Manufacturing Letters最新文献

{"title":"Energy-Aware Flexible Job Shop Scheduling with Speed Scaling under Uncertainty: A Simheuristic employing a Discrete Event Simulation","authors":"AbdelSalam Sharfy,&nbsp;Mohammad Aldurgam,&nbsp;Ahmed Azab","doi":"10.1016/j.mfglet.2026.07.021","DOIUrl":"10.1016/j.mfglet.2026.07.021","url":null,"abstract":"<div><div>This paper presents an energy-aware Flexible Job Shop Scheduling Problem with controllable processing times under uncertainty. Each operation may run on one of several eligible machines and at a discrete speed level that trades off the makespan against the total energy cost (TEC). A simheuristic employing simulated annealing (SA) and Arena discrete event simulation (DES) modeling is used to evaluate schedules under uncertainty. In Arena’s replications, operation times are sampled from Normal distributions and machines’ failure and repair are according to exponential up/down times. To avoid scale bias, the search is driven by a single normalized scalar objective that combines makespan and TEC using fixed best/worst references and a user weight <span><math><mrow><mi>λ</mi><mo>∈</mo><mo>[</mo><mn>0</mn><mo>,</mo><mn>1</mn><mo>]</mo></mrow></math></span>. Computational experiments on a 4-job, 3-operation, 6-machine benchmark perform a sensitivity analysis across different weights. The best-per-<span><math><mrow><mi>λ</mi></mrow></math></span> solutions quantify the trade-off moving from <span><math><mrow><mi>λ</mi><mo>=</mo><mn>0</mn></mrow></math></span> (energy-focused) to <span><math><mrow><mi>λ</mi><mo>=</mo><mn>1</mn></mrow></math></span> (makespan-focused) reduces the expected makespan from 498 to 233 time units (<span><math><mrow><mo>-</mo><mn>53</mn><mo>%</mo></mrow></math></span>) while increasing TEC from 80 to 347 units. SA convergence logs show rapid early gains followed by tightening acceptance, and a move-type analysis indicates that speed changes are most frequently accepted and drive much of the objective reduction, whereas occasional sequence swaps deliver larger makespan drops. Overall, the developed simheuristic reliably arrives at simulation-validated schedules across the time–energy spectrum and provides interpretable artifacts for decision makers in the addressed flexible, failure-prone stochastic job shop.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 119-130"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149096606","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":"Effect of rotational speed in FSW on the thinning behavior during drawing of tailor-welded blanks","authors":"Yugesh Raajha MS,&nbsp;Chanmi Moon,&nbsp;Torgeir Welo,&nbsp;Geir Ringen","doi":"10.1016/j.mfglet.2026.07.043","DOIUrl":"10.1016/j.mfglet.2026.07.043","url":null,"abstract":"<div><div>The formability of friction stir tailor-welded blanks made from aluminum alloys, used as structural components in the automotive industry, is a concern. Variation in process parameters controls the heat input during FSW, resulting in microstructural inhomogeneity and property differences between the weld material and the base material, which in turn lead to complex stress states. In this work, the influence of rotational speed in FSW on the subsequent formability of tailor-welded blanks (TWBs) is investigated. AA6082-T6 aluminum alloy sheets are welded together at different rotational tool speeds (1,000, 1,500, and 2,000 RPM) while employing a constant traverse speed of 100 mm/min. Post-weld annealing treatment (PWAT) was performed to improve formability, evaluated through square cup drawing tests. The deep drawing process was modelled in Abaqus to investigate the thickness distribution and thinning behaviour using a double-zone modelling approach. Results<!--> <!-->revealed that the as-welded TWBs exhibited pronounced hardness gradients across the weld region due to the variation in the heat input during welding. PWAT seemed to homogenize the microstructure and mechanical properties, with hardness values stable between 40-50 HV across the entire weld region. This tends to minimize local thinning during forming, regardless of initial weld zone disparities and processing conditions. FEA simulations incorporating the local mechanical properties from each weld region closely reproduced the experimentally observed thickness profiles and deformation patterns. This correlation between the modelling results and the experimental data implies that the approach<!--> <!-->is considered well-suited for fine-tuning welding and annealing parameters to achieve improved formability in TWBs.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 337-343"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149096534","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":"Investigating the Impact of SLM Scanning Speed on Corrosion and Wear in Al-Si-Mg Alloys","authors":"Samson D. Oguntuyi,&nbsp;Femi J. Akinfolarin,&nbsp;Peter A. Olubambi","doi":"10.1016/j.mfglet.2026.07.104","DOIUrl":"10.1016/j.mfglet.2026.07.104","url":null,"abstract":"<div><div>Optimizing selective laser melting (SLM) parameters is crucial for unlocking the full potential of alloy fabrication, enabling properties to be tailored for structural strength and functional reliability in demanding applications. In this work, variations on how laser power and scanning speed influence hardness, wear resistance, and corrosion behavior were explored. To evaluate this influence, the samples were produced under different processing conditions, resulting in varying microstructural properties and porosity levels. Mechanical and electrochemical responses were then methodologically evaluated: microhardness using Vickers indentation at 0.3 kgf load, wear resistance through a pin-on-disc tribometer, and corrosion performance via open circuit potential (OCP) and electrochemical impedance spectroscopy (EIS) in 3.5 wt% NaCl solution. The results reveal that careful optimized laser parameters enhance densification and refine the eutectic Si network, consequently raising the hardness values and superior wear resistance, demonstrated by lower material loss and smoother wear tracks. Also, enhanced microstructural homogeneity produced higher noble OCP and impedance values, signifying passive layer stability. But the enormous energy input, which decreased the porosity, resulted in microstructural irregularities and residual stresses that made the alloy more vulnerable to localized corrosion. Generally, these discoveries show the necessity of proper adjustment of SLM parameters to attain a balance between mechanical strength and corrosion resistance. Hence, having an insight into the resulting process–structure–property correlations is vital for enabling AlSi10Mg alloys to perform reliably in demanding aerospace, automotive, and marine applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 895-902"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149095979","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":"Challenges in additive manufacturing of multi-metals: Nitinol-maraging steel, a case study","authors":"Vinay Kenny,&nbsp;Guang Yang,&nbsp;Salil Bapat,&nbsp;Clara Mock,&nbsp;Ajay Malshe","doi":"10.1016/j.mfglet.2026.07.085","DOIUrl":"10.1016/j.mfglet.2026.07.085","url":null,"abstract":"<div><div>Powder-based directed energy deposition (DED) of dissimilar alloys offers a route to fabricate and repair multi-metal components, but large chemical and thermo-mechanical mismatches promote cracking and interfacial degradation. This work examines Nitinol deposited onto 18Ni maraging steel as a model system for Ti–Fe multi-metal architectures with Nitinol interlayers. A single-layer Nitinol was printed on maraging steel with three different percentage overlaps (PO = 20, 30, 40%) and characterized using an optical microscope/profilometer, scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). All conditions produced uniform deposition, but distinct cracking modes were observed: lower PO generated multiple vertical solidification cracks within the Nitinol layer, while higher PO suppressed these vertical cracks yet promoted severe edge cracking along the Nitinol/maraging steel interface. Cross-sectional SEM/EDS revealed that increasing PO reduced melt pool depth and Fe– Nitinol dilution, sharpening the interface but also decreasing the crack-free interfacial region. To interpret these trends, a thermo-mechanical finite-element model was implemented in Ansys Additive Suite with the DED Process Add-on to compute part-scale temperature histories. Simulated temperature–time profiles at the start, middle, and end of the deposition process showed that the central region experiences smaller thermal gradients and a sustained elevated temperature, correlating with the experimentally observed reduction in cracking away from the edges. These results highlight the competing roles of dilution control and residual-stress development in DED Nitinol-on-maraging steel, and they provide guidance for designing Nitinol interlayers in hybrid Ti64–Nitinol–18Ni maraging steel multi-metal builds.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 710-720"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149096082","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":"Additive Manufacture of Electrically Conductive Carbon Structures from Direct Ink Writing (DIW) and Laser-Induced Carbonization of Lignin-based Inks","authors":"Soham Yogeshbhai Makwana,&nbsp;Md Kaviul Islam,&nbsp;Dulce C. Resendiz,&nbsp;Sarah A. Bentil,&nbsp;Pranav Shrotriya","doi":"10.1016/j.mfglet.2026.07.078","DOIUrl":"10.1016/j.mfglet.2026.07.078","url":null,"abstract":"<div><div>Sustainable additive manufacturing of electrically conductive carbon structures requires a renewable materials-based process that enables precise control over shape and conductivity. We report the additive manufacturing of conductive carbon films based on direct ink writing (DIW) followed by laser-induced carbonization of three lignin-based inks (α, β, and γ). The inks were characterized to assess viscosity, yield stress, and shear-thinning behaviour. Subsequently, printing parameters—substrate temperature, speed, and nozzle diameter—were selected to establish a stable processing window for DIW-ink processing. A systematic three-factor analysis of variance (ANOVA) was performed to assess the impact of these parameters on the geometry and electrical resistivity. Among the formulations, ink α demonstrated the most consistent extrusion and the lowest average resistivity ((2.6 <span><math><mrow><mo>±</mo><mn>0.8</mn><mo>)</mo></mrow></math></span>×<span><math><msup><mrow><mn>10</mn></mrow><mrow><mo>-</mo><mn>4</mn></mrow></msup></math></span> Ωm), indicating good electrical conductivity and print fidelity. The nozzle size significantly affected the printed width, whereas the temperature and speed ranges considered in the experiments had a negligible impact on the printed material properties. Raman spectroscopy reveals that the printed structures exhibit low defect levels and two-dimensional carbon peaks, indicating that the conductive carbon lines are composed of few-layer graphene. The hybrid manufacturing process of DIW and laser-induced carbonization with the optimized printing parameters (50–70 °C and 85–135 mm/s) yielded uniform, defect-free lines with the lowest electrical resistivity and is suitable for printing conductive carbon structures for sensing and energy storage applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 661-671"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149096085","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":"Effect of Heat Treatment on Selective Laser Melted Ti6Al4V Alloys by adding Ta: Microstructure & Mechanical Properties","authors":"Anel Zhumabekova,&nbsp;Andrei Yankin,&nbsp;Asma Perveen","doi":"10.1016/j.mfglet.2026.07.093","DOIUrl":"10.1016/j.mfglet.2026.07.093","url":null,"abstract":"<div><div>This study investigates the effect of heat treatment on the microstructure and mechanical properties of (Ti6Al4V)₉₂Ta₈ alloys produced by Selective Laser Melting. This research is motivated by the limited understanding of how β-stabilizing elements such as tantalum (Ta) influence phase evolution and mechanical performance in additively manufactured titanium alloys. The samples were subjected to heat treatment to compare as-built and heat-treated conditions. Microstructural characterization was performed using scanning electron microscopy to examine morphological changes, phase development, and Ta distribution. Mechanical testing included hardness measurements, tensile tests, and fatigue strength evaluations to assess variations in material response. After heat treatment, the alloy exhibited increased hardness and ductility, accompanied by higher strain and elastic modulus. However, ultimate tensile strength, yield strength, and fatigue strength decreased. These results indicate a transition toward more ductile behavior caused by microstructural coarsening and phase redistribution. Unmelted Ta particles persisted within the Ti6Al4V matrix due to the limited melting capability of SLM, while annealing promoted localized diffusion and grain reorientation around these regions. Overall, this study provides insight into the interaction between alloy composition, thermal treatment, and mechanical properties, highlighting the importance of optimizing heat treatment conditions to achieve a balanced combination of strength, ductility, and structural stability in SLM-produced titanium alloys.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 794-805"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149096090","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":"Investigation of the effect of electrophoretic-assisted cooling conditions in diamond wire sawing of silicon carbide wafers","authors":"Eyob Messele Sefene,&nbsp;Chao-Chang Arthur Chen,&nbsp;Steve Hsueh-Ming Wang","doi":"10.1016/j.mfglet.2026.07.071","DOIUrl":"10.1016/j.mfglet.2026.07.071","url":null,"abstract":"<div><div>Slicing silicon carbide (SiC) wafers in diamond wire sawing (DWS) presents significant challenges due to the material’s hardness and brittleness. Implementing a chemical-mechanical sawing strategy can enhance the machinability of the SiC sawing process. This study investigates the effect of different cooling strategies on diamond wire wear and the surface quality of as-sawn wafers. Experiments were conducted under constant parameters using three distinct cooling conditions: traditional DWS (T-MDWS), reactive abrasive coolant DWS (R-MDWS), and electrophoretic-assisted reactive coolant (ER-MDWS). Diamond wire wear and surface roughness were examined using a scanning electron microscope (SEM) and coherent correlation interferometry. The results indicate that the ER-MDWS cooling condition significantly improves machinability, reducing diamond wire wear by 35.92% and surface roughness by 4.68% compared to the T-MDWS. The enhancement is attributed to electrophoretically assisted Fe₃O₄ particle deposition and the formation of a chemically softened surface layer, which decreases impact loading and facilitates a transition toward ductile-dominant material removal. These findings confirm that integrating electrophoretic-assisted chemical reactions into DWS effectively enhances machinability and provides a sustainable pathway for high-quality SiC wafer manufacturing.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 595-606"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149096159","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":"Modification of residual stress on chromium carbide interlayer of diamond-Ni-Cr filler brazed joint by HiPIMS Cr ion bombardment","authors":"E. Prakashraj,&nbsp;Amitava Ghosh","doi":"10.1016/j.mfglet.2026.07.055","DOIUrl":"10.1016/j.mfglet.2026.07.055","url":null,"abstract":"<div><div>Brazed diamond tools fabricated using Ni-Cr filler alloy often encounter adverse brazing-induced residual stresses within the bonding region, leading to the development of microcracks, particularly at the chromium carbide interlayer between the diamond and the filler alloy. These detrimental stresses primarily originate from the significant mismatch in thermo-mechanical properties between diamond and filler materials, coupled with uncontrolled cooling rates during the brazing process. To mitigate the adverse effects of tensile stresses and microcracks, both of which can cause premature failure of the brittle carbide interphase, a post-processing treatment involving fast-moving metal ion peening (Cr) via the High-Power Impulse Magnetron Sputtering (HiPIMS) technique has been proposed. This approach aims to induce beneficial compressive residual stresses in the intricate diamond–filler bonding zone. Upon Cr ion bombardment of the brazed diamond joints, especially at the etching-exposed carbide interlayer, which is a prime site for crack initiation and exhibits maximum tensile stress, XRD residual stress measurements confirm the significant reduction of tensile residual stress (65 %) from +2475.5 MPa to +865.8 MPa. Furthermore, morphological analysis of ion-peened samples reveals that Cr ion deposition onto the chromium carbide interphase during bombardment contributes to joint strengthening by partial sealing of existing microcracks. The findings indicate that the combined favourable effect of compressive stress generation and chromium ion deposition achieved through this post-processing ion-peening technique has the potential to significantly improve the durability of brazed diamond joints. Consequently, brazed diamond tools treated with this method could be utilised more effectively, extending their operational life to the maximum achievable limits.</div><div>© 2026 The Authors. Published by ELSEVIER Ltd. This is an open access article under the CC BY-NC-ND license (<span><span>https://creativecommons.org/licenses/by-nc-nd/4.0</span><svg><path></path></svg></span>)</div><div>Peer-review under responsibility of the scientific committee of the NAMRI|SME.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 444-452"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149096300","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":"Evaluation of process parameters on the surface integrity of nitinol samples by fiber laser cutting using surface response method","authors":"Giovanni Palencia-Mercado,&nbsp;Mariana Cadena,&nbsp;Luis Cedeño-Viveros,&nbsp;Ciro A. Rodríguez,&nbsp;Elisa V. Vázquez,&nbsp;Erika García-López","doi":"10.1016/j.mfglet.2026.07.046","DOIUrl":"10.1016/j.mfglet.2026.07.046","url":null,"abstract":"<div><div>Nitinol has been widely used in angioplasty procedures and other medical applications due to its remarkable biocompatibility and shape-memory effect. Laser cutting is crucial for processing Nitinol in medical applications due to its precision for complex geometries and its ability to preserve the alloy’s unique shape-memory and superelastic properties. This research investigates the influence of fiber laser cutting parameters—specifically spot overlap and pulse energy—on the surface integrity of Nitinol samples for medical applications. The performance was measured using surface roughness indicators Ra and Rz, and changes in cwhemical composition were assessed using Energy Dispersive X-ray Spectroscopy (EDS). The study varied spot overlap between 72.33% and 95.12% and pulse energy between 29.48 mJ and 32.16 mJ to determine proper conditions for improved surface quality. A surface response analysis was performed to develop a model describing the behavior of Ra and Rz. EDS analysis was performed to evaluate the presence of oxygen and carbon. Our results demonstrate that surface roughness (Ra) values ranging from 1.4 to 1.7 µm were achieved using 80% and 90% spot overlap. Analysis of variance (ANOVA) identified a model relating the process variables (i.e., spot overlap and pulse energy) to surface roughness (Ra and Rz). A minimum experimental Ra value of 1.484 µm was achieved at 83.7% spot overlap and 32.16 mJ pulse energy, with a model fit of 85.56% (R²). Similarly, a minimum experimental Rz value of 15.117 µm was observed at 83.7% spot overlap and 30.8 mJ pulse energy, with a linear model fit of 84.95% (R²). EDS analysis confirmed the presence of oxygen, carbon, and aluminum in samples with spot overlap ranging from 83.7 to 91.9%, and pulse energy between 30.15 and 32.16 mJ. Despite using argon as an assistive gas to minimize thermal damage, such as dross and microcracks, the results suggest that further refinement of gas pressure control and process parameters is essential to mitigate residual stresses and optimize surface integrity.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 361-366"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149096405","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":"Kalman Residual Analysis based Sensor-less Tool-Workpiece Contact Detection on Ultra-precision Machine Tool","authors":"Zongze Li,&nbsp;Ryota Taniguchi,&nbsp;Kyungki Lee,&nbsp;Takehiro Hayasaka,&nbsp;Eiji Shamoto,&nbsp;Yuta Iwasaki,&nbsp;Ryosuke Imura","doi":"10.1016/j.mfglet.2026.07.050","DOIUrl":"10.1016/j.mfglet.2026.07.050","url":null,"abstract":"<div><div>A sensor-less tool-workpiece contact detection method for an ultra-precision machine tool based on Kalman Filter (KF) is proposed in this study. The servo thrust signal of feed axis is processed using KF, and its Kalman Residual (KR) is calculated in real time. Parameters of KF are analyzed to achieve the optimized contact detection performance. A cumulative Kalman Residual (CKR) is constructed, and its threshold is experimentally determined, to detect the external disturbance of feed axis under a constant feed rate. Experimental studies were conducted in which the workpiece moved towards the tool initially and retracted in the opposite direction as soon as the tool and workpiece got in contact. The experiments were implemented with three different feed rates. The experimental results validate that the proposed contact detection method can achieve the micro-level tool-workpiece detection.</div><div>© 2026 The Authors. Published by ELSEVIER Ltd. This is an open access article under the CC BY-NC-ND license (<span><span>https://creativecommons.org/licenses/by-nc-nd/4.0</span><svg><path></path></svg></span>)</div><div>Peer-review under responsibility of the scientific committee of the NAMRI|SME.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"49 ","pages":"Pages 399-409"},"PeriodicalIF":2.8,"publicationDate":"2026-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149096409","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}