Manufacturing Letters最新文献

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3D soft material printer as a mesoscale additive biomanufacturing platform for in-space manufacturing 三维软材料打印机作为用于太空制造的中尺度增材生物制造平台
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.015
Albert J. Patrick, Salil Bapat, Ajay P. Malshe
{"title":"3D soft material printer as a mesoscale additive biomanufacturing platform for in-space manufacturing","authors":"Albert J. Patrick,&nbsp;Salil Bapat,&nbsp;Ajay P. Malshe","doi":"10.1016/j.mfglet.2024.09.015","DOIUrl":"10.1016/j.mfglet.2024.09.015","url":null,"abstract":"<div><div>With the burgeoning in-space manufacturing (ISM) industry, developing an on-demand additive manufacturing (AM) platform will be crucial for long-term space habitation. However, acute space boundary conditions, such as limited physical space, microgravity, vacuum, and others pose unique challenges for designing the printing process, the platform’s structure, and the materials’ printability. An AM platform operable in a space environment would enable production at the point of need (PoN), for example, on-demand food, nutrition, and pharmaceutical products. This research is focused on the design, fabrication, and testing of a 3D printer confined within CubeSat boundaries to study the feasibility of soft material printing aimed toward potential ISM applications. The printer unit was built using components off the shelf (COTS) while adhering to the severe spatial boundary conditions posed by the CubeSat dimensions and was tested using an edible material ink to demonstrate multi-layer prints of soft materials. Printing in ambient Earth conditions as well as under vacuum displayed consistent layer cohesion and comparison to 3D model data although vacuum prints showed visibly dehydrated prints owing to outgassing of air bubbles. The printer equipment’s structural integrity was validated under simulated launch and operation conditions using a vibration testing setup according to the NASA-recommended microsatellites standards. The results indicated that the printer assembly maintained its structural and operational integrity during and after testing. Using soft materials as the basis of testing allows scalability when expanding to more complex and structural materials to produce spare parts using a frugally engineered modular manufacturing platform.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 113-123"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434345","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}
引用次数: 0
Friction stir processing: A thermomechanical processing tool for high pressure die cast Al-alloys for vehicle light-weighting 摩擦搅拌加工:用于汽车轻量化的高压压铸铝合金的热机械加工工具
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.061
Avik Samanta , Hrishikesh Das , Glenn J. Grant , Saumyadeep Jana
{"title":"Friction stir processing: A thermomechanical processing tool for high pressure die cast Al-alloys for vehicle light-weighting","authors":"Avik Samanta ,&nbsp;Hrishikesh Das ,&nbsp;Glenn J. Grant ,&nbsp;Saumyadeep Jana","doi":"10.1016/j.mfglet.2024.09.061","DOIUrl":"10.1016/j.mfglet.2024.09.061","url":null,"abstract":"<div><div>This study uses friction stir processing (FSP) for thermomechanical processing of high-pressure die-casting (HPDC) to modify microstructure and improve mechanical properties. FSP is carried out on two different HPDC aluminum alloys: (a) general-purpose, high-iron, HPDC A380 alloy and (b) premium quality, low-iron HPDC Aural-5 alloy in thin wall, flat plate geometry. Subsequent mechanical testing shows ∼30 % and ∼65 % enhancement in yield strength and tensile ductility. In addition, FSP leads to ∼10 times improvement in fatigue life for A380 alloy and ∼70 % improvement in fracture toughness for Aural-5 alloy. These findings emphasize the capability of FSP to modify the microstructure of HPDC Al-alloys-based structural components so that they can demonstrate a good combination of strength, ductility, fracture toughness, and high fatigue properties for long-term durability and reliability.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 504-512"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434154","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}
引用次数: 0
Rotary ultrasonic surface machining of silicon: Effects of ultrasonic power and tool rotational speed 硅的旋转超声波表面加工:超声波功率和工具转速的影响
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.063
Sarower Kabir , Shah Rumman Ansary , Yunze Li , Meng Zhang , Weilong Cong
{"title":"Rotary ultrasonic surface machining of silicon: Effects of ultrasonic power and tool rotational speed","authors":"Sarower Kabir ,&nbsp;Shah Rumman Ansary ,&nbsp;Yunze Li ,&nbsp;Meng Zhang ,&nbsp;Weilong Cong","doi":"10.1016/j.mfglet.2024.09.063","DOIUrl":"10.1016/j.mfglet.2024.09.063","url":null,"abstract":"<div><div>The surging demand for monocrystalline silicon materials in the production of microelectronic components highlights its crucial role in the semiconductor and optic industries. Hence it is inevitable to produce a silicon workpiece with high quality finish to meet the demand in semiconductor industries. Due to high brittleness, controlling the quality of silicon in surface machining is quite difficult. Traditional manufacturing processes induce issues like rough surfaces and edge chipping. It was reported that rotary ultrasonic surface machining (RUSM) can effectively reduce cutting force, roughness, and edge chipping in machining of brittle materials. There have been several studies on drilling and sliding silicon materials using rotary ultrasonic machining investigating the effects of machining parameters on the output variables such as cutting force, torque, edge chipping, surface roughness etc. However, to the best of the authors’ knowledge, there are no reported investigations on effects of machining variables (ultrasonic power and tool rotation speed) in surface machining of silicon materials using the rotary ultrasonic machining. This study aimed to investigate the impacts of ultrasonic power and tool rotation speed on the cutting force, edge chipping, and surface roughness. Experimental results show that the ultrasonic vibration and tool rotation speed had a notable impact on edge chipping and cutting forces. Lastly, the current research has paved the way for widening the research on investigating grinding of the silicon wafer in semiconductor manufacturing with ultrasonic vibration and high rotation speed. In semiconductor wafer manufacturing, grinding process is used to reduce the flatness but generate surface and subsurface damage. With further investigations, RUSM can contribute to reducing these damages.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 518-525"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434156","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}
引用次数: 0
Unsupervised detection and mapping of sparks in the Electrochemical Discharge Machining (ECDM) process 电化学放电加工 (ECDM) 过程中火花的无监督检测和映射
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.052
Prayag Gore, Yu-Jen Chen, Murali Sundaram
{"title":"Unsupervised detection and mapping of sparks in the Electrochemical Discharge Machining (ECDM) process","authors":"Prayag Gore,&nbsp;Yu-Jen Chen,&nbsp;Murali Sundaram","doi":"10.1016/j.mfglet.2024.09.052","DOIUrl":"10.1016/j.mfglet.2024.09.052","url":null,"abstract":"<div><div>Material removal in electrochemical discharge machining is caused by sparks generated in a tool immersed in an electrolytic solution. Being the primary machining agent in this non-contact machining process, mapping the locations of microscopic sparks is of great interest. The distribution of sparks around the tool surface could give insights into the machined hole properties like the size, surface finish, and depth as compared to the machining parameters such as applied voltage, tool size, rotation speed, and feed rate. This paper is focused on detecting sparks in photographs of the ECDM process captured using a high-speed camera. A novel approach of using a tri-planar reflective surface for capturing the location of sparks in 3D space using a 2D camera output is attempted. Traditional spark detection methods use neural network classifiers that need labeled data for training. This labeled data often comes from human intervention and contains inherent biases that could lead to misclassification. In this paper, an unsupervised spark detection methodology is demonstrated, which eliminates the need for human intervention and relies on the number of neighboring pixels detected in regions of interest (ROIs). The feasibility of using adaptive background modeling to classify thousands of images and identify the ones with sparks is demonstrated in this work. The masking technique combining effects of erosion followed by dilation is used to determine the exact boundaries of the spark contours in every image. Centroids for each of these contours are then transformed from the skewed coordinate system as observed in camera images, to a three-dimensional orthogonal coordinates system centered around the tool. The same procedure is repeated for various voltages to benchmark the distribution of sparks around a tool tip in an ECDM process.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 435-441"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434206","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}
引用次数: 0
Design of thermomechanical processes for tailored microstructures 设计用于定制微结构的热机械工艺
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.050
Lukas Kluy , Lina Klinge , Christopher Spiegel , Carsten Siemers , Peter Groche
{"title":"Design of thermomechanical processes for tailored microstructures","authors":"Lukas Kluy ,&nbsp;Lina Klinge ,&nbsp;Christopher Spiegel ,&nbsp;Carsten Siemers ,&nbsp;Peter Groche","doi":"10.1016/j.mfglet.2024.09.050","DOIUrl":"10.1016/j.mfglet.2024.09.050","url":null,"abstract":"<div><div>Thermomechanical processes enable tailoring of material properties and microstructures for advanced products. In medical technology, next-generation titanium implants require tailored material properties to improve health and quality of life. However, the interaction correlation between process parameters and material properties poses a major challenge for the design of thermomechanical manufacturing processes.</div><div>In this paper, we present a methodology for the design of thermomechanical processes to achieve tailored microstructural properties through forming technology and heat treatments. The methodology consists of five systematic steps to address the complexity of multiphysical coupling relationships between temperature, stress, microstructure and alloy composition, and to provide a guideline for effective implementation. It is applied to the production of nanostructured Ti-13Nb-13Zr (NanoTNZ) alloy for dental implants. The designed process of severe plastic deformation, recrystallization treatment and aging lead to nanostructured microstructures smaller than 200 nm. The resulting mechanical properties (UTS &gt; 980 MPa, Young’s modulus of 73 GPa) meet the desired goals for improved biomedical implant-bone interactions. The tailored material properties and microstructures of NanoTNZ are therefore highly promising for use as an implant material.</div><div>The case study demonstrates the importance of a systematic method to manage the complexity of multiphysical coupling relationships in the design of thermomechanical processes to enable tailored microstructures for advanced materials and products.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 421-428"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434253","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}
引用次数: 0
Mass customization using hybrid manufacturing and smart assembly: An optimal configuration and platform design approach 利用混合制造和智能装配实现大规模定制:优化配置和平台设计方法
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.016
Hany Osman , Ahmed Azab , Rifat Bin Hasan , Fazle Baki
{"title":"Mass customization using hybrid manufacturing and smart assembly: An optimal configuration and platform design approach","authors":"Hany Osman ,&nbsp;Ahmed Azab ,&nbsp;Rifat Bin Hasan ,&nbsp;Fazle Baki","doi":"10.1016/j.mfglet.2024.09.016","DOIUrl":"10.1016/j.mfglet.2024.09.016","url":null,"abstract":"<div><div>Hybrid Manufacturing (HM) and smart assembly stand as pivotal pillars in advanced smart manufacturing systems, offering manufacturers highly efficient and adaptable solutions for manufacturing. This paper delves into the configuration of a production line that integrates HM and assembly stages, each comprising multiple cells, with each cell housing one or more parallel stations. The objective is to manufacture a family of final assemblies, leveraging the platform concept to defer mass customization to later stages and thereby minimize processing costs. A mathematical programming model is proposed to identify the optimal configuration for such production lines, considering constraints such as an allowable capital cost and machine availabilities. In addition, the precedence, inclusion, and seclusion restrictions imposed on the part family are considered. The proposed mathematical programming model aims to delineate which HM features are processed in the part platform cell versus those processed in the mass customization (part variants) cells. Simultaneously, the model determines the components (variants from the HM stage) of final assemblies processed in the assembly platform cell, as well as components assembled or disassembled in the final assembly cells. Furthermore, the model seeks to determine the required number of stations in each cell to meet periodic demand. The overall objective of the model is to minimize the capital and the processing cost. A detailed case study illustrates the effectiveness of the proposed configuration approach and mathematical model. The proposed model is solvable in a few seconds by using commercial solvers.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 124-132"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434346","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}
引用次数: 0
Employing the electrode of different diameters to join dissimilar Al-Cu thin sheets using resistance spot welding 使用不同直径的电极通过电阻点焊连接异种铝铜薄板
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.055
Rajdev Singh, Amit Choudhary, Navneet Arora
{"title":"Employing the electrode of different diameters to join dissimilar Al-Cu thin sheets using resistance spot welding","authors":"Rajdev Singh,&nbsp;Amit Choudhary,&nbsp;Navneet Arora","doi":"10.1016/j.mfglet.2024.09.055","DOIUrl":"10.1016/j.mfglet.2024.09.055","url":null,"abstract":"<div><div>This study aims to clarify the intricate connection between using different electrode tip diameters and the quality of spot joints. By investigating basic principles and process parameters, the research highlights how various combinations of electrode sizes affect weld quality. Specifically, to join aluminum (Al) and copper (Cu), two electrode sizes were employed: 4 mm and 8 mm tip diameter. Given that copper has higher conductivity (398 W/mK) and a higher melting temperature (1085 °C) compared to aluminum (237 W/mK and 660 °C respectively), efforts were made to enhance current density towards the copper side by using the smaller electrode tip diameter (4 mm) on that side. Experiments were conducted using two different combinations of sheet thicknesses (0.5 mm and 1 mm), revealing the need for optimized electrode tip diameter combinations for varying sheet thicknesses and materials with different thermos-physical properties. Overall, this study seeks to deepen our understanding of resistance spot welding, specifically focusing on the importance, challenges, and future prospects associated with varying electrode tip diameters in joining dissimilar metals.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 457-461"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434210","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}
引用次数: 0
Surface insight: Leveraging high-density dataset fusion for enhanced roughness classification 表面洞察力:利用高密度数据集融合增强粗糙度分类能力
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.022
Ronit Shetty, Ahmad Al Majali, Lee Wells
{"title":"Surface insight: Leveraging high-density dataset fusion for enhanced roughness classification","authors":"Ronit Shetty,&nbsp;Ahmad Al Majali,&nbsp;Lee Wells","doi":"10.1016/j.mfglet.2024.09.022","DOIUrl":"10.1016/j.mfglet.2024.09.022","url":null,"abstract":"<div><div>The ability to assess the surface quality quickly and accurately is of immense importance in manufacturing system. Modern metrology system along with machine learning is great at classification but requires more time. Traditionally accessing surface roughness is a time-consuming process. The progress in manufacturing technology necessitates improved approaches for quality control, specifically in the categorization of surface roughness, which has a substantial impact on the performance of materials. This research study introduces a novel method for classifying surface roughness by combining image data and point cloud data to create a comprehensive model. It then compares the performance of this model with a model that just relies on image data. A comprehensive analysis is conducted in this study, where image and point cloud data is collected and analysed. Multilinear principal component analysis (MPCA) along with random forest classifier is employed to create a model that classifies the surface texture. The primary goal is to showcase the enhanced precision and comprehensive understanding offered by the fused data model compared to the model that solely relies on images.</div><div>Furthermore, the work presents a pragmatic approach for developing this enhanced model offline and applying it online in real-time production environments, with a particular focus on using only image data. This strategy is in line with the objectives of Industry 4.0, which seeks to achieve more intelligent and data-driven manufacturing processes. Subsequent investigations will prioritize expanding the model’s suitability to various manufacturing settings, particularly highlighting its capacity to ensure quality in manufacturing lines through the utilization of images.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 182-190"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434270","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}
引用次数: 0
Improving surface integrity of GH4169 alloy through magnetic-assisted cutting 通过磁力辅助切割提高 GH4169 合金的表面完整性
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.077
Chao Tang, Yixuan Ye, Yu Zhang, Binghan Huang, Tao Huang, Dong Zhang, Xiaoming Zhang, Chang Ye
{"title":"Improving surface integrity of GH4169 alloy through magnetic-assisted cutting","authors":"Chao Tang,&nbsp;Yixuan Ye,&nbsp;Yu Zhang,&nbsp;Binghan Huang,&nbsp;Tao Huang,&nbsp;Dong Zhang,&nbsp;Xiaoming Zhang,&nbsp;Chang Ye","doi":"10.1016/j.mfglet.2024.09.077","DOIUrl":"10.1016/j.mfglet.2024.09.077","url":null,"abstract":"<div><div>GH4169 alloy presents superior properties such as high strength and resistance to high temperature, but possesses poor machinability. To ameliorate the problem and improve the machined surface integrity of GH4169 alloy, this paper focused on the application of magnetic-assisted cutting (MAC) for GH4169 alloy. In the MAC process, a permanent magnetic field (the magnetic field intensity is 0.25 T) was applied to the workpiece material during cutting, and its impact on chip morphology, tool damage and surface integrity was investigated. By comparing to traditional cutting (TC), the introduction of a magnetic field results in a reduction in the chip thickness and minimizes chip serration, leading to smoother cutting process and reduced fluctuations in cutting forces. Meanwhile, the introduction of magnetic field resulted in a substantial decrease in the notch wear and abrasion of cutting tool, and mitigated the excessive growth of built-up edge (BUE), which improved the tool life and machined surface integrity. By analyzing the machined surface at the end of TC and MAC, it was found that the surface roughness at the end of MAC was reduced by 22.4 %. Meanwhile, the cavity, side flow and debris of BUE, which tend to occur in the machined surface during the TC process, are effectively suppressed after MAC. Furthermore, Microstructural analysis of the machined surface indicated an enhancement in the dislocation density on the machined surface layer, suggesting the magnetoplastic effect of the magnetic field on GH4169 alloy.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 605-609"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434408","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}
引用次数: 0
Kalman filter-driven state observer for thermal error compensation in machine tool digital twins 用于机床数字双胞胎热误差补偿的卡尔曼滤波器驱动状态观测器
IF 1.9
Manufacturing Letters Pub Date : 2024-10-01 DOI: 10.1016/j.mfglet.2024.09.025
Sebastian Lang , Sofia Talleri , Josef Mayr , Konrad Wegener , Markus Bambach
{"title":"Kalman filter-driven state observer for thermal error compensation in machine tool digital twins","authors":"Sebastian Lang ,&nbsp;Sofia Talleri ,&nbsp;Josef Mayr ,&nbsp;Konrad Wegener ,&nbsp;Markus Bambach","doi":"10.1016/j.mfglet.2024.09.025","DOIUrl":"10.1016/j.mfglet.2024.09.025","url":null,"abstract":"<div><div>Sustainable reduction of thermal errors during production is the key challenge in modern high-precision manufacturing. Numerical compensation models provide an energy-efficient solution, but in the case of data-driven models, high-quality experimental data must be time-consuming and expensive to produce, negatively impacting overall productivity. Furthermore, robustness concerns arise in the case of new operating conditions, which were not contained in the training data. This paper presents a novel use of a Kalman filter together with model order reduced finite element models to observe the entire thermal state, which allows the subsequent solution of the mechanical model and computation of the thermal errors in real-time without requiring any training data but instead purely based on the physical system model. The effectiveness of this approach is evaluated using experiments on a thermal test bench with 16 out of 40 temperature sensors employed for observation and demonstrated on a 5-axis machine tool (MT) with 13 out of 25 temperature sensors used. Due to the combination of the reduced order model and Kalman filter these 13 temperature sensors are sufficient to represent a MT mesh of more than 350’000 elements. The entire temperature profile of the thermal test bench is reconstructed to achieve a root mean square error (RMSE) of the unobserved temperature sensors of only 2.7 °C, which accounts for more than 83% of all temperature variations and 1.3 °C for the 5-axis MT. For the thermal error of the thermal test bench, the RMSE could be reduced from <span><math><mrow><mn>67.4</mn><mspace></mspace><mi>μ</mi><mtext>m</mtext></mrow></math></span> to <span><math><mrow><mn>33.3</mn><mspace></mspace><mi>μ</mi><mtext>m</mtext></mrow></math></span>, corresponding to a reduction of 52.7 %. This could be achieved without the need for experimental data for model calibration, in a real-time capable physics-based model.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 208-218"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434276","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}
引用次数: 0
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