Manufacturing Letters最新文献

{"title":"Influence of flexible spindle characteristics on grinding dynamics in HydroFlex grinding: A numerical simulation with experimental validation","authors":"Patrick Chernjavsky ,&nbsp;Yumo Wang ,&nbsp;Jack Shanks ,&nbsp;Rohit Dey ,&nbsp;Shun Yu ,&nbsp;Xunzhi Xie ,&nbsp;Yang Liu ,&nbsp;Yihao Zheng","doi":"10.1016/j.mfglet.2025.06.060","DOIUrl":"10.1016/j.mfglet.2025.06.060","url":null,"abstract":"<div><div>Advanced manufacturing technologies have enabled the production of computer-optimized components with complex internal geometries, efficient fluid transport and cooling, and weight reduction. Polishing these channels is an essential post-processing step to attain precise geometric tolerance and reduce surface roughness, improving fatigue life and corrosion resistance. Conventional polishing methods for complex geometries struggle to maintain uniform performance in long, and tortuous channels and often use harsh acids which negatively impact the environment. HydroFlex has been shown as an effective internal polishing methods with increased adaptability and performance in highly complex geometries. Key to HydroFlex operation is the generation and maintenance of orbital motion, describing the orbit of the grinding wheel around the internal contour of the channel due to grinding, fluid, and spindle forces acting in the grinding zone. In this study, the spindle force was modeled using minimum potential energy method to determine the spindle position and contact point(s) throughout a complex workpiece. Experimental validation utilized a highspeed camera for shaft position and orbital motion capture, and a force sensing to determine the spindle force during orbit and no-orbit conditions. Results indicated that the model was able to predict the shaft position with visual contact point accuracy. A spindle force threshold of 0.19 N was found to overcome the orbital motion. These results suggest that MPE can be used to predict the spindle position and grinding condition based on threshold force for given spindle and workpiece properties.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 507-516"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926828","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":"New Investigations on the performance Enhancement of Cryogenic-LN2 assisted sustainable milling of titanium alloy","authors":"Aqib Mashood Khan,&nbsp;Salman Pervaiz,&nbsp;Muhammad Jamil,&nbsp;Wei Zhao,&nbsp;Longhui Meng","doi":"10.1016/j.mfglet.2025.06.047","DOIUrl":"10.1016/j.mfglet.2025.06.047","url":null,"abstract":"<div><div>The low-temperature properties of the titanium alloy Ti17 affect the milling process. In order to better understand the various physical phenomena in the cryogenic cutting process, cryogenic impact tests and tensile tests of titanium alloy Ti17 were undertaken in this study. Based on the cryogenic performance of the material, experiments on dry milling and cryogenic milling with a liquid nitrogen jet were conducted. It was found that the strength was increased, and the toughness was decreased under cryogenic conditions. The milling force shows an increasing trend with the increase of cutting speed and feed rate under both cooling conditions. The milling forces of cryogenic conditions were higher than that of dry cutting, and the surface roughness under cryogenic conditions was also improved compared to dry cutting. This study highlights how cryogenic milling of Titanium Alloy Ti17 can improve surface roughness and mechanical strength, leading to extended tool life and reduced material waste, which contributes to sustainable manufacturing. Additionally, using cryogenic cooling minimizes the need for conventional cutting fluids, reducing environmental impact and enhancing process sustainability.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 396-404"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926605","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":"Carbo-thermal reduction of lunar highland regolith simulant for in-situ manufacturing of SiC","authors":"Nithya Srimurugan ,&nbsp;Sathyan Subbiah","doi":"10.1016/j.mfglet.2025.06.049","DOIUrl":"10.1016/j.mfglet.2025.06.049","url":null,"abstract":"<div><div>In-situ resource utilization is important to ensure sustainability of exploration missions such as establishing a habitable extra-terrestrial base on the moon. Resources available on the lunar surface such as the regolith must be tapped to build structures and manufacture products on moon. This requires raw materials like metals, metal alloys and ceramics to be extracted from the regolith. Regolith contains silicon as an abundant element next to oxygen, and hence synthesis of silicon and its compounds seems pragmatic. Therefore, the objective of this study is to extract silicon carbide (SiC) from lunar regolith which has a wide range of applications in producing abrasives, electronics and ceramic components. The methodology involves heating the regolith to a high temperature so that volatile species such as Na, K, Fe, SiO are liberated and subsequently, the evolved SiO gases are reduced to SiC by using methane. This resulted in the formation of SiC whiskers which are verified by X-ray diffraction and Raman spectroscopy. Electron microscopy images reveal that the majority of the SiC whiskers are formed by vapor–liquid-solid mechanisms with diameters ranging from 0.3 to 2 µm. Detailed electron diffraction and microscopy studies reveal that the whiskers formed are single crystals having a core–shell structure containing SiC and SiO_x respectively. This study provides a foundation for the direct manufacturing of SiC whiskers from lunar regolith which can be used for fabricating electronic devices, construction materials, radiation shields and habitats on the surface of moon.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 416-423"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926607","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":"Elevated temperature structured light scanning for in situ monitoring of forging dies","authors":"Jake Dvorak,&nbsp;Tony Schmitz","doi":"10.1016/j.mfglet.2025.06.051","DOIUrl":"10.1016/j.mfglet.2025.06.051","url":null,"abstract":"<div><div>Metrology grade structured light scanning has been established as an effective non-contact measurement method for dimensional analysis of complex components at standard temperatures. Initial efforts have demonstrated the use of custom structured light systems for measurements of forgings and at elevated temperature environments. However, little work has been done to evaluate the performance of metrology grade structured light systems at elevated temperatures. This paper provides a performance baseline for a commercially available ZEISS ATOS Q structured light system using a calibrated gage block at elevated temperatures. Results show that the measured length of the gage block matches that of simulated lengths using a temperature-dependent coefficient of thermal expansion taken from handbook data. These results motivate the use of structured light scanning for measurements in forging and other elevated temperature manufacturing applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 430-433"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926609","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, hybrid manufacturing, and characterization of porous fracture fixators","authors":"Johnathan Perino ,&nbsp;Panayiotis Kousoulas ,&nbsp;Y.B. Guo","doi":"10.1016/j.mfglet.2025.06.099","DOIUrl":"10.1016/j.mfglet.2025.06.099","url":null,"abstract":"<div><div>Additive manufacturing (AM) enables the production of complex, highly porous geometries that would be impossible to create with subtractive methods. These geometries have generated much interest in their potential applications for decreasing the weight of traditional parts as well as their potential use in orthopedic implants, such as headless compression screws. Pore size and implant porosity play an important role in the osseointegrative performance of porous implants. Ensuring that the porosity of the physical part matches that of the CAD model is thus key to implant performance. However, more work is needed to design, fabricate, and evaluate the manufacturability of AM porous implants. The threefold objectives of this study are as follows. (1) Cylindrical screw blanks with three different porosity patterns are designed in CAD. (2) The blanks are fabricated using the laser-powder bed fusion (LPBF) process, followed by manual threading. (3) The resulting porosity of each LPBF blank is characterized using optical microscopy as well as micro-CT and compared to the CAD model. It was found that the as-printed porosity did not match well with the CAD model, with the measured mean pore size about 30% larger than the theoretical. Future work involves a redesign of the blank geometry to better integrate a porous core with threaded sections as well as mechanical testing to determine feasibility of use for fixation.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 839-846"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926656","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":"53rd SME North American manufacturing research conference (NAMRC 53, 2025) Preface","authors":"Xun Xu ,&nbsp;Stefania Bruschi ,&nbsp;Robert X. Gao","doi":"10.1016/j.mfglet.2025.06.001","DOIUrl":"10.1016/j.mfglet.2025.06.001","url":null,"abstract":"","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 1-2"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926658","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 feed rate milling of carbon fiber reinforced plastic with PCD tool","authors":"Sho Watanabe ,&nbsp;Fumihiro Uchiyama ,&nbsp;Shoichi Tamura ,&nbsp;Takashi Matsumura","doi":"10.1016/j.mfglet.2025.06.080","DOIUrl":"10.1016/j.mfglet.2025.06.080","url":null,"abstract":"<div><div>Carbon fiber reinforced plastic (CFRP) has recently been applied to aircraft structures. In milling of CFRP, the surface finish is sometimes deteriorated by delamination of polymer with uncut fibers. Because the cutting of CFRP also appears anisotropy, the surface finish depends on the fiber cutting angle, which is the cutting direction for the fiber orientation. Furthermore, in the manufacturing of aircraft parts, high machining rates are required for large removal areas. This study investigates the surface finish and the tool wear in the milling of CFRP with a 10 mm diameter PCD end mill at high feed rates up to 3000 mm/min. Delamination-free and wavy profile-free surfaces are finished at a cutting speed of 314 m/min and a feed rate of 3000 mm/min using the end mills at rake angles of 5°, 10°, and 15°. Delamination suppression is associated with the indentation load applied to the workpiece surface in the engagement of cutting edge in up-cutting. Then, the tool wear is discussed in the milling of 16-layered CFRP. An approach based on an abrasive wear model is presented to identify the wear characteristics for the fiber cutting angles. In the wear test of this study, the wear rate increases up to a fiber cutting angle of 45°; decreases to 135° (−45°); and increases again to 180° (0°). The presented approach is effective in estimation of flank wear distribution associated with the radial depth of cut</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 687-693"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926691","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":"Comparison study of Selective Laser melted Ti6Al4V and Ti6Al4V-8Ta Alloys: Mechanical & corrosion properties","authors":"Anel Zhumabekova,&nbsp;Asma Perveen,&nbsp;Didier Talamona","doi":"10.1016/j.mfglet.2025.06.095","DOIUrl":"10.1016/j.mfglet.2025.06.095","url":null,"abstract":"<div><div>This work explores the use of Selective Laser Melting (SLM) to enhance the mechanical and corrosion properties of titanium-tantalum (Ti6Al4V-8Ta) alloys for biomedical applications. The study addresses the limitations of the widely used Ti6Al4V alloy, such as potential aluminum and vanadium toxicity, by incorporating tantalum (Ta), which offers superior biocompatibility and corrosion resistance. Comprehensive characterization is performed using Scanning Electron Microscopy (SEM) to analyze the chemical composition and particle morphology, while particle size distribution is measured using a Mastersizer. Mechanical testing reveals that the Ti6Al4V-8Ta alloy exhibits slightly reduced mechanical properties compared to Ti6Al4V, with an ultimate tensile strength (UTS) of 1216.73 ± 3.20 MPa, yield strength (YS) of 1058.67 ± 24.49 MPa, and elastic modulus of 99.64 ± 5.52 GPa. In comparison, Ti6Al4V has a UTS of 1222.69 ± 2.63 MPa, YS of 1063.87 ± 49.19 MPa, and elastic modulus of 106.38 ± 12.44 GPa. Microstructural analysis demonstrates a refined acicular martensitic structure, which improves toughness, while fractographic examination reveals both ductile and brittle fracture features, suggesting enhanced durability with the addition of Ta. Corrosion testing using potentiodynamic analysis and Electrochemical Impedance Spectroscopy (EIS) shows that Ti6Al4V-8Ta offers improved corrosion resistance. It exhibits a lower corrosion current density of 1.89 ± 0.38 μA/cm² compared to 7.23 ± 1.40 μA/cm² for Ti6Al4V, and a higher polarization resistance (Rp) of 24547.67 ± 12,157.40 Ω·cm² compared to 6762.36 ± 3796.68 Ω·cm² for Ti6Al4V. Additionally, the corrosion rate of Ti6Al4V-8Ta is 0.043 ± 0.023 mm/a, nearly half that of Ti6Al4V (0.093 ± 0.076 mm/a). Improved wettability is also observed, with Ti6Al4V-8Ta showing contact angles of 48.12 ± 4.36° (0° print angle) and 57.56 ± 3.03° (90° print angle), compared to 41.44 ± 1.18° and 47.61 ± 3.95° for Ti6Al4V. In conclusion, the Ti6Al4V-8Ta alloy developed using SLM achieves a favorable combination of mechanical performance and enhanced corrosion resistance. Although mechanical properties are slightly reduced, the significant improvements in corrosion resistance and hydrophobicity make Ti6Al4V-8Ta a promising candidate for long-term biomedical applications. This study highlights the potential of advanced manufacturing techniques to develop next-generation biomaterials that ensure safer and more durable implants.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 804-815"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926693","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":"Assessment of the grindability of robocast silicon carbide","authors":"Taylor Barrett ,&nbsp;Beth L. Armstrong ,&nbsp;Corson L. Cramer ,&nbsp;Brigid Mullany","doi":"10.1016/j.mfglet.2025.06.085","DOIUrl":"10.1016/j.mfglet.2025.06.085","url":null,"abstract":"<div><div>The demand for high-performance lightweight optics has driven interest in silicon carbide (SiC) due to its exceptional thermal stability, hardness, and strength-to-weight ratio. This study investigates the potential of robocasting, an additive manufacturing process, as a viable method for producing lightweighted SiC components for optical applications. Four samples with varied starting powder phases (α and β) and sintering conditions were fabricated and evaluated. Post-sintering surface and form were assessed using coherence scanning interferometry (CSI) and coordinate measuring machine (CMM) techniques. A three-stage grinding process was applied to each sample, with surface roughness assessed at each stage. Results demonstrate that samples with predominantly α-phase SiC and smaller particle sizes achieved superior surface finish, particularly sample D2-α-2135 °C, which displayed the lowest post-grinding <em>Sq</em> value of 0.178 µm. The analysis also indicated no significant print-through effect from the lightweighting structure, or print artifacts, at this stage of grinding. However, β-phase samples showed poorer grindability, increased surface roughness, and pitting. These findings suggest that phase composition and particle size are critical for achieving the desired surface quality in robocast SiC optics. Future work will incorporate additional samples and finer grinding wheels to refine surface quality further, supporting the development of SiC for high-precision optical applications.</div><div>Click here to enter text.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 726-733"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926832","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":"Highly accurate hole making technology of Ti6Al4V experimental elucidation of process for hole diameter in the depth direction to be determined","authors":"H. Yagishita","doi":"10.1016/j.mfglet.2025.06.067","DOIUrl":"10.1016/j.mfglet.2025.06.067","url":null,"abstract":"<div><div>Ti6Al4V, which is one of difficult-to-cut metals, is widely used in an aircraft structure, parts of a gas turbine and medical equipment so that a hole making operation of Ti6Al4V is indispensable to fasten the parts. When a highspeed drilling by a conventional twist drill is applied to hole making of Ti6Al4V, it is very difficult to obtain highly accurate hole diameter in the depth of hole, also roundness and inlet–outlet edge quality due to a rise of cutting temperature caused by its small heat conductivity. Moreover, it is well-known that Ti6Al4V causes transiently phase transformation from α phase (close-packed hexagonal lattice) to β phase (body-centered cubic lattice) as soon as it reaches the phase transformation temperature of about 883 °C (1621 °F). Since cooling effect by coolant upon inner surface of hole being drilled would be considerably different between conventional drilling and orbital drilling, to make clear highly accurate hole making technology in the depth direction of Ti6Al4V a lot of hole making tests of φ15 mm × 258 mm depth were executed supplying coolant by conventional drilling of φ15 mm twist drill and by orbital drilling of φ11 mm endmill having 6 blades. In order to elucidate the process for hole diameter in the depth direction to be determined, both cutting speeds of conventional drilling and orbital drilling were set to nearly equal and they were varied at 12 values in the range from 23 m/min to 85 m/min. Hole diameter and roundness measured simultaneously at six positions in the depth direction of hole were drawn in relation to depth of hole and hole diameter in the depth direction was compared and considered deeply between the two drilling methods. Consequently, it is ascertained that although the hole diameter drilled by conventional drilling becomes smaller from top to bottom in the depth direction of hole, the hole diameter drilled by orbital drilling becomes slightly larger in the depth direction of hole since the temperature at the area neighboring inner wall of hole being drilled would be maintained under phase transformation temperature of Ti6Al4V over a drilling operation except the exit area of hole.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 566-575"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926543","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}