties, which is ideal for applications requiring highly customized parts, e.g., biomedical trauma fixation hardware.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100161"},"PeriodicalIF":3.9,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143679445","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":"Deformation behavior of anisotropic TA18 titanium alloy tube in hydroforming process at room temperature","authors":"Xiao-Lei Cui ,&nbsp;Yuanyang Zhao ,&nbsp;Shijie Yin ,&nbsp;Jiuqiang He","doi":"10.1016/j.aime.2025.100159","DOIUrl":"10.1016/j.aime.2025.100159","url":null,"abstract":"<div><div>While hydroforming of titanium alloy at room temperature is difficult due to its high strength, low hardening capacity, and significant springback, it is typically deformed into desired shape under high-temperature conditions exceeding 500°C, which increases the complexity of the process and raises costs. In this paper, the hydroforming method was used to manufacture TA18 titanium alloy variable-diameter tubular components at room temperature based on an innovative idea of useful wrinkles. The results show that the TA18 titanium alloy tube blank has a strong normal anisotropy of <span><math><mrow><mover><mi>r</mi><mo>‾</mo></mover></mrow></math></span> = 5.2, which is conducive to developing wrinkles while preventing excessive thinning. When the pressure increases from 0.4 <em>p</em>_s (<em>p</em>_s is initial yield internal pressure) to 0.8 <em>p</em>_s, the number of wrinkles produced on the tube blanks gradually decreases from three to two, and their width increases. When the pressure exceeds <em>p</em>_s, wrinkles cannot be formed on the tube blanks, which will undergo bulging deformation. In the simulation, the wrinkling behavior of the tube blanks does not match the experiment when the Mises yield criterion was used. While using the anisotropic Hill48 yield criterion, the wrinkling trend and development of wrinkles can be well predicted. Furthermore, the wrinkled tubes can be completely flattened under 70 MPa during calibration, and their wall thickness distributions are consistent with the simulation results, with the maximum thinning ratio of the formed components at 6.2%. All of these results provide basic support for manufacturing titanium alloy tubular components with large cross-sectional differences at room temperature using the hydroforming process.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100159"},"PeriodicalIF":3.9,"publicationDate":"2025-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143679444","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":"Hybrid investment casting of Al-Cu-Sc alloy-based lattice structures: Material and process characterization","authors":"Yifan Li ,&nbsp;José Marcelino Dias Filho ,&nbsp;Shirin Dehgahi ,&nbsp;Sajid Ullah Butt ,&nbsp;Hani Henein ,&nbsp;Ahmed Jawad Qureshi","doi":"10.1016/j.aime.2025.100160","DOIUrl":"10.1016/j.aime.2025.100160","url":null,"abstract":"<div><div>This paper characterizes the development and optimization of a hybrid investment casting approach tailored for accurately crafting lattice structures with Al-4.5 wt pct Cu-0.4 wt pct Sc alloy, emphasizing precision in mold making, complex surface detailing, and porosity reduction. The core of the research is the description of the manufacturing procedure and the dimensional optimization strategies associated with this hybrid cast lattice geometries. After exploring the lattice shape produced through this advanced casting method, this research explores the microstructural properties and the solidification cooling rate of this hybrid investment casting. Furthermore, this work also addresses the complexity of the manufacturing protocol and the dimensional refinement method.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100160"},"PeriodicalIF":3.9,"publicationDate":"2025-03-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143654663","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":"3D-printed motorcycle seats: Replicating polymer foam performance for rapid prototyping and rider comfort","authors":"Andrea Montalti,&nbsp;Patrich Ferretti,&nbsp;Fiammetta Spano,&nbsp;Alfredo Liverani","doi":"10.1016/j.aime.2025.100158","DOIUrl":"10.1016/j.aime.2025.100158","url":null,"abstract":"<div><div>The development of prototypes prior to the market launch of final products requires adapting production components to reduce costs and increase flexibility for potential modifications. While the manufacturing of rigid or structural components is well-established and widely practiced, the production of expanded materials presents significantly greater challenges due to the final product's reliance on the specific process employed. Changing the process to lower costs necessitates reproducing the same mechanical behaviour and appearance to ensure validation in terms of both style and function. This study focuses on replicating the behaviour of expanded polyurethane foam, commonly used in motorcycle seat padding, using thermoplastic polyurethane (TPU). The aim is to create a prototype or a customised version of the foam. The internal stochastic closed-cell structure is designed using slicing software, and test specimens are subsequently fabricated through Material Extrusion (MEX) additive manufacturing and subjected to compression testing. The results emphasise the critical influence of material hardness and infill density on the force-displacement curves. An experimental map, derived from three parameters (material hardness, elastic modulus, and foam density) illustrates the behaviour of the specimens, with iso-lines representing constant density. This map serves as a valuable tool for accurately replicating desired foam properties, providing guidance on material selection based on force-displacement characteristics.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100158"},"PeriodicalIF":3.9,"publicationDate":"2025-02-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143479400","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":"Manufacturing of irregular shapes through force control in incremental sheet forming with active medium","authors":"Sebastian Thiery ,&nbsp;Mazhar Zein El Abdine ,&nbsp;Jens Heger ,&nbsp;Noomane Ben Khalifa","doi":"10.1016/j.aime.2025.100157","DOIUrl":"10.1016/j.aime.2025.100157","url":null,"abstract":"<div><div>Convex shapes can be created in incremental sheet forming by supporting the workpiece with the pressure of an active medium. In this paper, a method is presented for creating irregular convex shapes by adjusting the pressure to control the forming forces. At first, the general characteristics of the forming forces in incremental sheet forming with active medium (IFAM) are investigated based on a truncated pyramid and a truncated cone. The findings show that the pressure has to be adapted for each contour of the toolpath to achieve a specific wall angle. However, this strategy cannot be applied for an irregular shape consisting of half a truncated pyramid and half a truncated cone since the forming forces fluctuate over one contour. To enhance the control approach, a data set is subsequently generated by recording the forming forces under the influence of the wall angle. The data analysis reveals a strong correlation between the height difference per contour and the tangential force. Finally, a control concept is proposed to adjust the tangential force and is subsequently validated on the irregular-shaped part. The results prove that irregular shapes require a sophisticated control of the forming forces to increase the geometrical accuracy.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100157"},"PeriodicalIF":3.9,"publicationDate":"2025-02-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143430050","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":"Analytical criterion to prevent thermal overshoot during dynamic curing of thick composite laminates","authors":"Jordi Farjas ,&nbsp;José Antonio González ,&nbsp;Daniel Sánchez-Rodríguez ,&nbsp;Norbert Blanco ,&nbsp;Marc Gascons ,&nbsp;Josep Costa","doi":"10.1016/j.aime.2024.100156","DOIUrl":"10.1016/j.aime.2024.100156","url":null,"abstract":"<div><div>Local overheating during curing of thermosetting resins is likely to occur for thick laminates or during fast curing. Overheating may lead to heterogeneous mechanical properties along the laminate thickness or even to an uncontrolled reaction. To avoid overheating, most thermoset resin manufacturers recommend a “safe” cure cycle. However, these cure cycles can be improved to shorten cure times in thin laminates and may not be good enough to avoid overheating in thick laminates. In this paper, we propose a new analytical model to determine the critical thickness above which thermal runaway occurs when the laminate is heated at a constant rate up to a constant temperature. The model considers different thermal boundaries between the mould and the laminate, i.e., from a perfect thermal contact to a contact of infinite resistance. The analytical model was corroborated through the numerical integration of the equations governing it and experimental data from the curing process of a thick laminate composed of the commercial VTC401 epoxy resin and M55J carbon fiber system. Model predictions indicate that, under the manufacturer's recommended cure cycle, which includes an initial heating rate of 2 K/min, thermal runaway occurs in laminates thicker than 12.4 mm, aligning with experimental observations. A 20-mm-thick laminate, exceeding this threshold, was cured using a reduced heating rate of 0.3 K/min based on our criteria, successfully preventing overheating. The maximum temperature gradient recorded experimentally remained below 1 °C, confirming the model's prediction of uniform thermalization.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100156"},"PeriodicalIF":3.9,"publicationDate":"2024-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138708","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":"Experimental investigation on micro-EDM hybrid drilling process","authors":"C. Ravasio,&nbsp;G. Pellegrini","doi":"10.1016/j.aime.2024.100155","DOIUrl":"10.1016/j.aime.2024.100155","url":null,"abstract":"<div><div>Micro-EDM drilling is highly appreciated to produce micro-holes on any type of conductive material. Several industrial fields use this technology thanks to its capability to realize very accurate machining. A greater use of micro-EDM drilling process is limited by its poor performance in terms of machining time. To overcome this limit, hybrid solutions are being tested. The idea consists of benefitting from the advantages of at least two technologies trying to overcome the limitation of each one of them. Typically, EDM is used as secondary operation and the process consists of executing the micro-hole on a pre-hole realized by another process like laser. In this way, both the process performance and the quality aspects are guaranteed. Aim of this work is the investigation of the behaviour of the micro-EDM drilling on a pre-hole. In fact, the presence of a pre-hole changes deeply the machining conditions especially in terms of the dielectric flushing. In order to understand how the pre-hole changes the performance of the EDM drilling process, several aspects were investigated: the effects of the diameter of the pre-hole, the behaviour of the type of electrode, the influence of the accuracy of centring operation on the pre-hole and the hole depth. Titanium alloy sheets were used to execute final hole using electrode diameter of 0.3 mm. The process was evaluated considering both the process performance and the accuracy of the machining. The study of the law of electrode motion along its Z axis was also used to gather process information. In general, working with pre-holes yields much better performances than traditional EDM drilling thanks to different level of debris contamination in the machining zone. It was found that increasing the dimension of the pre-hole, the Material Removal Rate undergoes little changes. The electrode type (cylinder or tubular) on the pre-hole does not have evident effects on the process performance but only on the geometrical characteristics. The misalignment of the final hole on the pre-hole can improve the debris flow making the process more efficient but only when a part of the pre-hole lays outside the final hole. Within the limit of this experiments, the hole depth does not affect the presented results.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100155"},"PeriodicalIF":3.9,"publicationDate":"2024-11-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142706113","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":"Impact of graphene nanoparticles on DLP-printed parts' mechanical behavior","authors":"Md Imran Hossain ,&nbsp;Ola L.A. Harrysson ,&nbsp;Mohammad Asaduzzaman Chowdhury ,&nbsp;Nayem Hossain","doi":"10.1016/j.aime.2024.100153","DOIUrl":"10.1016/j.aime.2024.100153","url":null,"abstract":"<div><div>Digital Light Processing (DLP) is one of the most promising techniques among the additive manufacturing (AM) technologies for polymer resin. The polymer parts produced through this technique demonstrate a diverse range of characteristics that can be specifically designed for various fields of application. Specific attributes can be attained by utilizing polymer composites composed of multiple materials in numerous ratios. This research delves into evaluating and comparing different properties, including microstructure, surface texture, and mechanical behavior, of resin-based polymer composites fabricated using the DLP 3D printing technology. To achieve this, specimens have been printed using photopolymer resin as the base material, with varying percentages of graphene nanoparticles added to the resin. Tensile tests and particle analysis based on optical microscope images validate that optimizing parameters, especially the energy setting of the printer, significantly impact the printed samples' strength, surface texture, layering, and microstructure. The findings indicate that at a specific percentage of graphene, such as 0.5%, there is an increase in tensile strength by 38.1%, Young's modulus by 54.7%, and Yield strength by 11.2%, accompanied by an improved surface roughness. A graphene concentration of 0.75% results in diminished tensile strength, yield strength, and Young's modulus. The significance of fine-tuning printing parameters to achieve desired properties in resin-based polymer composites manufactured via 3D printing is highlighted.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100153"},"PeriodicalIF":3.9,"publicationDate":"2024-11-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142653032","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":"Erratum to “Influence of changing loading directions on damage in sheet metal forming” [Adv. Ind. Manuf. Eng. 8 (2024) 100139]","authors":"Philipp Lennemann,&nbsp;Joshua Grodotzki,&nbsp;Yannis P. Korkolis,&nbsp;A. Erman Tekkaya","doi":"10.1016/j.aime.2024.100147","DOIUrl":"10.1016/j.aime.2024.100147","url":null,"abstract":"","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"9 ","pages":"Article 100147"},"PeriodicalIF":3.9,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141845945","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":"Modeling of equivalent strain in 2D cross-sections of open die forged components using neural networks","authors":"Nikhil Vijay Jagtap ,&nbsp;Niklas Reinisch ,&nbsp;Rasul Abdusalamov ,&nbsp;David Bailly ,&nbsp;Mikhail Itskov","doi":"10.1016/j.aime.2024.100152","DOIUrl":"10.1016/j.aime.2024.100152","url":null,"abstract":"<div><div>Open die forging is one of the oldest manufacturing methods known to remove defects in the ingot resulting from the casting process. The improved properties of the final component are highly dependent on the strain distribution. Although sinusoidal equations and empirical formulations have been already used to estimate the strain, they have been applied only to the core of the workpiece. In this work, a novel approach is presented to model the equivalent strain distribution in 2D cross-sections, in the direction of the press, of open die forged components using neural networks. The proposed method efficiently combines a parametric sinusoidal function with a neural network to learn the complex relationships between the process parameters and the resulting local strain. The neural network is trained on a dataset of finite element (FE) simulations of rectangular geometries that cover a wide range of aspect ratios, bite ratios, and height reductions. The presented methodology with near real-time prediction capabilities shows good agreement with FE results. Moreover, the parametric function captures the characteristic pattern of the strain distribution and reveals certain physical relationships affecting the deformation of the material. These patterns are later examined by analyzing the parameters identified in the parametric sinusoidal function.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"9 ","pages":"Article 100152"},"PeriodicalIF":3.9,"publicationDate":"2024-10-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142534310","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}