Manufacturing Letters最新文献

{"title":"Harnessing interpretable and ensemble machine learning techniques for precision fabrication of aligned micro-fibers","authors":"Imtiaz Qavi,&nbsp;George Tan","doi":"10.1016/j.mfglet.2024.09.044","DOIUrl":"10.1016/j.mfglet.2024.09.044","url":null,"abstract":"<div><div>Electrospinning is a robust technique for producing micro/nano-scale fibrous structures, influenced by intricate interplays of fluid dynamics, aerodynamics, and electromagnetic forces. Depending on the desired outcome, these fibers can adopt various morphologies, including solid, tubular, concentric, and gradient. Such morphologies are modulated by parameters such as collector configuration, flow rate, voltage, solution properties, and nozzle dimensions. However, the task of modeling and predicting these multifaceted morphologies remains complex. Aligned microfibers with 3D orientation hold promise in tissue engineering, regenerative medicine, and drug delivery, necessitating meticulous control over the fabrication parameters. In our research, we tapped into machine learning (ML) to address these challenges. Classification ML models were designed to predict fibrous patterns—aligned, random, or jet branching—based on determinants like voltage, flow rate, and collector configurations. Notably, the Random Forest (RF) and Support Vector Machine (SVM) models, especially with radial kernel-trick, displayed outstanding predictive capabilities on the test data. Furthermore, regression-based ML was harnessed to discern fiber alignment coherency and inter-fiber distances. Models such as Lasso and Ridge regression elucidated predictive coefficients for these characteristics, while ensemble models, like gradient-boosting (GB) decision trees (DT), showcased prowess in regression scenarios. Key findings spotlighted the significance of parameters like plate gap for alignment coherency and needle-to-collector distance for inter-fiber spacing. As we strive to gain granular control over micro/nano feature morphology in electrospinning, understanding predictor-response dynamics is imperative. Our investigation underscores the essential role of ML in enhancing both qualitative and quantitative precision in fabricating advanced fibrous structures. Moreover, fusing ML with real-time process monitoring offers groundbreaking potential, particularly in Bio-Fabrication, regenerative medicine, and tissue engineering, where high-precision manufacturing remains a top priority.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 364-374"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434247","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":"Coupled 3D non-orthogonal constitutive model for woven composites in preforming and compaction processes","authors":"Deyong Sun ,&nbsp;Wanrui Zhang ,&nbsp;Jianchao Zou ,&nbsp;Yifeng Xiong ,&nbsp;Chongrui Tang ,&nbsp;Weizhao Zhang","doi":"10.1016/j.mfglet.2024.09.049","DOIUrl":"10.1016/j.mfglet.2024.09.049","url":null,"abstract":"<div><div>Woven composites are considered promising for lightweight applications with great environmental and economic benefits. One of the most promising techniques for mass-production of woven composite parts with complex geometry is closed-mold thermoforming including preforming, compaction/consolidation and curing steps. The ignored effects on non-uniform thickness deformation and compaction modulus caused by preforming are considered in the coupled 3D non-orthogonal constitutive model to capture the coupled material behaviors during preforming and compaction. The in-plane tension, compression and shear modulus in the model are calibrated using tension, bending and bias-extension experiments, respectively. Meanwhile, the out-plane compaction experiments are designed, with high-accuracy measurement method for the initial thickness and deformation process, to obtain the material properties of sheared woven composites. These experiments can be regarded as one benchmark for compaction tests of woven composites. The new material model has been implemented in Abaqus software and validated by the bias-extension experiments.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 412-420"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434300","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":"Data analytics for working performance analysis in production management","authors":"Yuxin Wang,&nbsp;Yishu Yang,&nbsp;Ray Y. Zhong","doi":"10.1016/j.mfglet.2024.09.011","DOIUrl":"10.1016/j.mfglet.2024.09.011","url":null,"abstract":"<div><div>RFID technology has found widespread application in supply chain processes. Previous research has primarily focused on managing products or stocks, with limited attention given to analysing workers’ performances through RFID data. This paper proposes a model for analysing employee performance using RFID data in production management. Key Performance Indicators (KPIs) are defined and utilised to process, analyse, and visualise the data through various analysis tools to develop the proposed model. Comparisons are conducted to evaluate employee performance between different groups based on the defined KPI. The model is validated by testing an independent data set, demonstrating its effectiveness in analysing existing data. Predictably, the model has the potential to reduce supervisory and associated costs in case-like applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 73-80"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434341","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":"Mid-spatial frequency reduction via zero-depth of cut rapid-feed passes in face-turning","authors":"Aravind Shriram,&nbsp;Nithya Srimurugan,&nbsp;Sathyan Subbiah","doi":"10.1016/j.mfglet.2024.09.054","DOIUrl":"10.1016/j.mfglet.2024.09.054","url":null,"abstract":"<div><div>The single point diamond turning process (SPDT) is used widely in creating optical grade mirror surfaces on several engineering materials ranging from polymers, and metals, to brittle materials such as silicon and germanium. In visual optic mirror applications, mid-spatial frequency (MSF) errors generated during the SPDT process interfere with the visible spectrum of light thereby affecting the image quality. To overcome these errors, a post-processing operation of polishing the optical mirrors is required. The post-processing step not only increases the complexity of the manufacturing process but also leads to minor geometrical form changes in the mirror which affects performance. To avoid post-processing and minimize MSFs formed during turning- a novel method to modify the toolpath during the machining process has been proposed in this paper. The suggested toolpath strategy comprises two consecutive operations: i) employing variable low feed rates with the specified depth of cut (DoC) and ii) executing rapid traverse rates with zero depth of cut for a predetermined number of passes. The effectiveness of the proposed strategy is tested by carrying out facing experiments in a micro-precision CNC lathe. The power spectral density (PSD) content of the machined surface is then analyzed to check for any improvement in the frequency characteristics. The results show that the frequency errors generated by the toolpath in normal turning operations can be minimized, distributing the resulting PSD peak over a wide range of spatial frequencies. From the PSD plots, it is observed that there is a decrease of 77% and 85.82% in the peak intensity values when compared with surfaces machined at constant feedrates of 150 μm/rev and 200 μm/rev respectively. This method can be applied to nanoprecision SPDT machines to improve the surface quality and to eliminate the MSF errors of the visual optical grade mirrors without the need for post-processing.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 451-456"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434209","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":"Thermal profile modeling and microstructural evolution in laser processing of Inconel 625 plates by comparison of analytical and numerical methods","authors":"Stephanie B. Lawson,&nbsp;Milad Ghayoor,&nbsp;Xianzhe Fu,&nbsp;Ali Tabei,&nbsp;Andy Fan,&nbsp;Somayeh Pasebani","doi":"10.1016/j.mfglet.2024.09.091","DOIUrl":"10.1016/j.mfglet.2024.09.091","url":null,"abstract":"<div><div>Microstructural evolution of materials under specified process conditions and parameters can be predicted by thermal modeling of additive manufacturing laser processes. The objective of this study was to develop, analyze and compare two methods for prediction: an analytical method and a numerical method for laser processing of Inconel 625 material. These methods were compared with experimental results for thermal profiling, and the effect of thermal profiles on microstructure of the experimental samples was explored. Maximum temperature and cooling rate of the numerical method were shown in good agreement, while the analytical method proved more challenging when compared to the experimental results for three laser parameters. Cooling curves were correlated with microstructure in terms of grain size, morphology, and orientation, with findings trending with parameter adjustments. This research supports the numerical modeling approach as a method for examining optimal laser processing conditions for Inconel 625 that is ideally suited for complex fluid flow analyses.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 730-741"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434370","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":"Optical inspection of stator slots for electric motors","authors":"Sean Wagner,&nbsp;John Agapiou","doi":"10.1016/j.mfglet.2024.09.014","DOIUrl":"10.1016/j.mfglet.2024.09.014","url":null,"abstract":"<div><div>An optical non-contact inspection system was developed for measuring the slots in stator lamination stacks. To avoid passing go/no-go gage blocks through the slots, a machine vision system is instead used to measure the stator core slots and identify the presence of burrs within the slots. Utilizing telecentric optics along with an alignment monitoring system configured to monitor and orient the stator core, the core slots can be oriented relative to the imaging axis for further metrology measurements. Among these measurements, the smallest opening dimensions (slot width and depth) of each slot due to misalignment of laminations and the detection of burrs along the edges of the slots throughout the length of the lamination stack are critical for full stator assembly. Advanced image processing algorithms were developed to obtain sub-pixel accuracy which is required to measure the slots. This, used in conjunction with a robust vision calibration technique, increases the feasibility of building a device that can be implemented as a production inspection system. Experiments show the reliability of the computer vision approach and how it can be used in the inspection of slots in lamination stacks.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 103-112"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434344","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":"Implementation strategy for launch and performance improvement of high throughput manufacturing inspection systems","authors":"J. Patrick Spicer ,&nbsp;Debejyo Chakraborty ,&nbsp;Michael Wincek ,&nbsp;Jeffrey Abell","doi":"10.1016/j.mfglet.2024.09.018","DOIUrl":"10.1016/j.mfglet.2024.09.018","url":null,"abstract":"<div><div>Product technologies are changing rapidly in advanced automotive propulsion systems. These products are driving the need for new manufacturing processes and new inspection methods. To keep new propulsion systems affordable and ensure these new products are introduced with high quality, automotive manufacturers are seeking automated inspection solutions with low cost and near-zero error rates to inspect 100% of the items. In this paper, a progressive deployment strategy of a hybrid inspection system is presented and studied in the context of technology development and rapid deployment. It enabled us to begin with human inspection and gradually phase-in automated inspection technology, while almost never failing to identify a bad item. This strategy was applied successfully to inspect ultrasonic welds in lithium ion battery packs. At the time of this study, a 75% reduction in human inspection was achieved with prospects for further reduction. Actual results from the implementation of this strategy in production are presented. Recommendations are made regarding the most appropriate time to employ this strategy and how it could increase the use of advanced automated in-line inspection technologies.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 143-152"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434348","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":"Feasibility of 5G-enabled process monitoring in milling operations","authors":"Liwen Hu ,&nbsp;Baihui Chen ,&nbsp;ElHussein Shata ,&nbsp;Shashank Shekhar ,&nbsp;Charif Mahmoudi ,&nbsp;Ivan Seskar ,&nbsp;Qingze Zou ,&nbsp;Y.B. Guo","doi":"10.1016/j.mfglet.2024.09.024","DOIUrl":"10.1016/j.mfglet.2024.09.024","url":null,"abstract":"<div><div>5G monitoring holds immense potential for revolutionizing manufacturing processes by enabling real-time data transmission, remote control, enhanced quality control, and increased efficiency. However, it also presents challenges related to 5G monitoring infrastructure. To explore 5G’s potential for process monitoring, this study introduces a novel 5G-enabled architecture designed to address the challenges, enhancing the process monitoring’s efficiency, accuracy, and reliability in the case of milling operation. To investigate the feasibility of this sophisticated 5G network for process monitoring, two testbeds, i.e., the 5G robotic milling testbed and the 5G CNC milling testbed, have been developed. An accelerometer and a laser scanner have been retrofitted with 5G communications capability to capture critical process signals in the testbeds, respectively. It has shown that the sensor data can be upstreamed to a 5G edge server for data analytics and visualization in ultra-low latency. This work highlights the transformative impact of 5G communication on process monitoring for time-critical manufacturing.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 200-207"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434272","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":"Stereolithography-assisted sodium alginate-collagen hydrogel scaffold with molded internal channels","authors":"Chi Wang,&nbsp;Yingge Zhou","doi":"10.1016/j.mfglet.2024.09.045","DOIUrl":"10.1016/j.mfglet.2024.09.045","url":null,"abstract":"<div><div>Fabricating internal vascular networks within a hydrogel scaffold is essential for facilitating the supply of nutrients, oxygen, and metabolism exchange required by the encapsulated cells. The challenges in current hydrogel scaffold fabrication involve the difficulty of building adequate internal channels, poor scaffold geometry precision, and low cell viability caused by the fabrication process and polymer material properties. Stereolithography (SLA) stands out as a 3D printing technique distinguished by its superior production efficiency, advanced precision, and remarkable resolution in crafting intricate custom geometries. These attributes establish it as an innovative approach for templates in scaffold fabrication, potentially surpassing the fused deposition modeling (FDM)-based template strategy. Meanwhile, it exerts less shear stress on the cells compared to the direct bioprinting process. This novel strategy enables the fabrication of hydrogel vascular structure within the precision of 500 µm in both channel diameter and wall thickness. In this paper, various sodium alginate and collagen (SA-Col) composite hydrogels with varying collagen concentrations have been investigated to identify the optimal ratio for fabricating hydrogel scaffolds with channels.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 375-383"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434248","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":"Metallurgical characteristics and mechanical properties of dissimilar friction stir welded DH36 steel and UNS G10080 steel joints","authors":"Pardeep Pankaj ,&nbsp;Pankaj Biswas ,&nbsp;Dave Kim","doi":"10.1016/j.mfglet.2024.09.046","DOIUrl":"10.1016/j.mfglet.2024.09.046","url":null,"abstract":"<div><div>The present study expanded the scientific comprehension of the friction stir welding process for dissimilar steels, namely high-strength shipbuilding grade DH36 steel and UNS G10080 steel. The effect of tool traverse speed and plunge depth on temperature history, microstructure characteristics, and mechanical properties is investigated experimentally. The metallographic characterizations were examined through an optical microscope and field emission scanning electron microscopy equipped with an energy-dispersive X-ray system. Microhardness, impact, and tensile tests were carried out on the friction-stir-welded specimens. Increasing the plunge depth and reducing the traversal speed resulted in an augmentation of the peak temperature, primarily attributable to higher heat generation. Within the range of process parameters used, the tool produced complex material movement, resulting in swirl-like and vortex-intercalated features, particularly adjacent to the stir zone/workpiece interface. These vortex-like features exhibited dynamically recrystallized fine-grained microstructures. The grain size in the stir zone and the thermo-mechanically affected zone is reduced by increasing the plunge depth and decreasing the traverse speed due to enhanced dynamic recrystallization, subsequently improving the hardness and toughness values. In the stir zone, the microstructure revealed the acicular-shaped bainite ferrite in the DH36 steel and the Widmanstatten ferrite in the UNS G10080 steel. The microhardness contours revealed the uneven hardness distribution across the weld cross-section due to the microstructural heterogeneity in the dissimilar steels. The maximum welding efficiency of 106 % and toughness of 46 J are obtained at 40 mm/min traverse speed with a plunge depth of 0.2 mm, which is attributed to sufficient heat generation and grain refinement.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 384-394"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434252","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}