Manufacturing Letters最新文献

{"title":"Numerical investigation on machining of additively manufactured CFRP composite with different build orientations and layer widths","authors":"Sk Md Alimuzzaman ,&nbsp;Jianfeng Ma ,&nbsp;Muhammad P. Jahan","doi":"10.1016/j.mfglet.2024.09.086","DOIUrl":"10.1016/j.mfglet.2024.09.086","url":null,"abstract":"<div><div>Additive manufacturing (AM) is now a widely researched manufacturing technology in the past two decades to adopt in industry for its added advantage of customization and adopting complex geometries with comparatively low buy-to-fly ratio. Carbon fiber reinforced polymer (CFRP) composite has found applications in different high-performance industries for its greatest benefit of high strength-to-weight ratio. Additive manufacturing of CFRP composite (AM-CFRP) opens up the possibility of enhancing mechanical strength using different printing orientations and enables producing complex shapes maintaining sustainable manufacturing perspective. However, Limitation of AM parts of having surface irregularities and questionable dimensional accuracies. To use AM-CFRP parts in high precision assembly or industrial applications, post processing machining is often required to meet the customers’ specification of geometrical tolerances and acceptable surface finish. In this study, the influence of AM parameters on machinability of AM-CFRP composite has been evaluated using finite element analysis (FEA) based numerical simulation. The slot milling operation was simulated with a tungsten carbide end milling tool and AM-CFRP workpiece with four different printing directions, i.e., 0°-90°, 45°-135°, 0°-90°-45°-135°, two different layer widths, i.e., 50 µm and 100 µm, and two in-fill patterns, i.e., solid and perforated structures. The machinability of the 3D printed CFRP has been analyzed based on cutting forces, stress at first contact and maximum stress generation, and temperature increases at the interface during slot milling of AM-CFRP under different AM parameters. Evolution of failure mechanisms of AM-CFRPs under various machining conditions, such as, delamination, matrix rupture etc., have been discussed and chip and burr formation mechanisms have been analyzed. Finite Element analysis (FEA) package ABAQUS/Explicit was used to model 3D micro slot milling operation of AM-CFRP workpiece with appropriate damage and constitutive models, such as, damage initiation, progression and cohesion in adjacent passes and layers.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 679-690"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434296","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":"Analysis of contact length and temperature effect in rocking mode diamond wire sawing of monocrystalline silicon carbide wafer","authors":"Eyob Messele Sefene ,&nbsp;Steve Hsueh-Ming Wang ,&nbsp;Chao-Chang Arthur Chen","doi":"10.1016/j.mfglet.2024.09.082","DOIUrl":"10.1016/j.mfglet.2024.09.082","url":null,"abstract":"<div><div>Diamond wire sawing (DWS) is a primary and fundamental stage for slicing large-diameter ingots into multiple wafers, enabling high-volume production in a single process. However, the extended contact length between the diamond wire and work material generates heat, which detrimentally impacts the surface quality of the sliced wafers and accelerates the diamond wire wear rate. This study implemented a rocking mode sawing strategy to investigate the effect of contact length on the surface quality of as-sawn wafer and diamond wire wear rate. Experiments have been conducted on monocrystalline silicon carbide (4H-SiC) with and without a rocking-mode multi-DWS machine. The experimental sawing temperature has been validated using Fourier’s law of thermal conduction, a finite element model, and a linear time series regression model. Results indicated that the minimal sawing temperature had been observed with the rocking mode sawing strategy, attributed to its shorter contact length compared to the process without rocking mode. Additionally, the finite element and regression models closely matched the experimental data, achieving accuracies of 93.57 % and 99.96 %, respectively. Fourier’s law of thermal conduction proved significant for precisely determining the sawing temperature. Notably, the rocking mode sawing strategy significantly affected the sawing temperature, surface quality, and diamond wire wear rate compared with the sawing process without the rocking mode.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 641-652"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434354","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":"Evolution of microstructure and mechanical property enhancement in wire-arc directed energy deposition with interlayer machining","authors":"Asif Rashid,&nbsp;Akshar Kota,&nbsp;Shreyes N. Melkote","doi":"10.1016/j.mfglet.2024.09.094","DOIUrl":"10.1016/j.mfglet.2024.09.094","url":null,"abstract":"<div><div>Wire-Arc Directed Energy Deposition (Wire-Arc DED) has emerged as a promising additive manufacturing technique known for its high deposition rates. However, the variability in microstructure and mechanical properties (e.g., hardness) of the manufactured components poses significant challenges. This study delves into these issues, focusing on the influence of interlayer machining on the microstructural evolution and mechanical properties of thin-wall Wire-Arc DED structures. It is shown that as-built Wire-Arc DED structures exhibit a pronounced microstructure variation between different regions along the build direction, primarily governed by the differences in thermal history. In contrast, a Hybrid Wire-Arc DED process that integrates interlayer machining into the build process to induce severe plastic deformation leads to a microstructure characterized by refinement and homogenization, compared to a Wire-Arc DED process. This study provides insights into the impacts of plastic deformation due to machining and thermal cycling due to subsequent layer depositions on the microstructure and hardness obtained in Wire-Arc DED and Hybrid Wire-Arc DED processes, highlighting the potential of hybrid manufacturing to generate tailored microstructures to enhance the mechanical performance of functional components.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 758-765"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434369","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":"Production overrun optimization considering supply chain network reliability","authors":"Dawei Xue ,&nbsp;Xi Gu ,&nbsp;Hae Chang Gea","doi":"10.1016/j.mfglet.2024.09.026","DOIUrl":"10.1016/j.mfglet.2024.09.026","url":null,"abstract":"<div><div>Production overrun is a common practice in manufacturing to meet the demand by increasing the number of qualified products and compensating for manufacturing defects. While production overrun can improve Supply Chain Network Reliability (SCNR), it leads to higher material costs. In this paper, a model is proposed to evaluate SCNR by incorporating the reliabilities of inbound logistics, operations, and outbound logistics. Based on the proposed SCNR model, we study the optimal production overrun of each manufacturing site in a supply chain network and identify the production plan that satisfies the reliability requirement with minimum total production overrun penalty. By analyzing the monotonicity of the objective and constraint functions of the formulated problem, an algorithm based on linearization is developed to solve this optimization problem. Numerical examples across various scales are presented to illustrate the developed model and method. The impact of the penalty coefficient of the production overrun on the result is investigated. The results from the numerical examples provide managerial insights on allocating resources in the entire supply chain network and improving the supply chain reliability and competitiveness.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 219-228"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434249","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":"A review of ice cream manufacturing process and system improvement strategies","authors":"Asmaa Harfoush ,&nbsp;Zhaoyan Fan ,&nbsp;Lisbeth Goddik ,&nbsp;Karl R. Haapala","doi":"10.1016/j.mfglet.2024.09.021","DOIUrl":"10.1016/j.mfglet.2024.09.021","url":null,"abstract":"<div><div>The food industry faces several challenges, including intricate supply chains, compliance with food safety regulations, sustainability concerns, and the rising demand for high-quality products. Furthermore, consumers increasingly seek personalized food products with specific fat, sugar, and micronutrient levels. The ice cream industry is no exception in facing these challenges. Fortunately, Industry 4.0 technologies, such as smart manufacturing, data analytics, and the Industrial Internet of Things (IIoT), offer viable solutions to many of the aforementioned challenges. However, a deeper understanding of industrial ice cream manufacturing processes and systems is essential to apply these technologies effectively. While the related literature has often focused on ingredient selection to achieve the desired ice cream flavor and texture, there is a noticeable absence of comprehensive efforts to evaluate the impact of process- and systems-related aspects in ice cream manufacturing. This study employs a semi-systematic literature review approach to compile recent research that examines the influence of process- and system-level factors on ice cream product quality and production processes, focusing on the aspects that can benefit from implementing Industry 4.0 technologies. The literature review reveals that 1) at the process level, researchers have focused on three key processes (i.e., pasteurization, homogenization, and dynamic freezing) and their impact on the quality of the ice cream; 2) at the system level, researchers have concentrated their efforts on techno-economic factors, process scheduling, productivity, and sustainability.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 170-181"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434269","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":"Fusion IK: Solving inverse kinematics using a hybridized deep learning and evolutionary approach","authors":"Steven Rice ,&nbsp;Ahmed Azab ,&nbsp;Sherif Saad","doi":"10.1016/j.mfglet.2024.09.005","DOIUrl":"10.1016/j.mfglet.2024.09.005","url":null,"abstract":"<div><div>Inverse kinematics is a core aspect of robot manipulation. This paper presents an approach to solving Inverse Kinematics (IK) for robots, including articulated industrial ones, combining deep learning with an evolutionary algorithm. Fusion IK passes the manipulator’s target and current joint values into a neural network, the results of which are then used to seed an evolutionary algorithm, Bio IK, to complete the solution of the inverse kinematics problem. Fusion IK allows for solving the position and orientation of the robot while attempting to minimize joint movement times. Comparisons between Fusion IK and its underlying algorithm Bio IK are tested on a six-degree-of-freedom articulated industrial robot as well as a 20-degree-of-freedom robot to explore the move times that Fusion IK produces. The comparisons show that the variations of the Fusion IK algorithm show comparable results to its underlying evolutionary Bio IK algorithm on a six-degrees-of-freedom articulated robot and improvements on a 20-degree-of-freedom robot without any additional hyperparameter tuning. The results show that Fusion IK could be of real value regarding the movement time and the quality of the obtained solutions upon further research, especially with higher degree-of-freedom robots.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 9-18"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434273","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":"An unconstrained and non-redundant identification method of geometric errors and compensation of machine tools by X-AX Laserbar","authors":"Yukun Xiao ,&nbsp;Guangyan Ge ,&nbsp;Ming Deng ,&nbsp;Jun Lv ,&nbsp;Zhengchun Du","doi":"10.1016/j.mfglet.2024.09.007","DOIUrl":"10.1016/j.mfglet.2024.09.007","url":null,"abstract":"<div><div>Efficient and accurate measurement and identification of geometric errors are crucial for improving the precision of CNC machine tools. The X-AX Laserbar, as a novel tool for indirect measurement, has not been extensively studied for the identification of geometric errors in machine tools. In this paper, the geometric error model for a three-axis machine tool is established to illustrate the multilateration measurement principle of the laserbar, and a non-redundant and unconstrained identification method is proposed to identify these geometric errors. This method avoids the use of redundant parameters and additional constraints by employing pose error twists to describe the geometric errors. These pose error twists are identified in a transitional coordinate system, and then the geometric errors will be identified in the machine coordinate system by deriving the relationship between the pose errors and geometric errors. The proposed method is validated with the VMC-850E three-axis machine tool. The geometric error measurement using a laserbar is completed in about 40 min, showing great efficiency. The experimental results indicate that the proposed method is capable of accurately identifying the 17 geometric errors required for error compensation. The identified geometric errors are then applied to the machine tool’s accuracy improvement through error compensation. The results show that the actual geometric errors are controlled to a low level. The proposed method can efficiently measure the geometric errors of three-axis machine tools and contribute significantly to improving their geometric accuracy.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 31-42"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434274","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":"Model-based tool wear detection and fault diagnosis for end mill in various cutting conditions","authors":"Jun-Young Oh,&nbsp;Jae-Eun Kim,&nbsp;Wonkyun Lee","doi":"10.1016/j.mfglet.2024.09.076","DOIUrl":"10.1016/j.mfglet.2024.09.076","url":null,"abstract":"<div><div>In recent developments in the field of manufacturing systems, there has been a growing emphasis on optimizing cutting conditions. These optimizations are primarily based on intricate parameters, such as the material removal rate (MRR), surface roughness, and position accuracy. Simultaneously, there’s an increasing focus on enhancing manufacturing efficiency through equipment maintenance strategies that consider parameters, such as corrosion, pressure, temperature, vibration, and other environmental factors. Wear is inevitable during processing, which affects productivity. It is generated in various forms, such as flank, crater, and edge wear, which reduce the tool lifespan and impact machining quality, especially by increasing the cutting forces. Various studies have been conducted to address this issue. Direct measurements using microscopes have high accuracy but require interruption during the process, which adversely affects efficiency and productivity. As a solution, the modern era has witnessed an increase in indirect methods. These methods are often sensor-based, capture data during the machining process, and employ various models, including emerging artificial intelligence techniques, for predicting tool wear. However, these methods have problems with environmental susceptibility, reduced reliability, limitations of application, and excessive costs. This paper suggests a tool wear integrated cutting load prediction model, tool wear detection, and fault diagnosis mechanism. The tool-wear-integrated cutting-load prediction model was constructed by combining the cutting-load prediction and tool-wear models. The coefficients of the model were derived from the actual cutting data extracted by the spindle load. Tool wear detection was implemented by dividing regions based on the tendency of the coefficient of the constructed tool wear integrated cutting load prediction model and the errors between the predicted and actual values. The proposed model demonstrated a performance comparable to that of the existing models in a single-cutting-condition path. However, it excelled in extracting the tool wear coefficients in paths with a mixture of various cutting conditions, which was not achievable with conventional models. Based on these coefficients, the cutting force was predicted with a maximum error of 3.3 %. Also, an accurate determination of the tool-wear regions was possible. Furthermore, the performance of the tool fault diagnosis method was validated using images of tools identified as being at risk of damage.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 595-604"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434407","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 validation of the amplitude ratio as a metric for milling stability identification","authors":"Mark A. Rubeo","doi":"10.1016/j.mfglet.2024.09.078","DOIUrl":"10.1016/j.mfglet.2024.09.078","url":null,"abstract":"<div><div>This paper presents the experimental validation of the amplitude ratio, a metric for milling stability identification. The amplitude ratio quantifies the severity of chatter by comparing the amplitude of the expected frequency content of a milling signal (i.e., tooth passing frequency, runout frequency, and harmonics) to the amplitude of the chatter frequency, if present. Through multiple iterations of a milling time domain simulation, the amplitude ratio diagram, which characterizes stable and unstable milling behavior over a range of spindle speeds and axial depths of cut, may be generated. In this paper, a comparison of the simulated and measured amplitude ratios for a series of milling test cuts is presented. It is shown that the amplitude ratio is suitable for identifying milling stability in both simulations and experiments. Additionally, it is shown that through judicious selection of low-cost sensors, implementation of the amplitude ratio is cost efficient. Direct comparison of the simulated and measured amplitude ratios demonstrates the effectiveness of the approach.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 610-618"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434409","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":"Femtosecond laser joining of Stellite and stainless steel","authors":"David Fieser ,&nbsp;Lingyue Zhang ,&nbsp;Matthew Yao ,&nbsp;Hugh Shortt ,&nbsp;Peter Liaw ,&nbsp;Anming Hu","doi":"10.1016/j.mfglet.2024.09.039","DOIUrl":"10.1016/j.mfglet.2024.09.039","url":null,"abstract":"<div><div>This research explores the practicality of fusing Stellite 6, a cobalt-chromium alloy known for its high performance, with stainless steel, utilizing various laser welding approaches. The primary challenge addressed is the joining of dissimilar materials, which presents obstacles such as divergent melting points and disparate coefficients of thermal expansion. The aim is to achieve a metallurgical bond between Stellite and stainless steel that retains desirable properties. The study employs both continuous wave and femtosecond laser welding techniques, subjecting the resultant joints to rigorous analysis to assess their impact on the properties of the bond. Initial tensile testing delineated the intrinsic mechanical characteristics of the materials, revealing that while Stellite exhibits a lower ultimate tensile strength, it compensates with greater elongation compared to stainless steel. The use of continuous wave laser welding proved to be capable of creating the bond; however, it also precipitated a considerable decline in the tensile strength of the Stellite component as a result of the thermal processing involved. In contrast, femtosecond laser welding emerged as a more effective method, enhancing the joint’s overall strength and ductility. This improvement is attributed to the femtosecond laser’s precise control over thermal exposure, which confines the heat to the intended weld zone, thereby safeguarding the adjacent material from damage. Further insights were gleaned from Scanning Electron Microscopy, which showed a preferable intergranular fracture in samples welded with the femtosecond laser—a feature typically associated with ductile failure modes. The femtosecond laser welding approach culminated in a joint efficiency of 53.7%, mirroring the innate yield strength of the Stellite wire. This outcome suggests that such welded joints possess the requisite robustness for practical deployment, thus underscoring the potential of femtosecond laser welding in applications requiring the joining of Stellite to stainless steel.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 332-338"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434242","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}