Manufacturing Letters最新文献

{"title":"A virtual reality-based immersive teleoperation system for remote human-robot collaborative manufacturing","authors":"Ke Wan,&nbsp;Chengxi Li,&nbsp;Fo-Sing Lo,&nbsp;Pai Zheng","doi":"10.1016/j.mfglet.2024.09.008","DOIUrl":"10.1016/j.mfglet.2024.09.008","url":null,"abstract":"<div><div>In recent years, the cutting-edge technologies in smart manufacturing have presented promising opportunities for the utilization of human-robot collaborative teleoperation in personalized manufacturing tasks. To effectively leverage the creative capabilities of humans while benefiting from the efficiency and stability of robots, the provision of an intuitive teleoperation interface assumes paramount importance. However, current teleoperation systems still face limitations in terms of intuitive operability. In this study, we present a virtual reality-based teleoperation system that offers operators a more intuitive interaction platform for robot control, thereby facilitating personalized manufacturing processes. The overall system framework design, as well as the main components are elaborated in detail. Furthermore, an evaluative case study based on the battery disassembly task is conducted to assess the performance of the proposed system. The results demonstrate that the proposed teleoperation system exhibits improved intuitiveness.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 43-50"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434338","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":"Influence of micro- and macroscopic tool features and errors within one batch in end milling","authors":"Johanna Steiner-Stark,&nbsp;Maximilian Berndt,&nbsp;Benjamin Kirsch,&nbsp;Jan C. Aurich","doi":"10.1016/j.mfglet.2024.09.081","DOIUrl":"10.1016/j.mfglet.2024.09.081","url":null,"abstract":"<div><div>Among other things the tool geometry influences the accuracy of the machined part, the chip formation and the process forces in end milling. The tool geometry can be divided into two different features: the micro and the macro geometry. The micro geometry describes the shape of the cutting edge and can influence the process forces, tool life and surface quality. The macro geometry describes the general specification of the tool as well as the runout. The runout can also affect process forces, tool life and the surface topography. This study shows that the micro and macro geometry of end mills of the same specification can vary significantly in one batch. This also has an influence on the process forces and resulting surface topography in end milling processes.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 633-640"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434353","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":"Investigating the use of 3D printed tools for electrochemical machining: Lessons learned and future improvements","authors":"Rhett Jones,&nbsp;Robert Prins,&nbsp;Jack Zhao","doi":"10.1016/j.mfglet.2024.09.062","DOIUrl":"10.1016/j.mfglet.2024.09.062","url":null,"abstract":"<div><div>This paper describes the use of 3D printing in the production of tool electrodes for use in electrochemical machining (ECM). The majority of ECM jobs require the use of a unique form tool, production of which represents a significant expense. Additive manufacturing processes such as 3D printing offer the potential to lower cost of production and allow design of more complex tool electrode geometries. The tool electrodes used in this research effort were printed in polylactic acid (PLA) and subsequently fit with a copper electrode to serve as the electrical connection terminal for the tool. The tool surface intended for use as the electrode for ECM was coated with an electrically conductive paint before being copper electroplated to form a conductive surface. These 3D printed tool electrodes were successfully demonstrated to machine hardened tool steel in a prototype ECM machine, although challenges remain. This paper describes the development of ECM tools from 3D printed tool blanks, the prototype ECM system that was constructed to demonstrate use of the tool blanks, and the results of applying the 3D printed blanks to machine hardened tool steel. Next steps including potential improvements to tool electrodes are also discussed.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 513-517"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434155","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":"CAPP-GPT: A computer-aided process planning-generative pretrained transformer framework for smart manufacturing","authors":"Ahmed Azab ,&nbsp;Hany Osman ,&nbsp;Fazle Baki","doi":"10.1016/j.mfglet.2024.09.009","DOIUrl":"10.1016/j.mfglet.2024.09.009","url":null,"abstract":"<div><div>Smart manufacturing (SM) constitutes the backbone of Industry 4.0 (I4.0), allowing for heightened autonomy of the various interacting cyber-physical systems, making the various entities on the production floor. Connectivity, a vital enabler, plays a crucial role through state-of-the-art Digital Twinning (DT) technologies driven by underlying innovations like the industrial Internet of Things, Cloud Computing, and advancements in sensory devices. DT, which plays a vital role in the various planning functions under the production and operations management umbrella, is being used in the developed combined CAPP-GPT (Computer-Aided Process Planning-Generative Pretrained Transformer) and production scheduling approach to address disruptions on the shopfloor and in self-healing of the manufacturing processes at a micro-CAPP level by optimally adapting the process parameters and the developed toolpath on the fly based on online process signature measurements. In a leap commensurate with that which has taken place in Natural Language Processing-Large Language Models (Chat-GPT), similar efforts are currently being undertaken to parse CAD data structures and blueprints, fusing operations research and predictive analytics algorithms to carry out setup planning as well as sequencing and grouping manufacturing sub-operations. A hybridized Optimization and Machine Learning (ML) approach is employed where Logical Analysis of Data is used to solve the problem heuristically, exploiting various generative and variant methods at heart. Another extension of this macro-CAPP problem is being tackled by integrating the problem with delayed product differentiation, lot-sizing, and transfer line balance for futuristic batch-production shops employing Hybrid Manufacturing (HM) and Smart Assembly. At the micro-CAPP level, HM process parameters are optimized using a comprehensive approach employing the Taguchi loss function to assess surface roughness, internal failure costs, and other criteria, including greenhouse gas emissions and expended energy. Online measurements of the process signatures are also employed to adapt the initial set of process parameters using different automatic control schemes. ML is used to identify the process parameters carrying simulations on Simulink before the system is deployed.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 51-62"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434339","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":"Production efficiency analysis based on the RFID-collected manufacturing big data","authors":"Zhihui Chen ,&nbsp;Zeyu Xiao ,&nbsp;Yize Sun ,&nbsp;Yuhao Dong ,&nbsp;Ray Y. Zhong","doi":"10.1016/j.mfglet.2024.09.012","DOIUrl":"10.1016/j.mfglet.2024.09.012","url":null,"abstract":"<div><div>Radio Frequency Identification (RFID) technology is widely used for production data collection in manufacturing shop-floors. The RFID-collected manufacturing big data reflects detailed statuses of production processes and manufactured products, which, in turn, can be used to support a comprehensive production analysis. This paper introduces an analytical approach to conduct production efficiency analysis based on the RFID-collected manufacturing big data. The proposed method involves four key steps: data cleansing, data processing, key performance indicator (KPI) estimation, and data analytics. Specifically, speed and quality aspects of shopfloor manufacturing are investigated collectively as production efficiency to support the comprehensive production analysis. The findings highlight the influence of various factors, such as operation date, working hour, and machine failure, on production efficiency.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 81-90"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434342","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":"Smart design and additive manufacturing of bending tools to improve production flexibility","authors":"Michael Schiller ,&nbsp;Peter Frohn-Sörensen ,&nbsp;Florian Schreiber ,&nbsp;Daniel Morez ,&nbsp;Martin Manns ,&nbsp;Bernd Engel","doi":"10.1016/j.mfglet.2024.09.013","DOIUrl":"10.1016/j.mfglet.2024.09.013","url":null,"abstract":"<div><div>For the automotive industry, especially on the part of Tier 1 and Tier 2 suppliers, the future will be about maintaining sovereignty in the form of technology openness and accelerating digitization. The product portfolio, which is generally passed on by OEMs to suppliers for production, often includes body parts that cannot always be manufactured economically with the prevailing production technology. The reason for this is a high diversity of model-variants, which requires smaller batches. To this end, highly flexible large-series production cells for body sheet components that can be scaled in all dimensions are being developed and tested. For the first time, they will make it possible to redesign the process planning in series production on a component-specific basis. The aim is to reduce production costs for new, geometrically different component variants. The basic components of the flexible manufacturing system are, firstly, new flexible forming technologies which have the potential to produce typical vehicle part geometries. Secondly, a process generator develops the corresponding production plan. A digital mapping of the manufacturing processes enables the selection of cost-, efficiency-, flexibility- and resilience-optimized production chains depending on the number of parts. Established manufacturing processes to produce car body components are supplemented in the cell by flexible processes such as 3D swivel bending. As a use case for flexible manufacturing, a concept for Rapid Tooling of 3D swivel bending tools is developed. In the flexible manufacturing system to be developed, a method of a standardized process sequence to produce forming tools within 24 h has been lacking to date. For this purpose, the concept of an automated design is being developed in which a reconfigurable tool body can be sliced into sheet metal stripes The active tool surface is additively manufactured after the tool has been packaged using LMD and adapted to individual requirements. The goal in the application of Rapid Tooling is to reduce lead times and development costs through a largely automated tool design and lead time-optimized manufacturing concept.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 91-102"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434343","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":"Prediction of tool wear and surface finish using ANFIS modelling during turning of Carbon Fiber Reinforced Plastic (CFRP) composites","authors":"Anil K. Srivastava,&nbsp;Md. Mofakkirul Islam","doi":"10.1016/j.mfglet.2024.09.084","DOIUrl":"10.1016/j.mfglet.2024.09.084","url":null,"abstract":"<div><div>Carbon fiber-reinforced plastics (CFRP) are widely used in various industries due to their high strength to weight ratio, corrosion resistance, durability, and excellent thermo-mechanical properties. The machining of CFRP composites has always been a challenge for the manufacturers. In this study, CNC turning operation with coated carbide tool is used to machine a specific CFRP and the relationship between the cutting parameters (Speed, Feed, Depth of Cut) and response parameters (Vibration, Surface Finish, Cutting Force and Tool Wear) are investigated. An adaptive-network-based fuzzy inference system (ANFIS) model with two multi-input–single-output (MISO) system has been developed to predict the tool wear and surface finish. Speed, feed, depth of cut, vibration and cutting force have been used as input parameters and tool wear and surface finish have been used as output parameters. Three sets of cutting parameter have been used to gather the data points for continuous turning of CFRP composite. The model merged fuzzy inference modeling with artificial neural network learning abilities, and a set of rules is constructed directly from experimental data. This model is capable of predicting the cutting tool wear and surface finish during turning of CFRP composite. The predicted tool wear and surface finish data are compared to the experimental results. The predicted data agreed well with the actual experimental data with 98.96 % accuracy for tool wear and 99.61 % accuracy for surface finish.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 658-669"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434356","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":"Flow analysis and fabrication of micro scale controlled surfaces by ultrashort pulse laser for microfluidic device applications","authors":"Prasanna S. Abbigeri,&nbsp;Pavan Pandit,&nbsp;S. Niketh,&nbsp;Shalini Singh,&nbsp;G.L. Samuel","doi":"10.1016/j.mfglet.2024.09.041","DOIUrl":"10.1016/j.mfglet.2024.09.041","url":null,"abstract":"<div><div>Microfluidics finds a wide range of industrial applications mainly in fields such as biomedical, clinical, electrical, and thermal engineering. Microchannels are the building blocks of most microfluidic devices. Thus, it becomes evident to understand the properties and the effect of the surfaces on the outcomes of devices. In this study, the effect of the shape of microchannels and the roughness elements on the flow is evaluated. Microchannels with three cross-sections and roughness elements of three different geometries are considered. The effect of varying Reynolds numbers on the flow parameters such as Friction factor, Nusselt number, Poiseuille number, pressure drop and surface temperature at the base of the substrate is studied. It is observed that rough microchannels and rectangular roughness elements showed a higher Nusselt number than smooth microchannels. The rough microchannels with triangular roughness elements showed higher friction factors. The surface temperature is higher for the smooth microchannels with triangular roughness elements. Furthermore, to demonstrate the manufacturability of microfluidic channels with controlled surfaces and to validate the preliminary results of the numerical simulations, the ultrashort pulse laser micromachining technique is used to fabricate the microchannels with structures on Polymethyl Methacrylate (PMMA) material.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 344-350"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434244","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":"Developing a hybrid-built pre-hardened alloy steel for injection moulding tools using the laser powder bed fusion process","authors":"Yuk Lun Simon Chan ,&nbsp;Xun Xu ,&nbsp;Olaf Diegel","doi":"10.1016/j.mfglet.2024.09.103","DOIUrl":"10.1016/j.mfglet.2024.09.103","url":null,"abstract":"<div><div>Hybrid additive-subtractive manufacturing has been adopted as a cost-effective alternative for manufacturing plastic injection moulding tools with conformal-cooled inserts created by fusing powder and wrought material. This article reports the development of a hybrid power-wrought pre-hardened alloy steel to supplement the current material choice for fabricating injection mould inserts using this advanced manufacturing strategy. In this study, MS1 (maraging 300) steel powder was additively deposited onto pre-machined wrought Nimax steel to form a hybrid alloy material. The mechanical and microstructural properties of the fusion-bonded interface were examined. Microstructural observation revealed a 280 <span><math><mrow><mi>μ</mi></mrow></math></span>m thick interfacial region consisting of a homogenous mixing of powder and substrate materials. As a result of solid solution strengthening within the region, tensile tests established robust powder-substrate bonding with tensile ruptures occurring well away from the interface. The as-built hybrid-alloy steel possessed excellent mechanical properties, with 1200 MPa in ultimate tensile strength, 12.4 % in elongation at fracture and 39 HRC (Nimax)/42 HRC (MS1) in hardness. The overall results suggested that hybrid MS1-wrought Nimax steel is a suitable pre-hardened material for manufacturing durable and high-performance injection mould inserts as part of a cost-effective hybrid additive-subtractive manufacturing strategy.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 832-840"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434295","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":"Numerical investigation on machining of additively manufactured CFRP composite with different build orientations and layer widths","authors":"Sk Md Alimuzzaman ,&nbsp;Jianfeng Ma ,&nbsp;Muhammad P. Jahan","doi":"10.1016/j.mfglet.2024.09.086","DOIUrl":"10.1016/j.mfglet.2024.09.086","url":null,"abstract":"<div><div>Additive manufacturing (AM) is now a widely researched manufacturing technology in the past two decades to adopt in industry for its added advantage of customization and adopting complex geometries with comparatively low buy-to-fly ratio. Carbon fiber reinforced polymer (CFRP) composite has found applications in different high-performance industries for its greatest benefit of high strength-to-weight ratio. Additive manufacturing of CFRP composite (AM-CFRP) opens up the possibility of enhancing mechanical strength using different printing orientations and enables producing complex shapes maintaining sustainable manufacturing perspective. However, Limitation of AM parts of having surface irregularities and questionable dimensional accuracies. To use AM-CFRP parts in high precision assembly or industrial applications, post processing machining is often required to meet the customers’ specification of geometrical tolerances and acceptable surface finish. In this study, the influence of AM parameters on machinability of AM-CFRP composite has been evaluated using finite element analysis (FEA) based numerical simulation. The slot milling operation was simulated with a tungsten carbide end milling tool and AM-CFRP workpiece with four different printing directions, i.e., 0°-90°, 45°-135°, 0°-90°-45°-135°, two different layer widths, i.e., 50 µm and 100 µm, and two in-fill patterns, i.e., solid and perforated structures. The machinability of the 3D printed CFRP has been analyzed based on cutting forces, stress at first contact and maximum stress generation, and temperature increases at the interface during slot milling of AM-CFRP under different AM parameters. Evolution of failure mechanisms of AM-CFRPs under various machining conditions, such as, delamination, matrix rupture etc., have been discussed and chip and burr formation mechanisms have been analyzed. Finite Element analysis (FEA) package ABAQUS/Explicit was used to model 3D micro slot milling operation of AM-CFRP workpiece with appropriate damage and constitutive models, such as, damage initiation, progression and cohesion in adjacent passes and layers.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 679-690"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434296","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}