Manufacturing Letters最新文献

{"title":"Uniform patterning of MXene-based slurry on carbon cloth for flexible supercapacitor by roll-to-roll production","authors":"Taehyeon Kim,&nbsp;Jongwoo Hong,&nbsp;Seongsik Jeong,&nbsp;Sushanta K. Das,&nbsp;Amar M. Patil,&nbsp;Hae Jin Kim,&nbsp;Seong Chan Jun","doi":"10.1016/j.mfglet.2025.06.014","DOIUrl":"10.1016/j.mfglet.2025.06.014","url":null,"abstract":"<div><div>MXene is a 2D nanomaterial known for its excellent conductivity, large specific surface area, and unique physical and chemical properties, making it highly attractive for energy storage devices and various optoelectronic applications. In this study, we used a roll-to-roll process, a type of wet coating technique, to coat MXene onto a carbon cloth, producing flexible supercapacitor electrodes. The roll-to-roll production provides uniform surface coating and is highly efficient for large-scale production, significantly improving the electrodes’ electrochemical performance. We compared two approaches. The first involved applying the roll-to-roll process after fully drying, and the second involved using the roll-to-roll process before the wet slurry dried. The results showed that the timing of the roll-to-roll process significantly affected both surface uniformity and electrochemical performance. The electrode produced by using the roll-to-roll process before the wet slurry had dried exhibited a capacitance of 584.7 mF cm⁻² at 100 mV s⁻¹. On the other hand, the electrode produced by using the roll-to-roll process after the slurry had fully dried exhibited a capacitance of 784 mF cm⁻² at the same scan rate. These results provide important insights into the optimal process for producing supercapacitor electrodes using the roll-to-roll technique, thus contributing to the development of next-generation energy storage devices.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 102-109"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926665","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":"The influence of substrate microstructure and radial rake angle on the performance of TiAlN coated end mills in slot milling of SS304","authors":"Ronit Kumar Shah,&nbsp;Amitava Ghosh","doi":"10.1016/j.mfglet.2025.06.078","DOIUrl":"10.1016/j.mfglet.2025.06.078","url":null,"abstract":"<div><div>The removal of the tool coating exposes the carbide substrate, making the substrate’s microstructure and bulk mechanical properties critical to tool performance during machining in particular on SS304 steel. Microstructural characteristics, such as average grain size, grain size distribution, and cobalt content collectively influence the substrate’s hardness and fracture toughness. During slot milling operations, end-mill cutters experience intense mechanical and thermal loads, leading to accelerated flank wear. Rapid fluctuations in cutting force magnitude and direction introduce mechanical shocks to the tool, causing cutting edge chipping. In this context, substrate hardness primarily determines flank wear width, while fracture toughness governs edge chipping resistance. Beyond hardness and fracture toughness, the tool’s radial rake angle affects cutting forces and strengthens the cutting edge, thereby regulating the resistance to chipping. However, these attributes have not been sufficiently explored in slot milling. This study examines these properties in slot milling of SS304. Findings reveal that substrates with a bimodal grain size distribution and adequate cobalt binder content strikes a balance of hardness and fracture toughness. In the current study, tool hardness, shaped by a specific combination of grain size, distribution, and cobalt content, was found to be essential in retarding abrasive wear after coating failure, influencing flank wear width. The tool with the smallest average grain size (0.424 µm) and a cobalt content of 8.4 wt% with a right-skewed unimodal grain distribution displayed the highest hardness and consequently the lowest flank wear width. The study further demonstrated that the radial rake angle, which dictates cutting edge strength, played a significant role in controlling edge chipping, even more so than fracture toughness. The tool with the smallest radial rake angle (3°), highest cutting edge strength, and lower fracture toughness (9.24 MPa-m^1/2), less resistance to crack propagation, showed minimal micro-chipping compared to the tool with the largest radial rake angle (8°), lower strength, and highest fracture toughness (12 MPa-m^1/2), which exhibited extensive micro-chipping.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 668-677"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926825","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":"Modeling and analysis of two-stage manufacturing systems with parallel machines and phase-type cycle time","authors":"Xi Gu","doi":"10.1016/j.mfglet.2025.06.026","DOIUrl":"10.1016/j.mfglet.2025.06.026","url":null,"abstract":"<div><div>Modern manufacturing systems are facing an increasingly versatile manufacturing environment. Having multiple parallel machines in each stage of the system is a design strategy that improves the system reconfigurability and resilience and enables the system to respond effectively to the uncertainties and disruptions from various sources. In addition, because of the increased complexity in the manufacturing tasks, many operations in the modern manufacturing systems have non-deterministic cycle time. However, traditional discrete-time Markov Chain-based models usually assume there is only one machine per stage and the cycle time is deterministic. In this paper, we develop a new discrete-time Markov Chain model to analyze the system dynamics and evaluate performance of a two-stage manufacturing system that has multiple parallel machines in each stage and multiple operations assigned to every machine. It is assumed that the time to complete each operation follows a geometric distribution, so the cycle time of each machine follows a discreate phase-type distribution. Simplified one-parameter and two-parameter models are also developed to approximately analyze the system performance, and their relations to the traditional Bernoulli and geometric models are discussed. Numerical examples are provided to illustrate the proposed models and verify their effectiveness.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 214-222"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926726","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":"Enhancing surface quality and accuracy in hybrid incremental sheet forming and wire-arc directed energy deposition: A focus on path planning and reconfigurable support","authors":"Cherukupally Shivaprasad ,&nbsp;A.G. Wilfred ,&nbsp;Gururaj A. Bidnur ,&nbsp;Rakesh Lingam ,&nbsp;N. Venkata Reddy","doi":"10.1016/j.mfglet.2025.06.058","DOIUrl":"10.1016/j.mfglet.2025.06.058","url":null,"abstract":"<div><div>Double-sided incremental forming (DSIF) and metal additive manufacturing (MAM) are two of the most flexible processes that do not require geometry-specific tooling for producing customized and complex metal parts. The synergistic hybridization of DSIF and wire-arc directed energy deposition (WDED) offers a promising approach to enhance product complexity. In this hybrid approach, non-planar substrates are formed using DSIF, while planar and/or non-planar deposition is performed using WDED to fabricate components more efficiently and cost-effectively. Although this hybridization significantly reduces the need for support structures, critical aspects of surface quality and accuracy have not been studied. Surface quality depends on bead profiles and the distance between adjacent beads. In the present work, a methodology based on bead overlap is developed and validated to predict the distance between adjacent beads, aiming to minimize variation in layer height while considering process and geometrical parameters. Deposition on thin, non-flat substrates leads to significant geometrical variations due to thermal stresses, causing component inaccuracies. The use of reconfigurable support is proposed to minimize substrate deformation during deposition, and this approach is validated. The effectiveness of the proposed methodology and the importance of using reconfigurable support are demonstrated by successfully fabricating three different geometries using the Hybrid Deformation Aided Additive Manufacturing (HyDAM). Results indicate that components fabricated using the proposed overlap methodology and reconfigurable support have enhanced surface quality and improved accuracy.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 487-497"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926534","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":"Electric discharge machining of zirconia toughened alumina ceramic with an optimized assistive electrode method","authors":"Yazan Tuffaha,&nbsp;Quentin Allen","doi":"10.1016/j.mfglet.2025.06.074","DOIUrl":"10.1016/j.mfglet.2025.06.074","url":null,"abstract":"<div><div>Zirconia toughened alumina (ZTA) ceramics are commonly used in prosthetic hip implants because of their excellent mechanical properties and wear/corrosion resistance. Surface texturing can improve the lubricity and longevity of hip implant bearing surfaces, but precision machining of ceramics such as ZTA is difficult with traditional machining techniques. This work studies electric discharge machining (EDM) – a process usually reserved for conductive metals – to machine holes into the ZTA surface. EDM is enabled through the assistive electrode method (AEM), in which a combination of metal and carbon is first applied to the ceramic surface, and machining is conducted in a carbon-based dielectric oil. Voltage, current, and electric discharge time were varied to find the optimal parameter combination that minimized cracks and defects and maximized accuracy, repeatability, and quality of holes. The results identify an optimal parameter set (voltage of 71 V, current of 2.4 A, electric discharge time of 80 µs) to machine ZTA with high repeatability and dimensional accuracy and avoid cracking of the tool or workpiece. The combination of a gold–palladium, carbon, and copper assistive electrode layer, with the optimal parameter set and multi-pronged electrode, led to successful machining of ZTA using EDM. These results will facilitate reliable surface texturing in ZTA materials, which could enhance the capabilities of hip replacement manufacturing.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 631-642"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926808","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":"Improving vision-based tool wear state identification under varying lighting conditions using human guided-explainable AI approach","authors":"Ankit Agarwal ,&nbsp;Aitha Sudheer Kumar ,&nbsp;Vinita Gangaram Jansari ,&nbsp;K.A. Desai ,&nbsp;Laine Mears","doi":"10.1016/j.mfglet.2025.06.083","DOIUrl":"10.1016/j.mfglet.2025.06.083","url":null,"abstract":"<div><div>Vision-based tool wear monitoring systems augmented with Artificial Intelligence (AI)-based algorithms can effectively identify tool wear states. However, inconsistent image quality due to varying lighting conditions on manufacturing shop floors often obscures the scalability and reliability of these systems for practical applications. This study presents an on-machine vision-based tool wear monitoring system capable of handling varying lighting conditions using human guidance and an eXplainable AI (XAI) approach. The present study captured tool wear images under two lighting conditions, L1 and L2, using a microscope-based on-machine image acquisition system. The images were classified into four tool wear states: Flank, Flank + BUE, Flank + Face, and Chipping, commonly observed while machining Inconel 718 (IN718). Tool wear images captured under the L1 lighting condition were used to train the Convolutional Neural Network-based Efficient-Net-b0 model. The model was integrated subsequently with the Human Guided-XAI (HG-XAI) approach to predict tool wear states for images captured under the L2 lighting condition. The performance of the HG-XAI approach was evaluated using metrics such as Accuracy, Matthews Correlation Coefficient (<em>MCC</em>), and F1-Score and compared with the standalone Efficient-Net-b0 model. The results show that the HG-XAI approach achieved an accuracy of 96%, MCC of 0.96, and F1-Score of 0.97, demonstrating significant improvements over the standalone Efficient-Net-b0 model. The findings of this paper substantiate the scalability and reliability of the integrated HG-XAI approach under varying lighting conditions.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 709-717"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926830","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":"High-speed camera imaging-based investigations of compliance behaviour and flap interactions in coated abrasive flap wheels","authors":"MD Habibur Rahman ,&nbsp;Shyam Komath ,&nbsp;S. Subbiah","doi":"10.1016/j.mfglet.2025.06.059","DOIUrl":"10.1016/j.mfglet.2025.06.059","url":null,"abstract":"<div><div>Abrasive flap wheels, with coated abrasive rectangular strips attached radially to a hub like fan blades, are widely used in several industries as a surface finishing tool. The compliance of the flap wheel is a key reason for its wide use as it conforms to the work surface and polishes large flat and curved, convex and concave, surfaces. During polishing, the flaps wear out and become shorter in length, which alters their compliance behavior. The radial change in length also alters the gap between flaps and hence flap-to-flap interactions. We have used high-speed camera imaging to study both the compliance behavior of the flaps and their interactions with each other. The images are used to determine quantifiable parameters related to compliance and flap interactions such as contact length and its location, flap contact count, flap bending angle, curvature, and tip speed. These quantified parameters are then correlated with polishing performance signatures, such as contact area, forces and material removal rate. As the flaps wear out, significant changes in polishing signatures are observed and these changes can be explained using the compliance behavioural changes in the flap. This study helps in a systematic way to design and use abrasive flap wheels.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 498-506"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926535","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":"Modeling of adhesion dynamics in roll-to-roll lamination processes","authors":"Shihao Li,&nbsp;Christopher Martin,&nbsp;Enrique Velasquez Morquecho,&nbsp;Zijun Chen,&nbsp;Dongmei Chen,&nbsp;Wei Li","doi":"10.1016/j.mfglet.2025.06.065","DOIUrl":"10.1016/j.mfglet.2025.06.065","url":null,"abstract":"<div><div>Roll-to-roll (R2R) lamination is a continuous manufacturing process essential for producing multi-layered flexible products, such as flexible electronics, solar cells, and composite materials. This process allows for high-speed bonding of materials under controlled conditions, making it critical for efficient and scalable production in various industries. This paper examines the R2R lamination process, analyzing how bonding temperature, compression force, and lamination speed affect adhesion between layers. Using a physics-based approach and the Hertzian contact theory, we developed a process model to predict the adhesion force. Experiments were conducted to validate the model. Findings from this research provide insights for future process optimization of R2R lamination processes</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 552-558"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926541","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":"Design and fabrication of biodegradable bone tissue scaffolds based on the nuclear pasta theory","authors":"Hamzeh Al-Qawasmi ,&nbsp;Roozbeh “Ross” Salary","doi":"10.1016/j.mfglet.2025.06.045","DOIUrl":"10.1016/j.mfglet.2025.06.045","url":null,"abstract":"<div><div>Globally, around 2.2 million bone graft procedures are performed annually, with costs reaching approximately $664 million as of 2021. The number of surgeries to repair bone defects is projected to increase by about 13 % each year. However, traditional bone grafts often carry risks such as donor site morbidity and limited availability, driving the need for innovative solutions. This study explores the fabrication of biodegradable bone tissue scaffolds inspired by the nuclear pasta theory using extrusion-based Fused Deposition Modeling (FDM). The nuclear pasta theory, which describes complex geometrical formations within neutron stars, serves as a novel source of inspiration for designing scaffolds with enhanced mechanical properties and optimized porosity. Two bio-based, biodegradable polymers, Luminy LX175 and ecoPLAS, were used to fabricate scaffolds via an in-house filament extrusion process utilizing the Filabot EX6 system. The extrusion parameters were optimized to achieve a consistent filament diameter of 1.75 mm suitable for 3D printing on a Creality K1C printer. Seven scaffold designs were developed, including five based on Triply Periodic Minimal Surfaces (TPMS) and two inspired by nuclear pasta configurations, namely “lasagna” and a hybrid “lasagna-spaghetti” structure. The scaffolds were evaluated for their mechanical properties using uniaxial compression testing. Results showed that TPMS-inspired designs generally achieved a favorable balance between porosity and mechanical strength, while the nuclear pasta-inspired designs exhibited unique anisotropic and isotropic compression characteristics. The study concluded that nuclear pasta-inspired scaffold architectures exhibit unique mechanical properties and porosity characteristics, emphasizing their potential for future optimization in bone tissue engineering applications. Additionally, these structures can be further reinforced through material modifications or hybrid scaffold designs to enhance their load-bearing capabilities. This work demonstrates the potential of using bio-inspired designs in conjunction with sustainable, biodegradable materials for bone tissue engineering. Future research will focus on optimizing co-extrusion techniques and exploring composite materials to further enhance scaffold properties for clinical applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 376-385"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926603","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":"Investigating the microstructural and mechanical properties of nickel-aluminide based high entropy Alloys: a combined CALPHAD-Based modeling and nanoindentation study","authors":"Peter Ifeolu Odetola,&nbsp;Ufoma Silas Anamu,&nbsp;Peter Apata Olubambi","doi":"10.1016/j.mfglet.2025.06.022","DOIUrl":"10.1016/j.mfglet.2025.06.022","url":null,"abstract":"<div><div>This research explores the microstructural and mechanical properties of milled and sintered Ni-Al-Co-Cr-Cu-Mn-Ti high-entropy alloys (HEAs), employing a synergistic approach that integrates CALPHAD-based thermodynamic modeling with experimental nanoindentation techniques. The study meticulously investigated the behavior of HEAs subjected to mechanical alloying over varied durations (5, 10, and 15 h), followed by sintering under optimized conditions (900 °C, 100 °C/min heating rate, 50 MPa pressure, and 5 min holding time). Through Thermo-Calc predictions and subsequent validation via SEM-EDS and XRD analyses, a complex multiphase structure encompassing BCC_B2 solid solution, FCC_L21, and various intermetallic phases was revealed. Nanoindentation analysis used to characterize their mechanical properties at the nanoscale showed that the equiatomic alloy A, sintered at 900 °C for 15 min, exhibited the highest hardness (HIT = 14.9 GPa) and elastic modulus (EIT = 234.47 GPa), alongside the lowest indentation depth (923.431 ± 0.004 nm) at a 300 mN load, indicative of strong interatomic bonding and a uniform microstructure. In contrast, the non-equiatomic alloy C demonstrated the highest indentation depth (962.271 ± 0.005 nm) and a pop-in effect, suggesting the presence of localized defects or inhomogeneities potentially compromising its mechanical integrity. These findings underscore the critical role of compositional strategy and process optimization in tailoring the microstructural and mechanical properties of HEAs for advanced engineering applications, offering a methodical approach for the design and development of novel HEAs with enhanced performance characteristics.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 172-183"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926621","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}