Manufacturing Letters最新文献_第5页

Modeling of adhered powder particles and waviness on additive manufacturing part surface in electrochemical polishing 电化学抛光过程中增材制造零件表面附着粉末颗粒和波纹度的建模

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.040

Wenjian Cao , Andrea Ghiotti , Stefania Bruschi

{"title":"Modeling of adhered powder particles and waviness on additive manufacturing part surface in electrochemical polishing","authors":"Wenjian Cao , Andrea Ghiotti , Stefania Bruschi","doi":"10.1016/j.mfglet.2025.06.040","DOIUrl":"10.1016/j.mfglet.2025.06.040","url":null,"abstract":"<div><div>An innovative approach in electrochemical polishing (ECP) has been developed to enhance surface quality and precision in post-processing additive manufacturing surfaces, with a particular focus on leveling adhered powders and mitigating surface waviness. This study introduces a novel 2D model for quantitatively simulating the material removal process of spherical powder residues and waviness on sintered surfaces, utilizing adaptive triangular meshing technology. The initial geometric profiles of surface defects were modeled using the ellipse equation for spherical powder particles and the sine function for surface waviness. Key profile control nodes were tracked to observe changes over time, with detailed analyses of electric field strength, current density, material removal thickness, and removal rate. Predictive modeling results indicate that the electric field direction remains parallel to the surface, and the current density is approximately 0.23A cm<sup>−2</sup> after ECP, achieving a consistent material removal rate of 0.28 μm min<sup>−1</sup> during polishing. Surface roughness measurements, taken over a sampling length of 500 µm, showed a reduction from Ra 3.74 μm to Ra 0.21 μm, and the comparison of simulated and experimental surface profiles was presented with an error of only 0.04 μm, demonstrating the method’s efficacy in finishing both adhered powders and waviness. This study provides a new perspective to investigate the mechanism of ECP additive manufacturing parts.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 332-338"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926827","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}

引用次数: 0

Using machine learning with supplemented NC code to predict machining energy 利用机器学习辅助数控代码预测加工能量

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.086

Samuel Stencel , Nathan Hartman

{"title":"Using machine learning with supplemented NC code to predict machining energy","authors":"Samuel Stencel , Nathan Hartman","doi":"10.1016/j.mfglet.2025.06.086","DOIUrl":"10.1016/j.mfglet.2025.06.086","url":null,"abstract":"<div><div>Manufacturing contributes a significant amount of value to the economy while consuming nearly one-third of the total energy produced within the nation. Computer-aided manufacturing tools arose to streamline the process of manufacturing parts, but they lack energy-conscious practices. With this gap, research has been done in the development of mechanistic and data-driven models to accurately predict the energy consumption of this process. However, validation carried out in the experimental methodology in many of the research models is ill-fit to represent their realistic counterparts. In this paper, a data-driven deep learning model is developed, which properly accounts for the complexities associated with CNC machining, as it compensates for variations in operations observed during CNC machining. Furthermore, this deep learning model makes predictions by processing supplemented NC programs sequentially. These programs include additional information regarding the material removal process. Four variants of the model are created to provide insights into the effects of supplementing the program with different material removal variables. The variables include depth of cut, width of cut, material removal rate, and the volume of material removed per numerically controlled instruction. The prediction capability of these four models are then compared using several statistical tests.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 734-745"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926833","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}

引用次数: 0

Balancing trade-offs between first three moments of completion times for one-stage production 在一期生产的前三个完井时刻之间进行平衡

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.011

Wei Li , Barrie R. Nault

{"title":"Balancing trade-offs between first three moments of completion times for one-stage production","authors":"Wei Li , Barrie R. Nault","doi":"10.1016/j.mfglet.2025.06.011","DOIUrl":"10.1016/j.mfglet.2025.06.011","url":null,"abstract":"<div><div>For one-stage production, operations management faces the following three challenges to make decisions, which are inconsistencies between key performance indicators (KPIs) for production, trade-offs between the expected return and the risk in modern portfolio theory (MPT), and uncertainties in processing times. Traditionally, total completion time (<em>TCT</em>) and variance of completion times (<em>VCT</em>) are two KPIs for one-stage production scheduling, which relate to the first and second moments of completion times, respectively. We question whether the third moment of completion times is good to address the three challenges. In this paper, we introduce the skewness of completion times (<em>SCT</em>) in scheduling, and propose the ToB(<span><math><mrow><mi>a</mi><mo>,</mo><mi>b</mi></mrow></math></span>) heuristics for trade-off balancing. Through case studies with 5 levels of processing time uncertainties and compared to existing ToB(<span><math><mrow><mi>α</mi></mrow></math></span>) heuristics which balance trade-offs between <em>TCT</em> and <em>VCT</em>, we show that our ToB(<span><math><mrow><mi>a</mi><mo>,</mo><mi>b</mi></mrow></math></span>) heuristics dominate ToB(<span><math><mrow><mi>α</mi></mrow></math></span>) heuristics in terms of smaller expected values (<em>E</em>) of weighted sum of deviations from the best solutions of KPIs and smaller risks (<span><math><mrow><mi>σ</mi></mrow></math></span>) associated with these KPI deviations. Therefore, our ToB(<span><math><mrow><mi>a</mi><mo>,</mo><mi>b</mi></mrow></math></span>) heuristics are more robust to balance trade-offs between the three KPIs under processing time uncertainties.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 70-79"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926662","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}

引用次数: 0

Tunes of trust: A framework for auditory nudges in human-ai manufacturing collaboration 信任的旋律：人类与人工智能制造合作中的听觉推动框架

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.024

Fatemeh Mozaffar, Logan Smith, Beshoy Morkos

{"title":"Tunes of trust: A framework for auditory nudges in human-ai manufacturing collaboration","authors":"Fatemeh Mozaffar, Logan Smith, Beshoy Morkos","doi":"10.1016/j.mfglet.2025.06.024","DOIUrl":"10.1016/j.mfglet.2025.06.024","url":null,"abstract":"<div><div>This study investigates the application of musical and voice-based auditory nudges in enhancing human-AI interactions within a manufacturing setting, utilizing nudge theory to improve worker productivity, trust, and engagement. As AI technologies become more widespread in manufacturing environments, effective methods for fostering trust and collaboration between human operators and AI are essential. The increasing demand for customized products and rapid technological advancements in Industry 4.0 (I4.0) necessitate rapid employee adaptation, with humans playing a key role as the Human Component (HC) for its success. Therefore, the relationship between artificial intelligence (AI) and humans as inseparable parts of I4.0 need to be studied. Research has been done on improving the interaction between and performance of AI and humans. The impact of different nudge methods on worker productivity has also been studied, but not as an effective communication tool in human and AI teams. This study proposes a research framework that aims to explore using music as a medium for non-verbal cues, which has been shown to influence emotional perception and enhance task performance such as task continuity and worker productivity. This study employs a mixed-methods approach, incorporating quantitative metrics such as task completion times, alongside qualitative feedback to assess the impact of varied auditory nudges—including musical elements like tempo and pitch—on worker behavior and emotional response. Results from this experimental study will help to demonstrate the viability of musical nudges in increasing trust and efficiency in human-AI collaboration, providing insights into innovative strategies for optimizing Industry 4.0 environments.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 195-204"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926722","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}

引用次数: 0

Ultrafast laser micromachining of through-drill trenches in silicon wafers 硅晶圆中通钻沟槽的超快激光微加工

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.087

Chenyang Zhu , Rui Huang , Nian X. Sun , Xin Zhao

{"title":"Ultrafast laser micromachining of through-drill trenches in silicon wafers","authors":"Chenyang Zhu , Rui Huang , Nian X. Sun , Xin Zhao","doi":"10.1016/j.mfglet.2025.06.087","DOIUrl":"10.1016/j.mfglet.2025.06.087","url":null,"abstract":"<div><div>Silicon wafer processing is crucial in the semiconductor industry, especially in applications requiring precision through-trench fabrication. This study investigates the impact of various laser fluence, scan counts, and focal point dynamics on the trench width for both the entrance (top) and exit (bottom) surfaces using ultrafast laser machining on silicon wafers. Experiments revealed that while the trench width at the entrance remains nearly constant, the width at the exit increases with higher laser fluence and scan counts, stabilizing once a complete through-drill state is reached. Additionally, dynamic focal point strategy (step processing) experiments at laser fluences of 20 and 30 J/cm<sup>2</sup>, and total scan counts of 300 and 600 were conducted. It was found that when the scan count was below the through-drill threshold, increasing the number of steps led to a wider trench bottom. However, when the scan count exceeded the threshold, the trench width at the bottom reached its maximum at two steps and then decreased with additional steps. Furthermore, the effect of polarization direction on machining quality was assessed, showing improved trench uniformity when the polarization was perpendicular to the trench direction. These findings suggest that a 2-step processing approach, with each step meeting the through-drill scan threshold and maintaining perpendicular polarization to the trench, optimizes micro-machining quality and minimizes taper.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 746-751"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926749","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}

引用次数: 0

New Investigations on the performance Enhancement of Cryogenic-LN2 assisted sustainable milling of titanium alloy 提高低温- ln2辅助钛合金可持续铣削性能的新研究

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.047

Aqib Mashood Khan, Salman Pervaiz, Muhammad Jamil, Wei Zhao, Longhui Meng

{"title":"New Investigations on the performance Enhancement of Cryogenic-LN2 assisted sustainable milling of titanium alloy","authors":"Aqib Mashood Khan, Salman Pervaiz, Muhammad Jamil, Wei Zhao, 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}

引用次数: 0

Carbo-thermal reduction of lunar highland regolith simulant for in-situ manufacturing of SiC 月球高原表层模拟物原位制备碳化硅的碳热还原

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.049

Nithya Srimurugan , Sathyan Subbiah

{"title":"Carbo-thermal reduction of lunar highland regolith simulant for in-situ manufacturing of SiC","authors":"Nithya Srimurugan , 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<sub>x</sub> 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}

引用次数: 0

Elevated temperature structured light scanning for in situ monitoring of forging dies 锻模现场监测的高温结构光扫描

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.051

Jake Dvorak, Tony Schmitz

引用次数: 0

Design, hybrid manufacturing, and characterization of porous fracture fixators 多孔骨折固定器的设计、混合制造和表征

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.099

Johnathan Perino , Panayiotis Kousoulas , Y.B. Guo

{"title":"Design, hybrid manufacturing, and characterization of porous fracture fixators","authors":"Johnathan Perino , Panayiotis Kousoulas , 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}

引用次数: 0

53rd SME North American manufacturing research conference (NAMRC 53, 2025) Preface 第53届中小企业北美制造业研究会议（NAMRC 53,2025）前言

IF 2

Manufacturing Letters Pub Date : 2025-08-01 DOI: 10.1016/j.mfglet.2025.06.001

Xun Xu , Stefania Bruschi , Robert X. Gao

引用次数: 0