Manufacturing Letters最新文献

{"title":"Prediction of residual stresses induced in turning – Influence of cutting tool geometry","authors":"Joel Rech ,&nbsp;Sangil Han ,&nbsp;Alexis Cavard ,&nbsp;Marc Raffestin ,&nbsp;Frédéric Valiorgue","doi":"10.1016/j.mfglet.2025.06.075","DOIUrl":"10.1016/j.mfglet.2025.06.075","url":null,"abstract":"<div><div>It has long been recognised that machining processes induce residual stresses in machined surfaces. This article focuses on the longitudinal turning process of the martensitic stainless steel 15-5PH. The aim is to investigate the influence of tool geometry, specifically rake angle and edge sharpness, on surface residual stresses. Three turning tools were studied both experimentally and through numerical simulations using the MISULAB software. The results show that the geometry of the cutting tool does not significantly affect the residual stress state in the outer layer. On the contrary, edge radius and rake angle determine the thickness of the affected layer as well as the intensity of the compression peak below the outer layer. Cutting tools with a large edge radius and a small rake angle result in a thick affected depth, characterised by a deep compression peak below the outer layer. The trends observed experimentally are well predicted by the numerical simulations, providing new insights for the design of new cutting tools dedicated to the optimisation of the residual stress state.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 643-650"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926809","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":"Formation of graphitic micro-channels on boron-doped diamond electrodes via femtosecond laser irradiation: A Route for controlled sp2 functionalization","authors":"Sagarika Banik ,&nbsp;R. Ibdhu ,&nbsp;N. Arunachalam ,&nbsp;M.S. Ramachandra Rao","doi":"10.1016/j.mfglet.2025.06.077","DOIUrl":"10.1016/j.mfglet.2025.06.077","url":null,"abstract":"<div><div>Diamond is a promising material for electrodes in the field of electrochemical analysis, biosensing, and energy storage. However, the diamond has to be doped with charge carriers like boron to make it a p-type semiconductor material. Creating highly localized and geometrically confined sp² graphitic columns in boron-doped diamonds can improve the electrocatalytic properties of the electrode. In this work, graphitic columns were created on boron-doped diamond using 100 fs laser pulses at 800 nm wavelength. The laser fluence of 8.85–––44.2 J/cm² and the scanning speed of 0.1–1 mm/s were found to be suitable for graphitization. Microstructural analysis of the samples was done using scanning electron microscopy and Raman spectroscopy techniques. The Raman results showed that a suitable fluence of 22.1 J/cm² and graphitization speed of 0.5 mm/s improves the crystallinity of the graphitic column and suppresses the residual diamond content. A four-probe resistivity measurement was done on the graphitic columns to evaluate the resistivity difference. A minimum resistance of 66.39 Ω/sq was observed at a preferred laser fluence of 22.1 J/cm²; with an increase in laser fluence, an increase in the resistivity was observed.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 661-667"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926824","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":"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":"Impact of dynamic recrystallization in laser shock peening predicted via a coupled cellular automata finite element model","authors":"Karl Bailey ,&nbsp;Sumair Sunny ,&nbsp;Ritin Mathews ,&nbsp;Arif Malik","doi":"10.1016/j.mfglet.2025.06.044","DOIUrl":"10.1016/j.mfglet.2025.06.044","url":null,"abstract":"<div><div>A coupled cellular automata-finite element (CAFE) model has been developed to simulate the phenomenon of dynamic recrystallization (DRX) during the laser shock peening (LSP) process on the titanium alloy, Ti6Al4V. Although microstructure changes resulting from DRX during LSP treatment have been observed and studied experimentally, there is no work to-date on a model that is capable of simulating LSP while also capturing the potential effects of microstructure evolution due to DRX. Creating an LSP model that couples DRX during the high intensity shock wave propagation is a major challenge considering the very high-strain rates and nanosecond-scale time duration, as well as the requirement to repeatedly update the grain boundary locations and the localized mechanical properties of grains during the simulation. This paper introduces the first modeling framework for simulating microstructural evolution due to DRX during the LSP treatment process. The framework includes predictions of both continuous DRX (cDRX) and discontinuous DRX (dDRX), as well as the influence of the predicted microstructure evolution on the resulting stress–strain fields arising from LSP treatment. For an experimentally determined initial microstructure and specific LSP process parameters, the final state of residual stress predicted by this CAFE model shows substantially increased local variation in the compressive stress field as compared to the case when DRX is not considered. This variation is particularly evident in the vicinity of the part surface where most of the DRX is observed and predicted to occur. In addition, based on the process conditions for the specific LSP treatment considered, cDRX is predicted to be the dominant mechanism of microstructural evolution. This is because the overall temperature increase that occurs during LSP, arising due to plastic deformation alone when an ablative surface coating is included, is found to be insufficient to induce dDRX-based nucleation in the Ti6Al4V alloy.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 364-375"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926602","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":"Evaluating microstructural changes and hardness in equal atomic Ni-Al-Co-Fe-Mn-Ti-Cr high-entropy alloy subjected to heat treatment in oxidative and non-oxidative environments","authors":"Emmanuel Olorundaisi,&nbsp;Peter A. Olubambi","doi":"10.1016/j.mfglet.2025.06.048","DOIUrl":"10.1016/j.mfglet.2025.06.048","url":null,"abstract":"<div><div>Microstructural changes and hardness behaviour of equal atomic Ni-Al-Co-Fe-Mn-Ti-Cr High-Entropy Alloy (HEA) subjected to heat treatment in oxidative and non-oxidative environments were investigated. The samples were annealed for four hours at a temperature of 700 °C. The microstructure revealed the formation of a well-refined granular and needle-like eutectic phase with an average size. An oxidized layer was observed on the surface of the sample heat-treated in an oxidized environment. The heat-treated samples exhibited improved ductility with a drop in hardness value from 136.3 HV for the non-heat-treated to 98.1 and 92.8 HV for the heat-treated in an oxidized and non-oxidized environment, respectively. The heat treatment results can be considered a promising approach for producing high-performance HEAs, particularly for advanced engineering applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 405-415"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926606","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":"A 3DGS and LLM-based physical-to-virtual approach for human-robot interactive manufacturing","authors":"Wenhang Dong ,&nbsp;Shufei Li ,&nbsp;Pai Zheng ,&nbsp;Liang Liu ,&nbsp;Shuo Chen","doi":"10.1016/j.mfglet.2025.06.016","DOIUrl":"10.1016/j.mfglet.2025.06.016","url":null,"abstract":"<div><div>With the exploration of digital transformation in the industry, the introduction of the industrial metaverse is bringing unprecedented opportunities and challenges to the manufacturing industry. In the industrial metaverse, humans can interact safely and naturally with robots in high-fidelity digital environments, enabling non-technical operators to quickly validate industrial scenarios and help optimize decision-making and production processes. However, the complexity of Three-Dimensional (3D) modeling poses a challenge to achieving this goal. Additionally, programming-based Human Robot Interaction (HRI) also presents obstacles, as operators need significant time to learn how to control robots. Therefore, this paper proposes a 3D Gaussian Splatting (3DGS) and Large Language Model (LLM)-based physical-to-virtual approach for human-robot interactive manufacturing, which further facilitates digital interaction for non-technical operators in manufacturing environments. Specifically, 3DGS is first used for rapid visualization and reconstruction of the overall scene, achieving new perspective rendering and providing a gaussian ellipsoid representation. Then mesh extraction algorithms based on gaussian representation are used to build a physical-to-virtual transfer framework. Finally, LLM is utilized for understanding natural language commands and generating virtual robot Python programming to complete robot assembly tasks. This framework is implemented in the Isaac Sim simulator, and the case study shows that the proposed framework can quickly and accurately complete physical-to-virtual transfer and accomplish robot assembly manufacturing tasks in the simulator with low code.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 121-128"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926614","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":"A novel vibration suppressing method for robotic machining by inertial moment actuator using gyroscopic spindle","authors":"Jongyoup Shim,&nbsp;Jooho Hwang,&nbsp;Seung Guk Baek,&nbsp;Seung Kook Ro","doi":"10.1016/j.mfglet.2025.06.017","DOIUrl":"10.1016/j.mfglet.2025.06.017","url":null,"abstract":"<div><div>This study presents a novel gyroscopic spindle actuator designed for vibration suppression in robotic machining, addressing the limitations caused by the compliance and low stiffness of industrial robots. The actuator utilizes a rotating flywheel, driven by an air-pressure turbine, to generate stabilizing gyroscopic moments, enhancing machining precision and stability. Key design features include a lightweight structure, a wireless optical angular speed sensor, and an electro-pneumatic proportional valve for flywheel speed control. A proportional-integral control algorithm, using accelerometer feedback, enables real-time adjustment of the gyroscopic moment to counteract vibrations effectively. Experimental validation demonstrated significant suppression of low-frequency vibrations, particularly at about 6 Hz, alongside reductions in higher-frequency structural vibrations. These results highlight the actuator’s ability to improve surface quality and machining stability while maintaining reliable performance across various conditions. This work shows the potential of gyroscopic spindle actuators to overcome vibration-induced challenges in robotic machining and offers a foundation for future advancements in robotic manufacturing systems.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 129-135"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926615","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":"Development and initial testing of robotic blacksmithing apparatus","authors":"Pedro Doukas,&nbsp;Sha Ouyang,&nbsp;Jinjin Ha,&nbsp;Brad Kinsey","doi":"10.1016/j.mfglet.2025.06.057","DOIUrl":"10.1016/j.mfglet.2025.06.057","url":null,"abstract":"<div><div>Manufacturing-based robotic platforms with various end effectors to replicate different processes can provide cheaper and space efficient point-of-need capabilities. One such process of interest is robotic blacksmithing that can, e.g., provide a means to post-process composite materials with voids and material imperfections that are fabricated through additive manufacturing. In this paper, a robotic forging end effector is developed and used to cold forge, actually coin, an AA6061-T6 block. Analyses of deformation, both experimental and numerical simulations, allows for the changes to the material, hardness, penetration of the strain hardening, and surface properties to be measured. Penetration data provides insight into the thickness and number of material layers that can be deposited in an additive manufacturing process prior to such a post-processing step to affect the material and layer interface characteristics. Analysis of surface properties reveal the physical changes to the metal that affect its material characteristics.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 481-486"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926533","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":"Multi-layer multi-variable value stream mapping: A comprehensive framework across operational, environmental, and social layers with integrated KPIs interrelationships","authors":"Ayoub Heydarzade ,&nbsp;Niloofar Rezaei ,&nbsp;Seyed Alireza Vaezi ,&nbsp;Jaime A. Camelio","doi":"10.1016/j.mfglet.2025.06.023","DOIUrl":"10.1016/j.mfglet.2025.06.023","url":null,"abstract":"<div><div>Industry 4.0 technologies have increased the complexity and interconnectivity of manufacturing systems, challenging the conventional scope of Value Stream Mapping (VSM). In response, this paper proposes a Multi-Layer Multi-Variable Value Stream Mapping (MLMV-VSM) framework that integrates operational, environmental, and social layers within a single methodology. The approach captures Key Performance Indicators (KPIs) and their interdependencies, enabling more balanced system optimization. Unlike traditional VSM, MLMV-VSM explicitly incorporates human-centric metrics, such as stress and fatigue, along with operational and environmental factors. An illustrative example demonstrates how operator skill development can influence production speed, energy consumption, and ergonomic outcomes, highlighting cross-layer trade-offs and synergies. The paper also addresses practical challenges, including the measurement of social metrics, the prioritization of competing KPIs, and the need for real-time adaptability. Finally, avenues for future work are identified, emphasizing the integration of Industry 4.0 technologies such as the Internet of Things (IoT) and data analytics to support dynamic decision-making and foster sustainable manufacturing practices.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 184-194"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926536","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":"Computed Tomography Image-Based Measurements of Cortical Bone Thickness for Improved Bone Tissue Processing and Decision-Making","authors":"Dane Ungurait ,&nbsp;Chuanshen Zhou ,&nbsp;Kateland Hutt ,&nbsp;Yunxia Chen ,&nbsp;Adam Poniatowski ,&nbsp;Joe Shaara ,&nbsp;Paxton Howell ,&nbsp;Yong Huang ,&nbsp;Hitomi Yamaguchi","doi":"10.1016/j.mfglet.2025.06.019","DOIUrl":"10.1016/j.mfglet.2025.06.019","url":null,"abstract":"<div><div>Due to challenges with sourcing tissues for autografts, allografts are becoming increasingly popular in the transplantation of human tissue, including bone grafting, and it is important that available donor tissue is processed efficiently while minimizing discarded tissue. This paper describes the development of a computed tomography (CT) image-based system to nondestructively measure cortical-bone thickness of a donor sample, which helps determine how the tissue should be processed to maximize tissue utilization. The system uses a CT scanner to collect three-dimensional data of the donor tissue. The data is then processed into two-dimensional tomograms, which are processed using software developed to measure cortical-bone thickness. Based on these measurements, a score is assigned to the cortical bone that helps determine the types and sizes of allografts that can be processed from the tissue. It was demonstrated that high-resolution (85–200 microns) images can be generated and analyzed quickly with scan times as fast as 8 min and software run times of less than 5 seconds for 464 thickness measurements. This paper concludes that this process is an effective and efficient method to generate quantitative metrics that can be used to make more informed decisions on the processing of bone tissue for allograft production.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 148-156"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926666","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}