Manufacturing Letters最新文献

{"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}

{"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}

{"title":"Clinical-relevant sized tubular capillary mimicries by sacrificial core-sheath electrospinning","authors":"Yan Chen,&nbsp;Yingge Zhou","doi":"10.1016/j.mfglet.2024.09.056","DOIUrl":"10.1016/j.mfglet.2024.09.056","url":null,"abstract":"<div><div>Electrospinning is a versatile technique that is often used to fabricate ultra-fine fibers. With the help of a coaxial spinneret, microtubes can be fabricated as potential biomimetic capillary vessels. However, the sizes of electrospun microtubes in recent research were around 5 μm which is smaller to native capillary vessels (5–10 μm). The electrospun microtube diameter can be determined by various electrospinning parameters such as spinning materials, solvent, spinning distance, solution pump rate, applied voltage, etc. In this research, we explored the effects of spinning distance and core/sheath pump rate ratio on microtube diameter and wall thickness. Viscosity, wettability, and tensile tests were also conducted for microtube characterization. The results indicated that the microtube diameters range from 5 μm to 12 μm, which provides a promising direction for the fabrication of biomimetic capillary vessels.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 462-468"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434208","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":"Effect of drying temperature on binder/current collector interfacial adhesion in electrode manufacturing of Li-ion batteries","authors":"Xiaowei Yu ,&nbsp;Mengyuan Chen ,&nbsp;Ming Wang ,&nbsp;Jennifer Bracey ,&nbsp;Bradley Frieberg ,&nbsp;Roland Koestner ,&nbsp;Wai Ping Gloria Tam ,&nbsp;David Titmuss ,&nbsp;Nicholas Ware","doi":"10.1016/j.mfglet.2024.09.036","DOIUrl":"10.1016/j.mfglet.2024.09.036","url":null,"abstract":"<div><div>Li-ion battery manufacturing process parameters are critical to the electrode properties and the final cell electrochemical performance. During the electrode drying process, the drying temperature plays a critical role on the binder migration, which affects the interfacial adhesion between the electrode and the current collector. However, the influence of the temperature on the properties of the binder material and the binder/current collector interface is yet unknown. In this work, we studied the effect of drying temperature on the interfacial adhesion between the binder and the current collector by direct coating of polyvinylidene fluoride (PVDF) solution on Al foil and then drying at various temperatures. The interfacial adhesion strength between the PVDF and the Al foil was significantly increased, from 9.72 N/m (dried at room temperature) to &gt; 665.80 N/m (dried at 200 ℃) with increased temperature. DSC and XRD analyses showed the changes in the crystalline forms of PVDF under different drying temperature. This work revealed that the drying temperature during electrode manufacturing should be considered from the aspects of both binder migration in mid-stage and PVDF crystalline properties in late-stage solvent drying.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 304-309"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434239","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":"Investigations on ironing parameters in screw extrusion additive manufacturing (SEAM)","authors":"Yash Gopal Mittal ,&nbsp;Gopal Gote ,&nbsp;Yogesh Patil ,&nbsp;Avinash Kumar Mehta ,&nbsp;Pushkar Kamble ,&nbsp;K.P. Karunakaran","doi":"10.1016/j.mfglet.2024.09.102","DOIUrl":"10.1016/j.mfglet.2024.09.102","url":null,"abstract":"<div><div><em>Additive Manufacturing</em> (AM) is a novel manufacturing process that enables the physical realization of a given 3D model via layered deposition. <em>Material extrusion</em> (MEX) is one of the most widely used forms of the various AM techniques, in which the <em>screw extrusion</em>-based AM (SEAM) processing offers the most versatile characteristics, in terms of material handling and flow rate capacities. It involves continuous extrusion of the semi-solid material via an extruder screw. Ironing is a common practice in MEX techniques, to maintain <em>z</em>-height and improve the surface morphologies while deposition. Most commercially used nozzles for MEX are thin-walled, such that the ratio of the nozzle width to the diameter (<em>w/d</em>) is close to 1. In this research, investigations on the ironing effect during screw extrusion-based material deposition are explored using a set of wider nozzles (<em>w/d</em> as high as 40). Special emphasis is laid on the deposited surface finish, interlayer strength, and geometrical conformance of the extrusion. The nozzle diameter and the <em>stand-off distance</em> (SOD) are also independently varied. It is found that the best dimensional stability is achieved when the SOD is set between 75 % and 100 % of the nozzle diameter. Ironing improved the surface finish and the interlayer strength in all instances, with an average improvement of 50 % and 200 %, respectively.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 822-831"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434294","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":"Evaluation and quantification of diffusion wear between cutting chip and workpiece using forging press","authors":"Junichi Nakagawa ,&nbsp;Yusuke Yoshimi ,&nbsp;Katsumasa Chiba ,&nbsp;Ryutaro Tanaka","doi":"10.1016/j.mfglet.2024.09.075","DOIUrl":"10.1016/j.mfglet.2024.09.075","url":null,"abstract":"<div><div>The state of the interface between the workpiece and the cutting tool affects the cutting temperature and pressure on the tool surface during the cutting process. In particular, while cutting difficult-to-cut materials such as Ni-based alloy 718, the workpiece exhibits a high affinity for cutting tool materials and could easily adhere to them. Adhesion can, at times, adversely affect productivity. The diffusion between the cutting tool and the workpiece is a factor considered to contribute to the adhesion phenomenon during cutting. Addressing this issue involves choosing tool materials and coated materials with high resistance to diffusion and optimizing cutting conditions, particularly the cutting speed, which significantly impacts cutting temperature. However, because cutting tool wear comprises various forms, clarifying the effect of diffusion on tool wear remains open. In this study, to reproduce the diffusion phenomenon between cutting tool and workpiece, two pairs of test specimens were prepared: (1) cemented carbide-AISI 1045 and (2) cemented carbide-Alloy718, which could be held at high temperature under vacuum conditions by a forging press. The degree of diffusion phenomena was evaluated at each tool-work material interface, and the quantification of diffusion amount was performed by diffused element in each work material. Additionally, the theoretical analysis of the diffusion phenomenon using the thermodynamic and phase diagram calculation software Thermo-Calc was also performed.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 588-594"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434406","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":"Effect of laser beam incident angle on welding of Ti6Al4V with fiber lasers","authors":"Jigar Krushna Pathak,&nbsp;N. Ramesh Babu,&nbsp;D.S. Srinivasu","doi":"10.1016/j.mfglet.2024.09.057","DOIUrl":"10.1016/j.mfglet.2024.09.057","url":null,"abstract":"<div><div>Laser beam welding (LBW) is widely used for welding Ti6Al4V alloys in aerospace applications. LBW has localized high-energy fluence with low-energy input compared to other fusion welding processes, resulting in narrower heat-affected zones. On the other hand, most metals are highly reflective when the laser beam impinges perpendicular to the surface, making the process inefficient. Hence, this work proposes to employ shallow angle incidence to reduce the reflectivity during the welding of Ti6Al4V material. To explore the potential of this idea, the current study focuses on studying the effect of laser incident angle (15°-90°), power (300 W-1500 W), and feed rate (10 mm/s-25 mm/s) on autogenous weld bead geometry. For this purpose, bead-on plate (BOP) LBW is conducted on mill-annealed Ti6Al4V material of dimensions 25 mm × 25 mm × 3 mm by employing a fiber laser source with a maximum power of 3 kW and a wavelength of 1080 nm. It is observed from the results that at a normal incident angle and low laser power (&lt; 600 W), the penetration depth is too low to generate a weld bead. Analyzing the cross-section of the weld bead, obtained from SEM, perpendicular to the weld direction reveals that the increase in laser incident angle up to an optimal angle resulted in increased bead dimensions (width and height), and beyond that, the dimensions decreased. However, the optimal incident angle changed when the laser power was changed. The major finding of this study is that at 600 W and a normal incident angle, the laser could not penetrate and generate a weld bead due to low absorptivity, while at an incident angle of 30⁰, 45⁰, and 60⁰, weld beads are generated because of increased absorptivity. Similarly, the increase in weld dimensions with the increase in laser power is observed. At higher laser power, underfill and oxide formation are observed. The feed rate is less predominant than the incident angle and the power.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 469-474"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434150","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":"Heat partition evaluation during dry drilling of thick CFRP laminates with polycrystalline diamond drills","authors":"Fahim Shariar ,&nbsp;Umut Karagüzel ,&nbsp;Yiğit Karpat","doi":"10.1016/j.mfglet.2024.09.059","DOIUrl":"10.1016/j.mfglet.2024.09.059","url":null,"abstract":"<div><div>Since various material properties of carbon fiber-reinforced polymer (CFRP) are temperature dependent, dry drilling of CFRP is a delicate process. Thermal damage can be caused by a rise in temperature during drilling due to a large portion of heat being transferred into the material. Heat partition is used to quantify this, which represents the percentage of total heat being dissipated into the constituent objects during a machining operation. Drill margin and contact conditions at the tool-workpiece interface significantly affect the drilling of CFRP material. Drilling experiments were performed to measure thrust force, torque, and temperatures for five different sets of feed rates and rotational speeds. This study proposes a method for calculating heat partition values during CFRP drilling by developing a finite element-based thermal model. The FE model employs a Gaussian distributed ring-type heat flux that is a function of the equivalent contact length at the interface between the drill and the material surface and the geometry of the workpiece which operates as a moving heat source, emulating the progress of the drill through the CFRP laminate. The tool implements heat fluxes that use characteristic time-point-based step functions to represent the temperature on the drill as it advances through the workpiece during machining. The temperature profiles obtained from the FE analysis and the experiments for the workpiece and tool were subsequently matched iteratively to determine the corresponding heat partition value.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 483-493"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434152","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":"3D melt blowing of Elastollan thermoplastic polyurethane for tissue engineering applications: A pilot study","authors":"Advay Pawar ,&nbsp;Bruce Anderson ,&nbsp;Behnam Pourdeyhimi ,&nbsp;Amy L. McNulty ,&nbsp;Matthew Fisher ,&nbsp;Rohan Shirwaiker","doi":"10.1016/j.mfglet.2024.09.043","DOIUrl":"10.1016/j.mfglet.2024.09.043","url":null,"abstract":"<div><div>Scaffolds, in addition to being biocompatible, should possess structural and mechanical properties similar to the natural tissues they intend to replace. Many tissue engineering applications require porous 3D scaffolds characterized by unique microfibrous organization and mechanical anisotropy. Manufacturing process principles and process parameter-biomaterial interactions ultimately govern the properties that can be achieved in the scaffold. In this study, we investigate a recently developed nonwoven scaffold fabrication process, 3D melt blowing (3DMB), for processing Elastollan®, a thermoplastic polyurethane with basic mechanical properties suitable for musculoskeletal tissue engineering. The range of feasible processing parameters was screened and the effects of two sets of critical process parameters (fiber deposition offset and surface velocity of the collector) that produced contrasting scaffold morphologies were assessed. Results showed that scaffolds of Group B that were fabricated at the higher fiber deposition offset (90 %) and higher surface velocity of the collector (6 × 10⁵ mm/min) possessed significantly smaller fiber diameter and higher porosity and degree of fiber alignment along the principal direction of collector rotation during 3DMB (all p &lt; 0.05) compared to Group A scaffolds (fabricated at 50 % offset and 1 × 10⁵ mm/min surface velocity). Although both groups possessed similar tensile stiffness, the elongation at failure was significantly different (p &lt; 0.0001). The higher elongation at failure of Group B correlated with the higher degree of fiber alignment in these scaffolds. In contrast, the more isotropic fibrous organization of Group A contributed to their higher compressive stiffness (p = 0.004). The introduction of NaOH treatment to improve hydrophilicity of the scaffolds resulted in a significant reduction of tensile stiffness of Group A (p &lt; 0.05) but not Group B. This treatment did not significantly affect the elongation at failure or compressive stiffness of both groups. With NaOH-treatment, both groups demonstrated good biocompatibility when seeded with fibroblast cells over 14 days. This study confirms the ability to fabricate via 3DMB, biocompatible, micro-fibrous, Elastollan scaffolds relevant for musculoskeletal tissue engineering.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 357-363"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434246","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":"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}