Advances in Industrial and Manufacturing Engineering最新文献

{"title":"Performance of new cutting tool multilayer coatings for machining Ti-6Al-4V titanium alloy under cryogenic cooling conditions","authors":"Y. Zhang ,&nbsp;J.C. Outeiro ,&nbsp;C. Nouveau ,&nbsp;B. Marcon ,&nbsp;L.A. Denguir","doi":"10.1016/j.aime.2025.100165","DOIUrl":"10.1016/j.aime.2025.100165","url":null,"abstract":"<div><div>Cr/CrN/AlCrN multilayer coatings were recently developed to meet the high challenges of machining Ti-6Al-4V alloy under cryogenic cooling conditions. The multilayer coatings were optimized by multiple deposition conditions and were characterized by multi-methods. It was proved that they are suitable for tribological applications with this alloy under extreme conditions. This paper addresses the performance of these coatings through tool wear tests and analysis. This performance was compared with that obtained in standard machining conditions used in the aerospace industry, which include flood metalworking fluids and uncoated cemented carbide tools. The results show that the application of a multilayer coating can improve significantly the tool life under cryogenic cooling conditions compared to the flood conditions. 33 % improvement of tool life was found under cryogenic cooling conditions when comparing this coating to the uncoated one. A statistical analysis shows a strong correlation between tool wear and the machining forces. This analysis also permitted to build models for predicting tool wear in function of measured forces.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100165"},"PeriodicalIF":3.9,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143928140","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":"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":"2025-05-01","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":"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":"2025-05-01","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":"Toward generalizable machine learning prediction of downskin surface roughness in laser powder bed fusion","authors":"Jigar Patel,&nbsp;Mihaela Vlasea,&nbsp;Sagar Patel","doi":"10.1016/j.aime.2025.100163","DOIUrl":"10.1016/j.aime.2025.100163","url":null,"abstract":"<div><div>Downskin surface quality of laser powder bed fusion (L-PBF) remains a challenge due to the complex, multi-scale physics governing it. While numerical or experimental approaches alone can be significantly resource intensive, data-driven approaches such as machine learning (ML) have the potential to be more practical. However, the generalizability of ML models currently reported in literature is unclear; few ML models can predict reliably outside of their training domain. This study addresses these challenges by (i) demonstrating a downskin surface roughness classification model, trained on the largest reported dataset for downskin roughness (<span><math><mo>∼</mo></math></span>400 downskin specimens spanning five builds and two ferrous alloys) and (ii) conducting a thorough investigation of the model’s generalizability. Additionally, this study highlights critical issues such as data imbalance, generalization to unseen data, and the importance of rigorous evaluation. By implementing robust ML practices, we focused on model performance across different training and evaluation domains. Our findings indicate satisfactory performance when using the more conservative balanced accuracy metric, achieving about 95% inter-domain and 83% intra-domain accuracy. Although there is still room for improvement, these results demonstrate a significant reduction in the risk of overfitting, thereby enhancing the classifier’s generalizability. This work underscores the importance of methodological rigor in machine learning applications, advocating for greater attention to data treatment and evaluation strategies. This approach may ultimately lead to more effective and usable ML models. The data-centric results indicated that (i) physics-informed features can improve performance during domain shifts, and (ii) increased the size and variety of datasets allows even computationally light models to achieve favorable performance.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100163"},"PeriodicalIF":3.9,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144115375","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":"Integrating 3D printing, simulations and surrogate modelling: A comprehensive study on additive manufacturing focusing on a metal twin-cantilever benchmark","authors":"C. Mallor ,&nbsp;S. Lani ,&nbsp;V. Zambrano ,&nbsp;H. Ghasemi-Tabasi ,&nbsp;S. Calvo ,&nbsp;A. Burn","doi":"10.1016/j.aime.2025.100162","DOIUrl":"10.1016/j.aime.2025.100162","url":null,"abstract":"<div><div>Additive Manufacturing by powder bed fusion of metals using a laser beam (PBF-LB/M) is constantly growing as an advanced technology to produce metal components. It offers greater design freedom compared to conventional processes and allows the production of complex, lighter geometries with numerous applications in a variety of industries. However, the time and cost required to achieve production readiness present significant challenges to the widespread adoption of new parts development. Success in builds is not reliable until tested, with common issues including distortion, and warpage. The expensive costs of physical iteration to optimize parameters calls for digital simulation to mitigate build failures. This paper presents the successful development of a surrogate model for predicting distortion in a PBF-LB/M metal part. The methodology is grounded on a design of experiments, additive manufacturing tests, finite element modelling playing a critical role, alongside reduced order methods to achieve a surrogate model for improving the additive manufacturing process. The reduced order method for creating the surrogate model is based on tensor decomposition and designed for easy integration into a digital twin, while preserving the underlying physics by retaining the effects of input variables on the final output. The validity of the proposed approach is demonstrated through a benchmark example involving the manufacturing of a metal twin-cantilever part using different laser power, scan speed, and preheating conditions. The twin-cantilever surrogate model developed embeds physics-based simulations and facilitates efficient estimation of deflections. It offers accurate results useful during process setting calibration and improves understanding of how the process parameters affect the final built part.</div></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"10 ","pages":"Article 100162"},"PeriodicalIF":3.9,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785235","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":"2025-05-01","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":"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":"2025-05-01","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":"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":"2025-05-01","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":"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":"2025-05-01","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":"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":"2025-05-01","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}